The manufacture of PVC windows is a complex process, requiring the use of advanced equipment and quality control at all stages of production. Compliance with the production technology alone ensures that the final product meets the standards of environmental friendliness and has high-performance characteristics. A lot of people wonder about the window manufacturing process at the factory. We will try to answer this question in our article using the most popular PVC constructions as an example.
Main phases of production of windows made of PVC and other materials
The window manufacturing process involves multiple steps. Here are the basic ones:
Designing a construct.
Cutting and armoring the profile. Filling.
Welding window frames and sashes.
Installing double-glazed windows.
Checking the finished window for quality.
Now let’s take a closer look at each of the steps.
Sure enough, there are some standard designs used to make most of the goods, but some companies need custom windows, so in these cases, new designs are made. For this, they use special software. In this program, they enter the dimensions and other parameters of future products, such as type of profile, the shape of double-glazed window, the types and number of fittings, etc.
Once all the data are entered, the tool will automatically calculate the amount of material required to produce a single unit and estimate the cost of the window. This considerably speeds up the design process and simplifies it.
Cutting and armoring
This is the stage where they work with the profile and cut the frames and sashes to the right size. A traditional piece of equipment used for cutting and parting is a double head saw that cuts from both sides at once. With this technology, you can achieve the exact cut geometry, which is especially important since the subsequent welding process makes the joints smooth and tight.
Once cut, they arm the profile, thus increasing its strength and insuring against deformation.
Condition of armoring:
They use galvanized steel. Its thickness for standard window sizes is 1.4-1.5 mm or higher for larger products.
The reinforcement steel should have a regular n-shape and a bend at the sash.
The workpiece should be reinforced solidly, from edge to edge.
The reinforcement steel must have a regular n-shape and have a bend at the sash.
This is the stage where they drill holes to install fittings, fasteners, condensate drains. Special attention should be paid to drainage devices that automatically drain water from the construct into the outside environment.
After milling, the workpieces are sent for welding – typically on a 4-head welder (although other types of equipment can also be used). The welding is required to heat the profile edges to the melting temperature of the material used, which is 230-260⁰C (440-500 ℉) for plastic. Next, they joint the edges.
A four-head unit helps you to connect all four corners simultaneously so that the frame geometry is close to perfection. Once welded, the construct is conveyed via a traveling belt for deseaming.
What is important is that seam durability should be close to that of the base material. For this, they check the corners for rupture. There are standards for each profile thickness, so it is best if the figures are twice as high as the standard ones.
Installing seals and fittings
Next, they proceed to the installation of fittings and seals. The latter is just as important as other window elements. Heat and sound insulation – the main characteristics for all windows – depends on the quality of the seals and their installation. You need to ensure that the seals retain their properties when exposed to extreme temperatures.
Through fittings, we open and close windows, install mosquito nets, and ventilate the room. So, the service life of the window depends on the quality of its installation, because the fittings break down the fastest.
In addition to the basic fittings, you can also add:
Handle rotation lock.
Anti-burglary elements: locking pins, strikes, etc.
Handles with locks to prevent children from falling out.
Step openers, etc.
Installing double-glazed units
Not only window glass helps to provide visibility and limit airflow from outside, but also to save energy. For this purpose, double-glazed units with a tin-silver coating are produced. The glass surface is first coated with a composition, then the glass is installed, and then argon is injected into the air chamber. For conventional windows, the production task is somewhat simplified, which lowers the price.
If the insulated glazing unit is installed incorrectly, the sash may be skewed, which will affect the service life and quality of the functions. During installation, the insulating glazing must be properly wedged with welted inserts and laying. Wedged glazing units are fixed by means of glazing beads.
In the final stage, the finished product is subjected to quality control and shipped to the customer.
Based on this information, we can conclude that this is a complex, multi-step process, requiring the qualifications of workers and the use of modern equipment. Following the technology guarantees a good quality of the final product.