METHODS AND EQUIPMENT FOR ASSEMBLING TRIPLE-PANE INSULATING GLASS UNITS

• US 20110154635A1
• Filed: 12/31/2009
• Published: 06/30/2011
• Est. Priority Date: 12/31/2009
• Status: Active Grant

• Current Assignee: Cardinal IG Company (Cardinal Glass Industries Incorporated)
• Original Assignee: Cardinal IG Company (Cardinal Glass Industries Incorporated)
• Inventors: Wunnicke, William R., Westley, Martin, Walsh, Robert E.
• Granted Patent: US 8,381,382 B2
• Time in Patent Office: Days
• US Class Current: 29/428
• CPC Class Codes: E06B 3/67373 Rotating panes, spacer frames or units
• CPC Class Codes: E06B 3/67386 Presses; Clamping means holding the panes during assembly
• CPC Class Codes: Y10T 156/17 Surface bonding means and/or assemblymeans with work feeding or handling means
• CPC Class Codes: Y10T 156/1702 For plural parts or plural areas of single part
• CPC Class Codes: Y10T 156/1744 Means bringing discrete articles into assembled relationship
• CPC Class Codes: Y10T 29/49826 Assembling or joining
• CPC Class Codes: Y10T 29/49828 Progressively advancing of work assembly station or assembled portion of work
• CPC Class Codes: Y10T 29/49829 Advancing work to successive stations [i.e., assembly line]
• CPC Class Codes: Y10T 29/49885 with coating before or during assembling
• CPC Class Codes: Y10T 29/49904 Assembling a subassembly, then assembling with a second subassembly
• CPC Class Codes: Y10T 29/53978 including means to relatively position plural work parts

Abstract

Embodiments of the present invention provide methods and equipment for automatically assembling three panes of glass and corresponding spacers so that air or other gas can be injected into the two between-pane spaces. The equipment can receive two glass panes that each have spacers coupled to one of their major surfaces, along with a third glass pane having no spacer coupled to its major surfaces, and can assemble the three glass panes into a “teepee” configuration in which the two spacers each contact two of the glass panes along a common edge of the glass panes. Preferred equipment can receive a glass pane in a first orientation and rotate the glass pane 180° to a second orientation in which the glass pane'"'"'s two major surfaces face opposite directions from the first orientation. Such preferred equipment can then receive a two-pane teepee from a previous piece of equipment and can add the “flipped” single glass pane to the teepee to create a three-pane teepee.

Claims

1. An apparatus used in the construction of triple-pane insulating glass units, the apparatus comprising:

(a) a base;

(b) a glass pane handling mechanism including (i) a support structure that is rotatably coupled to the base, (ii) two opposed side panels that are coupled to or integral with the support structure, (iii) a conveying mechanism coupled to the support structure, the conveying mechanism adapted to convey glass panes into and out of a position between the opposed side panels, and (iv) a securing mechanism coupled to the support structure, the securing mechanism adapted to releasably secure glass panes conveyed into the position between the opposed side panels; and

(c) an actuating mechanism in electronic communication with the glass pane handling mechanism, the actuating mechanism adapted to cause (i) the conveying mechanism to convey a first glass pane into the position between the opposed side panels, a first-pane spacer being coupled to one major surface of the first glass pane, (ii) the securing mechanism to secure the first glass pane on an opposite major surface of the first glass pane, (iii) the glass pane handling mechanism to rotate 180°

relative to the base, (iv) the conveying mechanism to convey second and third glass panes into the position between the opposed side panels, a third-pane spacer being coupled to one major surface of the third glass pane, one edge of the second glass pane being pressed together with one edge of the third glass pane such that the third-pane spacer contacts the second glass pane, (v) the securing mechanism to (A) press one edge of the first glass pane together with the one edge of the second glass pane and the one edge of the third glass pane such that the first-pane spacer contacts the second glass pane and (B) release the first glass pane, and (vi) the conveying mechanism to convey the first, second, and third glass panes out of the position between the opposed side panels.

2. The apparatus of claim 1, wherein the support structure is rotatable about a vertical axis relative to the base.

3. The apparatus of claim 1, wherein the first, second, and third glass panes are rectangular.

4. The apparatus of claim 1, wherein the conveying mechanism comprises a conveyor belt oriented generally perpendicularly to the opposed side panels and a plurality of idler rollers coupled to each of the opposed side panels.

5. The apparatus of claim 4, wherein the one edge of the first glass pane, the one edge of the second glass pane, and the one edge of the third glass pane are opposite the conveyor belt.

6. The apparatus of claim 5, wherein the securing mechanism presses one edge of the first glass pane together with the one edge of the second glass pane and the one edge of the third glass pane and releases the first glass pane by bringing a lower edge of the first glass pane into contact with the conveyor belt and activating one or more pins to press the respective edges of the glass panes together.

7. The apparatus of claim 5, wherein the securing mechanism secures the first glass pane by lifting the first glass pane off of the conveyor belt.

8. The apparatus of claim 4, wherein the major surface of the first glass pane that is opposite the first-pane spacer is adapted to contact at least some of the plurality of idler rollers when the first glass pane is being conveyed into the position between the opposed side panels.

9. The apparatus of claim 1, wherein the major surface of the first glass pane to which the first-pane spacer is coupled is coated with one or more glass coatings.

10. The apparatus of claim 9, wherein the major surface of the third glass pane to which the third-pane spacer is coupled is coated with one or more glass coatings.

11. The apparatus of claim 1, wherein the conveying mechanism comprises a glass pane positioning sensor adapted to sense when the glass panes are in the position between the opposed side panels and to provide related information to the actuating mechanism.

12. The apparatus of claim 1, wherein the securing mechanism comprises a plurality of vacuum cups adapted to secure glass panes when signaled by the actuating mechanism.

13. The apparatus of claim 12, wherein the plurality of vacuum cups comprises first and second horizontal rows of vacuum cups.

14. The apparatus of claim 13, wherein the first horizontal row of vacuum cups is vertically adjustable to accommodate different sizes of glass panes.

15. The apparatus of claim 14, wherein the securing mechanism further comprises a rod that is fixedly coupled to the second row of horizontal vacuum cups and releasably coupled to the first row of horizontal vacuum cups, the rod adapted to be released from the first row of horizontal vacuum cups while the first row of horizontal vacuum cups is being vertically adjusted and adapted to be coupled to the first row of horizontal vacuum cups while the first row of horizontal vacuum cups is not being vertically adjusted.

16. A system for the construction of triple-pane insulating glass units, the system comprising first and second apparatuses, both apparatuses including

(a) a base,

(b) a glass pane handling mechanism including (i) a support structure that is coupled to the base, (ii) two opposed side panels that are coupled to or integral with the support structure, (iii) a conveying mechanism coupled to the support structure, the conveying mechanism adapted to convey glass panes into and out of a position between the opposed side panels, and (iv) a securing mechanism coupled to the support structure, the securing mechanism adapted to releasably secure glass panes conveyed into the position between the opposed side panels, and

(c) an actuating mechanism in electronic communication with the glass pane handling mechanism,

wherein the first apparatus'"'"'s actuating mechanism is adapted to cause (i) the first apparatus'"'"'s conveying mechanism to convey a first glass pane through the first apparatus, a first-pane spacer being coupled to one major surface of the glass pane, and to convey a second glass pane into the position between the first apparatus'"'"'s opposed side panels, (ii) the first apparatus'"'"'s securing mechanism to secure the second glass pane, (iii) the first apparatus'"'"'s conveying mechanism to convey a third glass pane into the position between the first apparatus'"'"'s opposed side panels, a third-pane spacer being coupled to one major surface of the third glass pane, (iv) the first apparatus'"'"'s securing mechanism to press one edge of the second glass pane together with one edge of the third glass pane such that the third-pane spacer contacts the second glass pane, and (v) the first apparatus'"'"'s conveying mechanism to convey the second and third glass panes through the first apparatus, and

wherein the second apparatus'"'"'s actuating mechanism is adapted to cause (i) the second conveying mechanism to convey the first glass pane into the position between the second apparatus'"'"'s opposed side panels, (ii) the second apparatus'"'"'s securing mechanism to secure the first glass pane on a major surface of the first glass pane that is opposite the first-pane spacer, (iii) the second apparatus'"'"'s glass pane handling mechanism to rotate 180°

relative to the second apparatus'"'"'s base, (iv) the second apparatus'"'"'s conveying mechanism to convey the second and third glass panes into the position between the second apparatus'"'"'s opposed side panels, (v) the second apparatus'"'"'s securing mechanism to (A) press one edge of the first glass pane together with the one edge of the second glass pane and the one edge of the third glass pane such that the first-pane spacer contacts the second glass pane and (B) release the first glass pane, and (vi) the second apparatus'"'"'s conveying mechanism to convey the first, second, and third glass panes through the second apparatus.

17. The system of claim 16, further comprising a third apparatus that includes:

(a) a base,

(b) a glass pane handling mechanism comprising (i) a support structure that is coupled to the base, (ii) two opposed side panels that are coupled to or integral with the support structure, and (iii) a conveying mechanism coupled to the support structure, the conveying mechanism adapted to convey glass panes into and out of a position between the opposed side panels, and

(c) an actuating mechanism in electronic communication with the glass pane handling mechanism,

wherein the third apparatus'"'"'s actuating mechanism is adapted to cause (i) the third apparatus'"'"'s conveying mechanism to convey the first, second, and third glass panes into the position between the third apparatus'"'"'s opposed side panels and (ii) the third glass pane handling mechanism to (A) supply gas to space between the first and second glass panes and between the second and third glass panes and (B) press remaining edges of the first, second, and third glass panes together such that both the first-pane and third-pane spacers contact the second glass pane.

18. The system of claim 17, wherein the third apparatus'"'"'s actuating mechanism is further adapted to cause the third apparatus'"'"'s conveying mechanism to convey the first, second, and third glass panes through the third apparatus.

19. The system of claim 16, wherein the second apparatus'"'"'s support structure is rotatable about a vertical axis relative to the base.

20. The system of claim 16, wherein the first, second, and third glass panes are rectangular.

21. The system of claim 16, wherein the second apparatus'"'"'s conveying mechanism comprises a conveyor belt oriented generally perpendicularly to the opposed side panels and a plurality of idler rollers coupled to each of the opposed side panels.

22. The system of claim 21, wherein the one edge of the first glass pane, the one edge of the second glass pane, and the one edge of the third glass pane are opposite the conveyor belt.

23. The system of claim 22, wherein the second apparatus'"'"'s securing mechanism presses one edge of the first glass pane together with the one edge of the second glass pane and the one edge of the third glass pane and releases the first glass pane by bringing a lower edge of the first glass pane into contact with the conveyor belt and activating one or more pins to press the respective edges of the glass panes together.

24. The system of claim 22, wherein the second apparatus'"'"'s securing mechanism secures the first glass pane by lifting the first glass pane off of the conveyor belt.

25. The system of claim 21, wherein the major surface of the first glass pane that is opposite the first-pane spacer is adapted to contact at least some of the plurality of idler rollers when the first glass pane is being conveyed into the position between the second apparatus'"'"'s opposed side panels.

26. The system of claim 16, wherein the major surface of the first glass pane to which the first-pane spacer is coupled is coated with one or more glass coatings.

27. The system of claim 26, wherein the major surface of the third glass pane to which the third-pane spacer is coupled is coated with one or more glass coatings.

28. The system of claim 16, wherein the second apparatus'"'"'s conveying mechanism comprises a glass pane positioning sensor adapted to sense when the glass panes are in the position between the second apparatus'"'"'s opposed side panels and to provide related information to the second apparatus'"'"'s actuating mechanism.

29. The system of claim 16, wherein the second apparatus'"'"'s securing mechanism comprises a plurality of vacuum cups adapted to secure glass panes when signaled by the second apparatus'"'"'s actuating mechanism.

30. The system of claim 29, wherein the plurality of vacuum cups comprises first and second horizontal rows of vacuum cups.

31. The system of claim 30, wherein the first horizontal row of vacuum cups is vertically adjustable to accommodate different sizes of glass panes.

32. The system of claim 31, wherein the second apparatus'"'"'s securing mechanism further comprises a rod that is fixedly coupled to the second row of horizontal vacuum cups and releasably coupled to the first row of horizontal vacuum cups, the rod adapted to be released from the first row of horizontal vacuum cups while the first row of horizontal vacuum cups is being vertically adjusted and adapted to be coupled to the first row of horizontal vacuum cups while the first row of horizontal vacuum cups is not being vertically adjusted.

33. A method of constructing triple-pane insulating glass units, the method comprising:

(a) conveying a first glass pane into a position between two opposed side panels of an assembly apparatus, a first-pane spacer being coupled to one major surface of the first glass pane;

(b) securing the first glass pane on an opposite major surface of the first glass pane with the assembly apparatus;

(c) rotating at least part of the assembly apparatus 180°

, thereby causing the first glass pane to rotate 180°

;

(d) conveying second and third glass panes into the position between the two opposed side panels of the assembly apparatus, a third-pane spacer being coupled to one major surface of the third glass pane, one edge of the second glass pane being pressed together with one edge of the third glass pane such that the third-pane spacer contacts the second glass pane;

(e) pressing one edge of the first glass pane together with the one edge of the second glass pane and the one edge of the third glass pane such that the first-pane spacer contacts the second glass pane;

f) releasing the first glass pane; and

(g) conveying the first, second, and third glass panes out of the position between the opposed side panels of the assembly apparatus.

34. The method of claim 33, further comprising:

(h) conveying the first, second, and third glass panes into a position between two opposed side panels of a gas-supplying apparatus;

(i) supplying gas with the gas-supplying apparatus to space between the first and second glass panes and between the second and third glass panes;

(j) pressing remaining edges of the first, second, and third glass panes together such that both the first-pane and third-pane spacers contact the second glass pane.

35. The method of claim 34, further comprising:

(k) conveying the first, second, and third glass panes out of the position between the opposed side panels of the gas-supplying apparatus.

36. The method of claim 33, wherein rotating at least part of the assembly apparatus 180°

comprises rotating at least part of the assembly apparatus 180°

about a vertical axis, thereby causing the first glass pane to rotate 180°

.

37. The method of claim 33, wherein the first, second, and third glass panes are rectangular.

38. The method of claim 33, wherein conveying glass panes into the position between the two opposed side panels of the assembly apparatus includes conveying the glass panes via a conveyor belt oriented generally perpendicularly to the opposed side panels and a plurality of idler rollers coupled to each of the opposed side panels.

39. The method of claim 38, wherein pressing the one edge of the first glass pane together with the one edge of the second glass pane and the one edge of the third glass pane comprises bringing an edge of the first glass pane into contact with the conveyor belt and activating one or more pins to press the respective edges of the glass panes together.

40. The method of claim 39, wherein securing the first glass pane includes lifting the first glass pane off of the conveyor belt.

41. The method of claim 38, wherein conveying glass panes into the position between the two opposed side panels of the assembly apparatus includes contacting the major surface of the first glass pane that is opposite the first-pane spacer with at least some of the plurality of idler rollers.

42. The method of claim 33, wherein the major surface of the first glass pane to which the first-pane spacer is coupled is coated with one or more glass coatings.

43. The method of claim 42, wherein the major surface of the third glass pane to which the third-pane spacer is coupled is coated with one or more glass coatings.

44. The method of claim 33, wherein conveying the first glass pane into a position between two opposed side panels of the assembly apparatus includes sensing when the first glass pane is in the position between the opposed side panels of the assembly apparatus with a glass pane positioning sensor and providing related information to an actuating mechanism of the assembly apparatus.

45. The method of claim 33, wherein securing the first glass pane on the opposite major surface of the first glass pane includes securing the first glass pane on the opposite major surface of the first glass pane with a plurality of vacuum cups.

46. The method of claim 45, wherein the plurality of vacuum cups comprises first and second horizontal rows of vacuum cups.