Abstract:
The technology disclosed herein generally relate to assembly equipment for window units. In one embodiment, a window unit assembly system is taught that has a frame component that is configured to support equipment for a window unit assembly line. A pane conveyor is supported by the frame component and is configured to move panes along the window unit assembly line. A spacer conveyor is supported by the same frame component as the pane conveyor and is configured to move spacer elements along the window unit assembly line.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a non-provisional of “ASSEMBLY EQUIPMENT LINE AND METHOD FOR WINDOWS,” U.S. Ser. No. 61/716,871, filed Oct. 22, 2012 (Atty. Docket No. 724.0032USP1), which is incorporated herein by reference in its entirety. 
         [0002]    This application is related to the following U.S. patent applications: “TRIPLE PANE WINDOW SPACER, WINDOW ASSEMBLY AND METHODS FOR MANUFACTURING SAME”, U.S. 2012/0151857, filed Dec. 15, 2011 (Atty. Docket No. 724.0017USU1); “SEALED UNIT AND SPACER”, U.S. 2009/0120035, filed Nov. 13, 2008 (Atty. Docket No. 724.0009USU1); “BOX SPACER WITH SIDEWALLS”, U.S. 2009/0120036, filed Nov. 13, 2008 (Atty. Docket No. 724.0012USU1); “REINFORCED WINDOW SPACER”, U.S. 2009/0120019, filed Nov. 13, 2008 (Atty. Docket No. 724.0011USU1); “SEALED UNIT AND SPACER WITH STABILIZED ELONGATE STRIP”, U.S. 2009/0120018, filed Nov. 13, 2008 (Atty. Docket No. 724.0013USU1); “MATERIAL WITH UNDULATING SHAPE” U.S. 2009/0123694, filed Nov. 13, 2008 (Atty. Docket No. 724.0014USU1); and “STRETCHED STRIPS FOR SPACER AND SEALED UNIT”, U.S. 2011/0104512, filed Jul. 14, 2010 (Atty. Docket No. 724.0015USU1); “WINDOW SPACER APPLICATOR”, U.S. 2011/0303349, filed Jun. 10, 2011 (Atty. Docket No. 724.0016USU1); “WINDOW SPACER, WINDOW ASSEMBLY AND METHODS FOR MANUFACTURING SAME”, U.S. Provisional Patent Application Ser. No. 61/386,732, filed Sep. 27, 2010 (Atty. Docket No. 724.0008USP1); “SPACER JOINT STRUCTURE”, US-2013-0042552-A1, filed on Oct. 22, 2012 (Atty. Docket No. 724.0009USI1); “ROTATING SPACER APPLICATOR FOR WINDOW ASSEMBLY”, U.S. 2013/0047404, filed on Oct. 22, 2012 (Atty. Docket No. 724.0016USI1); “SPACER HAVING A DESICCANT”, filed on Oct. 21, 2013 (Atty. Docket No. 724.0031USU1); “TRIPLE PANE WINDOW SPACER HAVING A SUNKEN INTERMEDIATE PANE”, filed on Oct. 21, 2013 (Atty. Docket No. 724.0034USU1), which are all hereby incorporated by reference in their entirety. 
     
    
     TECHNOLOGICAL FIELD 
       [0003]    The technology disclosed herein generally relates to assembly equipment. More particularly, the technology disclosed herein relates to assembly equipment for window units. 
       SUMMARY 
       [0004]    The technology disclosed herein generally relate to assembly equipment for window units. In one embodiment, a window unit assembly system is taught that has a frame component that is configured to support equipment for a window unit assembly line. A pane conveyor is supported by the frame component and is configured to move panes along the window unit assembly line. A spacer conveyor is supported by the same frame component as the pane conveyor and is configured to move spacer elements along the window unit assembly line. 
         [0005]    In another embodiment taught herein, a window unit assembly has a frame component arranged in a window unit assembly line. A pane conveyor is supported by the frame component and is configured to move panes along the window unit assembly line in a first direction. A spacer conveyor is configured to move spacer elements along the window unit assembly line in a second direction, wherein the second direction is directly opposite to the first direction. 
         [0006]    In yet another embodiment, the technology disclosed herein is related to a window unit assembly system that has a plurality of frame components configured to support equipment for a window unit assembly line. A plurality of pane conveyors, which are each supported by one of the frame components, are configured to move panes along the window unit assembly line. A plurality of spacer conveyors, which are each supported by one of the frame components, are configured to move spacer elements along the window unit assembly line. The plurality of frame components includes a first frame component and at least a second frame component. The first frame component supports both one of the plurality of pane conveyors and one of the plurality of spacer conveyors, and the second frame component support both another one of the plurality of pane conveyors and another one of the plurality of spacer conveyors. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0007]      FIG. 1  is a perspective view of a window assembly. 
           [0008]      FIG. 2  is a side view of the window assembly of  FIG. 1 . 
           [0009]      FIG. 3  is a perspective view of a spacer suitable for use with the window assembly of  FIG. 1 . 
           [0010]      FIG. 4  is a perspective view of the spacer having a plurality of notches. 
           [0011]      FIG. 5  is an enlarged perspective view of a portion of the spacer of  FIG. 4 . 
           [0012]      FIG. 6  is a schematic view of one embodiment of a window assembly system for assembling a window unit. 
           [0013]      FIG. 7  is a perspective view of one embodiment of a window assembly system for assembling a window unit. 
           [0014]      FIG. 8  is a close-up perspective view of a portion of the window assembly system of  FIG. 7 . 
           [0015]      FIG. 9  is a front view of the window assembly system of  FIG. 7 . 
           [0016]      FIG. 10  is a perspective view of one embodiment of a window assembly system for assembling a window unit. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Reference will now be made in detail to the exemplary aspects of the present disclosure that are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like structure. 
         [0018]    A series of machines and arrangement of those machines is described herein that will allow window manufacturers to save valuable floor space while manufacturing window assemblies by combining the processing of both the panes of glazing materials, such as glass panes, and spacer materials on a single assembly line structure. In one embodiment, the panes are loaded and processed using pane conveyers while the spacer is loaded and processed using spacer conveyors, and the spacer conveyors are mounted on the same frame elements as the pane conveyors. As a result, a separate line for processing the spacer is not required and valuable floor space is conserved. Also, separate frame elements are not required, so the cost of the assembly equipment is reduced. In one embodiment, the spacer conveyors are mounted below the pane conveyors. 
         [0019]    In one embodiment, the spacer conveyors move the spacer in a first direction along the assembly line during processing, while the pane conveyors move the panes in a second opposite direction along the assembly line during processing. In one embodiment, the second direction is 180 degrees from, or directly opposite to, the first direction. The panes and the spacer are transferred along the assembly line, in opposite directions, until they meet at a spacer application unit, which attaches a spacer to at least one pane. 
         [0020]    The basic structure of a window assembly will now be described in more detail with reference to  FIGS. 1 ,  2  and  3 . 
         [0021]    Referring now to  FIG. 1 , a window assembly  10  is shown. The window assembly  10  includes a first pane  12 , a second pane  14  and a spacer  16  disposed between the first and second panes  12 ,  14 . In the subject embodiment, the first and second panes  12 ,  14  are adapted to allow at least some light to pass through the panes  12 ,  14 . The first and second panes  12 ,  14  are made of a translucent or transparent material. In the subject embodiment, the first and second panes  12 ,  14  are made of a glass material. In another embodiment, the first and second panes  12 ,  14  are made of a plastic material. 
         [0022]    Referring now to  FIG. 2 , the first pane  12  includes a first surface  18  and an oppositely disposed second surface  20 . The second pane  14  includes a first surface  22  and an oppositely disposed second surface  24 . 
         [0023]    The spacer  16  is disposed between the first and second panes  12 ,  14  to keep the first and second panes  12 ,  14  spaced apart from each other. The spacer  16  is shaped into a spacer frame. The spacer  16  is adapted to withstand compressive forces applied to the first and second panes  12 ,  14  and to maintain a desired space between the first and second panes  12 ,  14 . 
         [0024]    The spacer  16  is sealingly engaged to each of the first and second panes  12 ,  14  at an edge portion  26  of each of the first and second panes  12 ,  14 . The edge portion  26  is adjacent to the outer perimeter of the panes. In the depicted embodiment, the spacer  16  is sealingly engaged to the second surface  20  of the first pane  12  and the second surface  24  of the second pane  14 . 
         [0025]      FIGS. 1 and 2  illustrate one possible embodiment of a window assembly unit that can be manufactured using the methods and equipment described herein. However, other window assembly units could also be made using the methods and equipment described herein. For example, a triple pane window unit could be manufactured using many of the techniques described herein. 
         [0026]    Referring now to  FIG. 3 , one embodiment of a spacer  16  is shown. Further options for a spacer suitable for use with the window assembly  10  are numerous and some have been described in the other patent applications and patents that are incorporated by reference herein. 
         [0027]    The spacer  16  includes a first strip  30  of material and a second strip  32  of material. The first and second strips  30 ,  32  are generally flexible in both bending and torsion. In some embodiments, bending flexibility allows the spacer  16  to be bent to form non-linear shapes (e.g., curves). Bending and torsional flexibility also allows for ease of window manufacturing. Such flexibility includes either elastic or plastic deformation such that the first and second strips  30 ,  32  do not fracture during installation into window assembly  10 . Some embodiments of spacer  16  include strips that do not have substantial flexibility, but rather are substantially rigid. In some embodiments, the first and second strips  30 ,  32  are flexible, but the resulting spacer  16  is substantially rigid. 
         [0028]    In one embodiment, the first and second strips  30 ,  32  are formed from a metal material or a plastic material. In the depicted embodiment, each of the first and second strips  30 ,  32  has a plurality of undulations  34 . The first strip  30  includes a first side portion  36  and an oppositely disposed second side portion  38 . The first strip  30  further includes a first surface  40  and an oppositely disposed second surface  42 . The second strip  32  includes a first side portion  44  and an oppositely disposed second side portion  46 . The second strip  32  further includes a first surface  48  and an oppositely disposed second surface  50 . 
         [0029]    The second strip  32  includes a plurality of passages  52  that extend through the first and second surfaces  48 ,  50  of the second strip  32 . In the depicted embodiment, the passages  52  are generally aligned along a central longitudinal axis  54  of the second strip  32 . Other embodiments include other arrangements of passages  52 , such as multiple rows of passages  52 . Passages can be openings or apertures of any shape including slits, circular apertures, or the like. 
         [0030]    The spacer  16  includes a first sidewall  56  and a second sidewall  58 . The first and second sidewalls  56 ,  58  extend between the first strip  30  and the second strip  32 . In the depicted embodiment, the first sidewall  56  is engaged to the first side portion  36  on the first surface  40  of the first strip  30  and the first side portion  44  on the first surface  48  of the second strip  32 . In one embodiment, the first and second sidewalls  56 ,  58  extend the length of the first and second strips  30 ,  32 . 
         [0031]    Each of the first and second elongate strips  30 ,  32  includes a first elongate edge and a second elongate edge. The first elongate edge is at the edge of the first side portion  36 ,  44  of each strip and the second elongate edge is at the edge of the second side portion  38 ,  46  of each strip. The first extruded sidewall  56  is closer to the first side portion  36 ,  44  of each strip  30 ,  32  than to the second side portion  38 ,  46  of each strip  30 ,  32 . The first sidewall  56  is offset from the first edge of the first elongate strip  30  and from the first edge of the second elongate strip  32  by a first offset distance. The second extruded sidewall  58  is closer to the second side portion  38 ,  46  of each strip  30 ,  32  than to the first side portion  36 ,  44  of each strip  30 ,  32 . The second sidewall  58  is offset from the second edge of the first elongate strip and from the second edge of the second elongate strip by a second offset distance that will be substantially similar to the first offset distance. 
         [0032]    In one embodiment, the first and second sidewalls  56 ,  58  are manufactured from a plastic material. The plastic material can be extruded, rolled or molded to form the first and second sidewall  56 ,  58 . 
         [0033]    The first and second strips  30 ,  32  and the first and second sidewalls  56 ,  58  cooperatively define an interior region  60  of the spacer  16 . In one embodiment, a filler material is added to the interior region  60 . An exemplary filler material that may be added to the interior region  60  is and/or includes a desiccant material. In the event that moisture is present between the first and second panes  12 ,  14  ( FIGS. 1 and 2 ), the moisture passes through the passages  52  of the second strip  32  and is absorbed by the desiccant material in the interior region  60  of the spacer  16 . 
         [0034]    The first side portion  36  of the first strip  30 , the first sidewall  56  and the first side portion  44  of the second strip  32  cooperatively define a first side  62  of the spacer  16 . The second side portion  38  of the first strip  30 , the second sidewall  58  and the second side portion  46  of the second strip  32  cooperatively define a second side  64  of the spacer  16 . The interior region  60  is disposed between the first and second sides  62 ,  64  of the spacer  16 . 
         [0035]    Many additional spacer embodiments can be used with the assembly system described herein, including spacers constructed of foam, for example. The spacer embodiment of  FIG. 3  is just one example of a spacer element that can be used with the assembly system described herein. 
         [0036]    In some embodiments of the window assembly system, a reeled length of spacer is provided to the assembly system coiled on a storage spool. The reeled length of spacer on the spool is much longer than is needed for assembly of each individual window unit. In one embodiment, the reeled length of spacer is continuously wrapped about the storage spool. During the window assembly process, the reeled length of spacer is unreeled and cut into discrete spacer elements  202 , such as shown in  FIG. 4 , having a first end  204  and a second end  206 . In one embodiment, each discrete spacer element  202  is sized to be bent to form a spacer frame that is adjacent to the entire perimeter of a window unit  10  ( FIG. 1 ). In one embodiment, the spacer element  202  can include corner notches  210 , as shown in  FIGS. 4 and 5 , to facilitate bending of the spacer element  202  at the corners of the window unit. In other embodiments, discrete spacer elements are each sized to be positioned along a single side of the window unit. 
         [0037]    In the depicted embodiment of  FIGS. 4 and 5 , the notches  210  are generally V-shaped. Each notch  210  extends through the second strip  32 , the first and second sidewalls  56 ,  58  and up to partially through the first surface  40  of the first strip  30 . In the depicted embodiment, the notch  210  defines an angle that is about 90 degrees, although the angle of the corner notch  210  can have different measurements depending on the desired angle measurement of the resultant corner in the formed spacer frame. 
         [0038]      FIG. 6  is a schematic view of a series of machines arranged into a window assembly system  600 . The system  600  includes many machines that can be roughly divided into two types of equipment: spacer processing equipment and window unit assembly equipment. The spacer processing equipment generally acts on the spacer element alone to prepare the spacer for incorporation into a window unit, which may also be referred to as a glazing unit. The window unit assembly equipment generally acts on the panes, joins the panes with the spacer to form subassemblies, acts on the subassemblies to form window units, and acts on the window units. The spacer processing equipment is provided with spacer conveyor elements  602  to move the spacer from machine to machine. The window unit assembly equipment is provided with pane conveyors  604  that move the panes of material from machine to machine, and then move the assembled window unit from machine to machine for further processing. Some pieces of equipment, such as the spacer application unit, could be described as both spacer processing equipment and window unit assembly equipment. 
         [0039]    In one embodiment, the spacer conveyors  602  move the spacer in a first direction indicated by arrow  606  along the assembly line  600  during processing, while the pane conveyors  604  move the panes and window units in a second opposite direction indicated by arrow  608  during processing. In the embodiment of  FIGS. 6-9 , the second direction is 180 degrees from, or directly opposite to, the first direction. The panes and the spacer are transferred along the assembly line, in opposite directions, as they undergo processing steps, until they meet at a spacer application unit  620 . The spacer application unit  620  assembles a discrete length of the spacer into a spacer frame and applies the spacer frame to a pane to form a pane/spacer subassembly. Then the subassembly proceeds in the second direction indicated by arrow  608  along pane conveyors  604  to undergo further processing steps. 
         [0040]    The assembly system  600  has a first end  601  and a second end  603 . In one embodiment, the panes are input at the first end  601  and the pane conveyors  604  are present at the first end  601  and continue in the second direction  608 . In one embodiment, the spacers are input at the second end  603  and the spacer conveyors  606  are present at the second end  603  and continue in the first direction  606 . 
         [0041]      FIG. 7  is a perspective view of one embodiment of a window unit assembly system  600 . The arrows  606 ,  608  indicating the direction of movement of the spacers and panes, respectively, are shown in  FIG. 7 . The spacer conveyors  602  and pane conveyors  604  are also labeled in  FIG. 7 , although they are small in the representation of  FIG. 7 . The machines of the assembly line  600  are supported by frame elements  622  shown in  FIG. 7 , which are positioned along the assembly line. In one embodiment, at least some of the spacer conveyors  602  and pane conveyors  604  are supported by the same frame elements  622 . 
         [0042]      FIG. 8  shows a close up view of one portion of a frame element  622  where both a spacer conveyer  602  and a pane conveyor  604  are supported by the same frame element  622 . As a result, a separate line for processing the spacer is not required and valuable floor space is conserved. Also, separate frame elements are not required, so the cost of the assembly equipment is reduced. A conveyor is any type of mechanical apparatus that moves articles from place to place. One example of a conveyor that is illustrated in  FIG. 8  includes two or more pulleys and a continuous loop of material that rotates around the pulleys. Many other options for conveyors may be used with the embodiments described herein. 
         [0043]    In the embodiment of  FIGS. 7-9 , the spacer conveyors are mounted below the pane conveyors. Other arrangements are also possible, such as spacer conveyors being mounted above the pane conveyors. 
         [0044]      FIG. 9  is a front view of the window unit assembly system  600  of  FIG. 7 . Now referring to  FIGS. 6 ,  7  and  9 , examples of machines included in the window assembly system  600  will now be described. However, these examples should not be considered limiting, as many different types of machines may be present on a window assembly line. The patents and patent applications incorporated herein by reference provide further examples of and further descriptions of machines that can be located in a window unit assembly system. 
         [0045]    First, some examples of spacer processing equipment will be provided. One example of spacer processing equipment is an unwind station  630  to unwind a length of spacer from a longer reeled length of spacer on a spool  632  for incorporation into a window unit. The spacer processing equipment can also include a punching station  636  for punching corner notches into the length of spacer and for cutting the ends of the spacer length to separate the discrete spacer length from the reeled spacer. An extruder station  638  is used to extrude sealant onto the spacer, in some embodiments. For the spacer  16  shown in  FIG. 3 , the sealant is extruded into the cavities present at the first side  62  and the second side  64  of the spacer  16 . The spacer with sealant is conveyed to the spacer application station  620 . In one embodiment, the spacer application station  620  wraps the spacer around a spacer retention structure to shape the spacer into a spacer frame. The spacer frame may have a rectangular shape or another closed shape. The spacer application station  620  then applies the wrapped spacer to a pane that is present on a pane conveyor at the spacer application station  620 . 
         [0046]    In one embodiment, the spacer conveyors  602  are present from a second end  603  of the system line  600  to the spacer application station  620 . In the embodiment of  FIGS. 6-9 , the extruder station  638  is present at the same location as another piece of window unit assembly equipment, such as a buffer station  660 . Both spacer conveyors  602  and pane conveyors  604  are present at the combination of the extruder station  638  and the buffer  660 . In the spacer flow of the first direction  606 , the extruder station  638  is upstream from the spacer application station  620  but not upstream from all the rest of the window unit assembly equipment. This aspect is in contrast with the embodiment of  FIG. 10 , where the extruder station  638  is upstream from all of the window unit assembly equipment. 
         [0047]    Examples of window unit assembly equipment will now be provided, starting at one end of the assembly line and moving in the second direction indicated by arrow  608 . The system  600  includes an edge coating removal station  650 , where edge coatings can be removed from the panes, a loading station  656 , where panes can be loaded onto a pane conveyor  604 , and a vertical washer  658 , where panes can be washed. Although only one is pictured in the schematic drawing of  FIG. 6 , the system may include several buffer conveyor units  660  that are illustrated in  FIGS. 7 and 9  and may be positioned between some of the other machines. The buffer conveyor units  660  serve to hold a pane on pane conveyors  604  to be ready for the next step in the process. 
         [0048]    The pane is delivered by pane conveyors  604  from the first end  601  of the system  600  to the spacer application station  620  where a pane is joined to a spacer frame, in one embodiment, forming a pane/spacer subassembly. The pane/spacer subassembly is moved in the second direction of arrow  608  to further processing machines. One example of such a machine is a muntin station  664 , which applies muntin bars or other structures that will be located between the first and second panes to the pane/spacer subassembly, if appropriate for the window unit being assembled. The pane/spacer subassembly then moves to the assembly station  668  where the second pane is attached to the spacer to form a window unit. The window unit moves to the buffer conveyor station  660 , which is held on the same frame element  622  as the sealant extruder station  638 . Next the window unit moves to the gas filling station  670 , which fills the space between the first and second panes with a selected gas or gas mixture. Next the window unit moves to the press station  672  where it is pressed to a specified thickness. The pressure provided at this step wets out the sealant connections within the window assembly. Then the window unit moves to the second seal station  674  where sealant is applied around the perimeter of the window unit adjacent to the spacer  16  ( FIG. 1 ). Finally the window unit moves to the unload station  676  where the window unit can be unloaded. In one embodiment, the pane conveyors  604  are present along the system line  600  from a first end  601  to the unload station  676 , and are not present at the punch station  636  or spacer unwind station  630 , which are examples of spacer processing equipment. 
         [0049]      FIG. 10  illustrates an alternate embodiment  1000  of a window unit assembly system. System  1000  has many elements in common with system  600  of  FIGS. 7-9 , and like reference numbers are used to refer to like parts. In system  1000 , the extruder station  638 , which applies sealant to the spacer before it is applied to a pane, is located at a different location compared to system  600 . In system  600 , the extruder station  638  is located on the same frame element  622  as a buffer conveyor  660  and in between machines that are used to process the panes, subassemblies and window units. In system  600 , the extruder station  636  is located between the assembly station  668  and the gas filling station  670 . 
         [0050]    In system  1000 , the extruder station  638  is located at one end of a row of window unit assembly equipment machines that are used to process the panes, subassemblies and the window units. Like system  600 , in system  1000  the spacer moves along spacer conveyor elements in a first direction indicated by arrow  606  while the panes, subassemblies and window units move in a second direction indicated by arrow  608 . The spacer conveyors transport the spacer with sealant from the extruder station  638  to the spacer application station  620  where the spacer is shaped to form a spacer frame and applied to a pane. Like system  600 , in system  1000  many of the spacer conveyors and pane conveyors are located on common frame elements  622 . 
         [0051]    Various modifications and alterations of this disclosure will become apparent to those skilled in the art without departing from the scope and spirit of this disclosure, and it should be understood that the scope of this disclosure is not to be unduly limited to the illustrative embodiments set forth herein.