Glass seal tracking spacer applicator

Various embodiments provide a method for applying a spacer to a planar substrate, comprising supplying the spacer to be adhered to the planar substrate; defining a first notch, a second notch, and a third notch in the spacer; applying an adhesive to the spacer; translating the spacer in a longitudinal direction; aligning a first end of the spacer with a first corner of the planar substrate; feeding the spacer and the planar substrate between a front carriage and a rear carriage along a longitudinal axis of an unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, and rotating, with a six-axis robot, the planar sheet and adhered portion of spacer.

FIELD

Embodiments herein relate to systems and methods for applying a spacer to a pane of glass.

SUMMARY

In an embodiment, a method for applying a spacer to a planar substrate, is included, the method can include supplying the spacer to be adhered to the planar substrate, wherein the spacer comprises a first spacer corner, a second spacer corner, and a third spacer corner; applying an adhesive to the spacer; translating the spacer in a longitudinal direction; aligning a first end of the spacer with a first corner of the planar substrate; feeding the spacer and the planar substrate between a front carriage and a rear carriage along a longitudinal axis of an unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, wherein a portion of the spacer between a first end and a first spacer corner and a portion of the planar substrate between the first corner and a second corner is fed between the front carriage and the rear carriage resulting in a first adhered portion of the spacer; rotating, with a six-axis robot, the planar substrate and the first adhered portion of the spacer to bend the spacer at the first spacer corner, wherein the first spacer corner is aligned with the second corner of the planar substrate; feeding the spacer and the planar substrate between the front carriage and the rear carriage along the longitudinal axis of the unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, wherein a portion of the spacer between the first spacer corner and the second spacer corner and a portion of the planar substrate between the second corner and a third corner is fed between the front carriage and the rear carriage resulting in a second adhered portion of the spacer; rotating, with a six-axis robot, the planar substrate, the first adhered portion of the spacer, and the second adhered portion of the spacer to bend the spacer at the second spacer corner, wherein the second spacer corner is aligned with the third corner of the planar substrate; feeding the spacer and the planar substrate between the front carriage and the rear carriage along the longitudinal axis of the unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, wherein a portion of the spacer between the second spacer corner and the third spacer corner and a portion of the planar substrate between the third corner and a fourth corner is fed between the front carriage and the rear carriage resulting in a third adhered portion of the spacer; rotating, with a six-axis robot, the planar substrate, the first adhered portion of the spacer, the second adhered portion of the spacer, and the third adhered portion of the spacer to bend the spacer at the third spacer corner, wherein the third spacer corner is aligned with the fourth corner of the planar substrate; and feeding the spacer and the planar substrate between the front carriage and the rear carriage along the longitudinal axis of the unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, wherein a portion of the spacer between the third spacer corner and a second end of the spacer and a portion of the planar substrate between the fourth corner and the first corner is fed between the front carriage and the rear carriage resulting in a fourth adhered portion of the spacer.

In an embodiment, supplying the spacer to be adhered to the planar substrate, comprises: unwinding a length of spacer material from a spool of spacer material; straightening the length of spacer material that has been unwound from the spool; defining a first notch at the first spacer corner, a second notch at the second spacer corner, and a third notch at the spacer corner; and separating the length of spacer material from the remainder of the spacer material on the spool to form the spacer that has the first end and the second end, and that is equivalent in length to a final spacer perimeter.

In an embodiment, applying the adhesive to the spacer further includes applying the adhesive to a first side of the spacer and to a second side of the spacer.

In an embodiment, aligning the first end of the spacer with the first corner of the planar substrate results in the first end of the spacer being adjacent to or inset from the first corner of the planar substrate.

In an embodiment, rotating the planar substrate and an adhered portion of the spacer includes a rotation of 90°.

In an embodiment, applying the adhesive to the spacer at least partially overlaps in time with feeding the spacer and the planar substrate between the front carriage and the rear carriage.

In an embodiment, feeding the spacer and the planar substrate between the front carriage and the rear carriage includes moving the front carriage along the longitudinal axis of the unadhered portion of the spacer.

In an embodiment, feeding the spacer and the planar substrate between the front carriage and the rear carriage includes moving the planar substrate and spacer along the longitudinal axis of the unadhered portion of the spacer.

In an embodiment, at least one of the rotations of the planar substrate includes a translation and a rotation of the planar substrate.

In an embodiment, the translation of the planar substrate involves feeding the planar substrate between the front carriage and the rear carriage.

In an embodiment, a system for applying a spacer to a planar substrate, is included having a. a spacer preparation element configured to supply and prepare a spacer, b. an adhesive applicator, wherein the adhesive applicator is configured to apply an adhesive to the spacer, c. a transport mechanism configured to move the spacer in a longitudinal direction, d. a spacer application element, can include a front carriage and a rear carriage, wherein the front carriage and rear carriage define a gap, wherein the gap is configured to allow a portion of the spacer and a portion of the planar substrate to be fed between the front carriage and rear carriage, wherein the front carriage is configured to press the spacer against the planar substrate that is fed through the gap to apply the spacer to the planar substrate, and e. a six-axis robot configured to retain the planar substrate, to rotate the planar substrate and to move the planar substrate in the longitudinal direction, wherein the six-axis robot translates the planar substrate in the longitudinal direction at the same speed at which the transport mechanism moves the spacer.

In an embodiment, the front carriage is configured to move in the opposite direction that the six-axis robot translates the planar substrate in while compressing the spacer and the planar substrate.

In an embodiment, the front carriage and rear carriage are in a fixed location.

In an embodiment, the front carriage includes a horizontal roller and a vertical roller.

In an embodiment, the rear carriage includes a horizontal roller.

In an embodiment, the front carriage is configured to contact the spacer and the rear carriage is configured to contact a back surface of the planar substrate opposite from the spacer.

In an embodiment, the vertical roller and the horizontal roller are arranged such that an axis of rotation of the vertical roller is perpendicular to an axis of rotation of the horizontal roller.

In an embodiment, the system is configured to apply a spacer to a planar substrate that has an outer perimeter of up to 50 feet.

In an embodiment, the transport mechanism includes a conveyor belt.

In an embodiment, a method for applying a spacer to a planar substrate, is included, the method can include a. unwinding a length of spacer material from a spool of spacer material, b. straightening the length of spacer material that has been unwound from the spool, c. defining a first notch, a second notch, and a third notch in the length of spacer material, d. separating the length of spacer material from the remainder of the spacer material on the spool to form the spacer that has a first end and a second end, e. applying an adhesive to a first side and a second side of the spacer, f. translating the spacer in a longitudinal direction, g. aligning a first end of the spacer with a first corner of the planar substrate, h. feeding the spacer and the planar substrate between a front carriage and a rear carriage along a longitudinal axis of an unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, wherein a portion of the spacer between a first end and the first notch and a portion of the planar substrate between the first corner and a second corner is fed between the front carriage and the rear carriage resulting in a first adhered portion of the spacer, i. rotating, with a six-axis robot, the planar substrate and the first adhered portion of the spacer 90° to bend the spacer at the first notch, wherein the first notch is aligned with the second corner of the planar substrate, j. feeding the spacer and the planar substrate between the front carriage and the rear carriage along the longitudinal axis of the unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, wherein a portion of the spacer between the first notch and the second notch and a portion of the planar substrate between the second corner and a third corner is fed between the front carriage and the rear carriage resulting in a second adhered portion of the spacer, k. rotating, with a six-axis robot, the planar substrate, the first adhered portion of the spacer, and the second adhered portion of the spacer 90° to bend the spacer at the second notch, wherein the second notch is aligned with the third corner of the planar substrate, l. feeding the spacer and the planar substrate between the front carriage and the rear carriage along the longitudinal axis of the unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, wherein a portion of the spacer between the second notch and the third notch and a portion of the planar substrate between the third corner and a fourth corner is fed between the front carriage and the rear carriage resulting in a third adhered portion of the spacer, m. rotating, with a six-axis robot, the planar substrate, the first adhered portion of the spacer, the second adhered portion of the spacer, and the third adhered portion of the spacer 90° to bend the spacer at the third notch, wherein the third notch is aligned with the fourth corner of the planar substrate, and n. feeding the spacer and the planar substrate between the front carriage and the rear carriage along the longitudinal axis of the unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, wherein a portion of the spacer between the third notch and a second end of the spacer and a portion of the planar substrate between the fourth corner and the first corner is fed between the front carriage and the rear carriage resulting in a fourth adhered portion of the spacer.

DETAILED DESCRIPTION

Many window assemblies or insulating glass units can include a first sheet or pane of glass, a second sheet or pane of glass, and a spacer that separates the first sheet and second sheet. During the manufacturing process of the window assembly, the spacer can be formed into a spacer frame having the same shape as the perimeter of the window assembly, such as a rectangle, a triangle, a trapezoid, other polygons, archtop, doghouse, or other irregular shapes. In many examples, the spacer can be unwound from a spool of spacer material and cut to the desired length. The spacer can also have one or more notches cut into the spacer, such as to allow for a corner or a bend to be formed in the spacer. The spacer can have an adhesive or sealant applied to two opposite sides of the spacer, such as to adhere the spacer to the two sheets.

Described herein are various systems and methods for applying a spacer to a planar substrate of a window assembly or insulated glass unit (IGU). Various embodiments disclosed herein can provide a system or method which can quickly and accurately apply a spacer to the planar substrate. Various embodiments provide reduced assembly times and a smaller footprint than present systems and methods that are used to apply a spacer to a planar substrate. In some embodiments, a portion of the spacer can be applied or adhered to the planar substrate while another portion of the spacer, such as the opposite end, is still being prepared, which can result in the system requiring a smaller footprint.

FIG. 1shows a perspective view of a window assembly100, according to some embodiments.FIG. 2shows a cross-section view of the window assembly100along line2-2inFIG. 1. The window assembly100can include a first planar substrate and a second planar substrate, or a first sheet102and a second sheet104. The window assembly100can include a spacer106disposed between the first sheet102and the second sheet104. In some embodiments, the spacer106is slightly inset from the outer perimeter of the first sheet102and the second sheet104. In various embodiments, the spacer106can be adhered to an inner surface of the first sheet102and an inner surface of the second sheet104. The inner surfaces of the first sheet102and the second sheet104can face each other. In various embodiments, the window assembly100can include a frame that extends around the perimeter of the first sheet102and the second sheet104. The frame is not shown inFIG. 1.

The first sheet102and the second sheet104can include a translucent, transparent, or semi-transparent material, such as to allow light to pass through the two sheets102,104or to allow a person to see through the two sheets102,104. In various embodiments, the first sheet102and the second sheet104include glass, such as a clear glass. In various embodiments, the first sheet102and the second sheet104can be similar, such that the two sheets102,104have a substantially similar shape and/or size.

The spacer106can be coupled to or adhered to the first sheet102and the second sheet104. The spacer106can extend from the first sheet102to the second sheet104, such as to define a volume220. The volume220is shown inFIG. 2, which is a cross-sectional view of the window assembly ofFIG. 1in accordance with some embodiments. The volume220is defined between the first sheet102and the second sheet104. The spacer106also forms a boundary of the volume220.

The spacer106is formed into a spacer frame105that surrounds the volume220. The spacer frame105has a shape that matches the outer perimeter shape of the window assembly100. For example, where the window assembly100is rectangular as inFIG. 1, the spacer frame105is a rectangle. In other embodiments, the window assembly100can be a different shape, such as mentioned before. In various embodiments, the spacer106can be formed into a square, a rectangle, a triangle, a trapezoid, a polygon, a regular polygon, a doghouse shape, or an irregular shape such as an archtop.

In various embodiments, the window assembly100can include one or more muntin bars107. One or more muntin bars107can be disposed within the window, such as between the first sheet and the second sheet. Muntin bars107can be included in a window assembly, such as to increase the aesthetic appeal. In some window assemblies the muntin bars can be arranged in a grid, such as a one by one grid as shown inFIG. 1, including one vertical muntin bar and one horizontal muntin bar. The muntin bars107can be disposed within the volume220defined by the first sheet102, the second sheet104and the spacer106. The muntin bars107can have a first end and a second end. The first end and second end can be coupled to opposite portions of the spacer106, such that the muntin bar107can extend across the window assembly100.

The spacer106shown inFIGS. 2-4are examples of spacers that can be applied using the systems and methods described herein. It should be understood that other spacer shapes and configurations could also be used.

In some embodiments, the spacer106can include a first elongated strip208, a second elongated strip210, a first lateral side wall212, and a second lateral side wall214. The spacer106can define an interior space216. In various embodiments, the interior space216can be at least partially occupied by a filler226, where the filler226includes a desiccant. The purpose of the desiccant is to absorb moisture from the gas within the interior space216of the window assembly100in order to reduce or eliminate fogging on the interior surfaces of the first sheet102and second sheet104.

The filler226provides a structure for retaining desiccant within the interior space216of the spacer106. As a result, there is not a need for loose beaded desiccant positioned in the spacer in many embodiments. In other spacers, it is common to have loose beaded desiccant positioned within the spacer.

The filler226is generally configured to contain/hold a desiccant material. The filler226can be a variety of materials and combinations of materials. In a variety of embodiments, the filler226holds its form and does not break apart easily. The filler226can generally be any type of adhesive material. As used herein, the term “adhesive material” is defined as any material that chemically hardens and is from natural or synthetic origins. Examples of synthetic substrates are acrylics, silicones, urethanes, etc. Examples of natural substrates include starches, collagen, natural resin, and the like.

The filler226can include a matrix material and can have a desiccant disposed within. Examples of matrix desiccants include those manufactured by W.R. Grace & Co. based in Columbia, Md. and H.B. Fuller Company based in Saint Paul, Minn. One particular example matrix material is HL-5157 produced by H.B. Fuller Company. In some embodiments, the filler226can incorporate beaded desiccant within or attached to the filler226. One example is described in “SPACER HAVING A DESICCANT”, U.S. 2014/0113098, filed on Oct. 21, 2013.

In a variety of embodiments, the filler226is also configured to provide an increased surface area exposed to the atmosphere compared to the surface area in contact with a strip of a spacer. As such, the surface area of the filler226in contact with the elongate strip is less than the surface area of the filler226that is not in contact with the elongate strip. The filler226can be a variety of shapes, although it is depicted in the Figures as having a semi-circle cross-section. In one alternate example, the filler has a tubular cross section. Those having skill in the art will appreciate that other shapes can also be used.

In some embodiments, the first elongated strip208can define one or more breather holes, such as small apertures in the first elongated strip208that can allow gas to pass from the volume220between the first sheet102and the second sheet104into the interior space216, where the gas can come into contact with the filler226. It is also possible for gas from the volume220to pass into the interior space216through other openings, such as corner notches or muntin openings, which are further described herein.

In some embodiments of the spacer106, the first elongated strip208can be parallel with the second elongated strip210. In some embodiments, the first lateral side wall212can be parallel with the second lateral side wall214. In some embodiments, the first elongated strip208and the second elongated strip210can be perpendicular to the first lateral side wall212and the second lateral side wall214.

In various embodiments, the lateral side walls212,214can be recessed from the edge of the first elongated strip208and the second elongated strip210, such as to define an exterior space218along elongate edges of the spacer106. The exterior space218can be separated from the interior space216of the spacer106by the lateral side walls212,214. In various embodiments, the exterior space218can be further bounded and defined by the first sheet102or the second sheet104. In some embodiments, the exterior space218can be at least partially or completely filled with an adhesive or sealant, such as to adhere the spacer106to the first sheet102and/or the second sheet104, and to adhere the first sheet102to the second sheet104.

FIG. 3shows a top view of a spacer106in accordance with various embodiments herein.FIG. 4shows a front view of the spacer106fromFIG. 3. In various embodiments, the spacer106can have a plurality of notches332,334,336cut into the spacer106. The number of notches can be equivalent to the number of corners the spacer106will be bent at. The spacer106can be bent at each of the notches, such as to form the spacer frame105. In some embodiments, the locations of the notches332,334,336can be the location of spacer corners. Spacer corners are can be portions of the spacer106that can be intended to be corners of the spacer frame. In some embodiments, the spacer corners are substantially the same the majority of the remainder of the spacer106. In some embodiments, the spacer corners can be marked, such as to have a visual indication as to where the spacer106will be bent. In some embodiments, the notches332,334,336can be defined at the spacer corners.

In some embodiments, the spacer106does not include a plurality of notches. In some embodiments, the system can be configured to bend the spacer at the corners without a notch, such as that an outer portion of the spacer106can be in tension, while an inner portion of the spacer106is in compression. In some embodiments, the system does not need to align notches with corners of the sheet102, since a corner can be bent in any portion of the spacer106.

In various embodiments, the spacer106can include a first end328and a second end330. The first end328and the second end330can be configured to mate with each other to form a closed loop for the spacer frame105. In some embodiments, the second end330can include a tail338, such as a portion of the first elongated strip208that extends beyond the remainder of the spacer106.

In various embodiments, the spacer106can include one or more notches332,334,336, such as to facilitate bending the spacer106into the spacer frame105. In some embodiments, the spacer106can include a first notch332, a second notch334, and a third notch336. The notches332,334,336can be disposed between the two ends328,330. In some embodiments, the first end328can include half of a fourth notch340and the second end330can include the second half of the fourth notch340, such that the first end328can mate with the second end330at a corner of the spacer frame105that aligns with a corner of the first sheet102and/or second sheet104. In some embodiments, the distance between first end328and first notch332is equivalent to the distance between the second notch334and the third notch336, and the distance between the first notch332and the second notch334is equivalent to the distance between the third notch336and the second end330.

FIG. 5shows a perspective view of a system500for applying a spacer106to a sheet102,104in accordance with various embodiments herein.FIG. 5also shows the x-axis, y-axis, and z-axis. The arrows of the axes point in what will be referred to as the positive direction along the given axis. In various embodiments, the system500can be configured to apply a spacer106to a sheet102. In some embodiments, system500can be configured to accept a planar substrate or sheet102that can be up to 2.5 meters tall, 5 meters long, and weigh about 380 kilograms.

The system500can include a spacer preparation element550, an adhesive application element552, and a spacer application element554. In various embodiments, a transport mechanism556can move the spacer106through one or more of the elements in the system500. The transport mechanism556can be configured to move the spacer106in a longitudinal direction. In the figures, the longitudinal direction is in the X direction. In some embodiments, the transport mechanism556can include a conveyor, such a conveyor belt or motorized rollers.

In some embodiments, a portion of the spacer106can still be within the spacer preparation element550while the first end of the spacer106is being adhered to the sheet102. The footprint of the system500can be greatly reduced as a result of the second end of the spacer still being prepared while the first end of the spacer is being applied, because the footprint of the system does need not extend to a length equivalent to the length of the unbent spacer106.

Spacer Preparation

The spacer preparation element550can prepare a spacer106to be applied to a sheet102. The spacer preparation element550can cut, trim, or otherwise define the one or more notches into the spacer106. The spacer preparation element550can cut the spacer106to a desired length, such as to separate the spacer106from a stock or reel of spacer material. In some embodiments, the spacer preparation element550can unwind and/or straighten a spacer106. In various embodiments, once the spacer106leaves the spacer preparation element550, the spacer106can proceed into the adhesive application element552. In some embodiments, the spacer preparation element550can alter, form, or prepare the spacer106to receive one or more muntin bars or SDL (“simulated divided lites”) bars.

Adhesive Application

The adhesive application element552can apply an adhesive or sealant to the spacer106. In some embodiments, the system can include a spacer106that has already been prepared with a sealant or adhesive prior. In some embodiments, the adhesive or sealant can be applied to two sides of the spacer106, such as the two sides of the spacer106that will face the first sheet102and the second sheet104. In some embodiments, the adhesive or sealant can be applied to the exterior spaces218of the spacer106as discussed above. The adhesive application element552can extrude the adhesive at a constant rate onto the spacer106. In some embodiments, the spacer106can move in the +X direction at about 200 mm/s. In some embodiments, the spacer106can move in the +X direction at a speed of at least 50 mm/s and not more than 1500 mm/s.

In various embodiments, the adhesive or sealant can include polyisobutylene (PIB), butyl, curable PIB, hot melt silicon, acrylic adhesive, acrylic sealant, and other Dual Seal Equivalent (DSE) type materials.

Spacer Application

Various embodiments provide a spacer application element554for applying a spacer106to a sheet102. The spacer application element554can include a front carriage564and a rear carriage566. The front carriage564and rear carriage566can define a gap. The gap is configured to allow a portion of the spacer106and a portion of the sheet102to be fed between the front carriage564and rear carriage566, such as shown inFIG. 9. The spacer106and the planar substrate102that is fed through the gap can be compressed to apply the spacer to the planar substrate, such as the front carriage564contacting the spacer106to apply the spacer106to a surface of the sheet102and the rear carriage566contacting an opposite surface of the sheet102.

The spacer application element554can include a six-axis robot558configured to retain the sheet102, to rotate the sheet102and to move the sheet102in the longitudinal direction. The six-axis robot558can translate the sheet102in the longitudinal direction at the same speed at which the transport mechanism556moves the spacer106in the longitudinal direction.

The spacer application element554can apply or adhere a spacer106to a sheet102. In some embodiments, the spacer application element554can include a robot558. The robot558can move the sheet102, such as to lift, lower, rotate, or translate the sheet102. In various embodiments, the robot558can combine two motions, such as a rotation and a translation. In some embodiments, the robot558can include a six-axis robot, such as able to translate and rotate about the X-axis, the Y-axis, and the Z-axis. In some embodiments, the robot558can include a base560. In some embodiments, the base560can be mounted on rails (not shown), such as to translate the robot558along the x-axis or the longitudinal direction, such as to provide a seven-axis robot. In some embodiments, the robot558can include one or more vacuum elements562configured to temporarily couple the sheet102to the robot558.

In some embodiments, the spacer application element554can include a front carriage564and/or a rear carriage566. In various embodiments, the sheet102can be positioned between the front carriage564and the rear carriage566while a spacer106is applied to the sheet102. In various embodiments, the spacer106being applied to the sheet102can be disposed between the front carriage564and the sheet102.

The steps that the system500performs to apply the spacer106to the sheet102are shown inFIGS. 6, 11, and 14-16. The spacer106can exit the adhesive application element552and enter the spacer application element554. Upon entering the spacer application element554, the system500can know the size of the sheet102, the size of the spacer106, when and where the spacer106is located at all times, and the position of the sheet102in reference to the center of rotation of the robot558. In some embodiments, this information can be read by the system, such as a barcode the includes size information. In some embodiments, this information can be sensed or measured using sensors. In some embodiments, some of this information can be read, and other information can be sensed or measured.

The sheet102can include a first corner568, a second corner570, a third corner572and a fourth corner574. While the figures depict the sheet102as a rectangle, it should be understood that other shapes, some that include more than four corners, are also within the scope of this disclosure.

In some embodiments, the system500can apply the first notch332at the second corner570, the second notch334at the third corner572, and the third notch336at the fourth corner574. The first and second ends328,330, as well as the fourth notch340, can be applied at the first corner568. In some embodiments, the system500can start by aligning the first end328with the first corner568, such as shown inFIGS. 6-8 and 11.

FIG. 6shows a front view of the system during a step of applying a spacer106to a sheet102in accordance with various embodiments herein. The spacer106can be controlled after exiting the adhesive application element552by the front carriage564and/or the transport mechanism556.FIGS. 7 and 8show a close up of a portion of the spacer106being aligned with the sheet102.FIGS. 7 and 8show the front carriage564and a rear carriage566.

The front carriage564can include a first roller776which is a vertical roller which can rotate around an axis along the Z-axis. The first roller776can move along the Y-axis and/or the longitudinal axis (X-axis) of the unadhered spacer, such as to clamp the spacer106along the transport mechanism556. The first roller776can move along the X-axis, such as to follow the sheet102. The second roller778or horizontal roller can move along the Z-axis, such as to press the spacer106against the sheet102. The second roller778can move along the X-axis, such as to press along a portion of the spacer106to contact the sheet102. In various embodiments, the axis of rotation for a vertical roller can be perpendicular to the axis of rotation for a horizontal roller.

The sheet102can be held by the robot558in a pre-stage position, such as while the robot558waits for the spacer106to exit the adhesive application element552. The pre-stage position can be parallel or nearly parallel with the spacer106with the sheet102a distance away from the application position. The sheet102can rest on rollers (not shown), the first rear carriage566, and/or the second rear carriage682.

As the spacer106exits the adhesive application element552, the robot558(holding the sheet102) can match the speed of the spacer106in the +X direction, and position the sheet102to attached the first end328with the first corner568. At this point, the robot558, the sheet102, and/or the spacer106can be moving in the +X direction at the same speed. In some embodiments, the sheet102and the spacer106can continue moving in the +X direction while the front carriage564and the rear carriage are in a fixed location, such as to feed the sheet102and the spacer106through the front carriage564and the rear carriage566. In some embodiments, the sheet102and the spacer106can be still or in a fixed location as the front carriage564moves in the −X direction, such as to feed the sheet102and the spacer106through the front carriage564and rear carriage566. In some embodiments, the sheet102and the spacer106can move in the +X direction and the front carriage564can simultaneously move in the −X direction, such as to feed the sheet102and the spacer106through the front carriage564. In some embodiments, the front carriage564is configured to move in the opposite direction that the robot558translates the sheet102in while compressing the spacer106and the sheet102.

In some embodiments, once the first leg of the spacer106(between the first end328and the first notch332) is aligned with the edge of the sheet102between the first corner568and the second corner570(as shown inFIG. 12), the front carriage564can travel in the −X direction applying the spacer106to the sheet102, such as with a pneumatically actuated roller778, the sheet102and the spacer106can moved in the +X direction, or a combination thereof. In some embodiments, while the front carriage564is moving in the −X direction the sheet102and the spacer106can continue to move in the +X direction, such as at the same speed as the spacer106is exiting the adhesive application element552. In some embodiments, the front carriage564can travel in the −X direction at about 1500 mm/s.

In some embodiments, the front carriage564can travel towards the second corner570for a distance that is less than the distance between the first corner568and the second corner570, or a portion of the sheet102and the spacer106that is less than the distance between the first end328and the first notch332. In some embodiments, the front carriage564travels 50% of the distance towards the second corner570from the first corner568or 50% of the sheet102between the first corner568and the second corner570and 50% of the spacer106between the first end328and the first notch332is fed through the front carriage564. In other examples, the percentage can be 60%, 70%, 80%, 90%, or 95%. In various embodiments the front carriage564does not travel the entire length of the spacer106between the first end328and the first notch332, such as shown inFIG. 11. After the front carriage564has reached its desired amount of travel in the −X direction, the robot558can start locating a new tool center at the second corner570.

FIG. 9shows a schematic of a portion of the sheet102and spacer106being fed through the front carriage564and the rear carriage566in accordance with various embodiment herein.FIG. 9shows the sheet102and the spacer106with adhesive980disposed between. InFIG. 9, the sheet102and spacer106are being fed from left to right between the front carriage564and the rear carriage566. The portion of the spacer106that has already been fed through the carriages564,566is adhered to the sheet102resulting in an adhered portion982of the spacer106and an unadhered portion984of the spacer106. In various embodiments, a gap or space986can be defined between the adhesive980and the sheet102before the portions of the sheet102and spacer106have passed through the front carriage564and the rear carriage566.

FIG. 10shows a cross-section schematic of a portion of the sheet102and a portion of the spacer106being fed between the front carriage564and the rear carriage566in accordance with various embodiment herein. The front carriage564can include a horizontal roller778and a vertical roller776. The vertical roller776and the transport mechanism556can restrict movement of the spacer106in the Y-direction. The horizontal roller778and sheet102can restrict movement of the spacer106in the Z-direction. Restricting movement of the spacer106can ensure the system continues to know the location of the spacer and ensure proper alignment of the spacer106and the sheet102.

FIG. 11shows the sheet102in position for a first leg or portion of the spacer106to be applied the sheet. For clarity purposes, the spacer is not shown inFIG. 11.FIG. 12shows a schematic view of the spacer106and the planar substrate aligned in accordance with the configuration ofFIG. 11.

As shown inFIG. 12, the first end328can be aligned with the first corner568of the sheet102. At the same time, the first notch332can be aligned with the second corner570of the sheet102. In some embodiments, as the first portion of the spacer106is aligned with the sheet102, a portion of the spacer106(such as the second end330) can still be within the spacer preparation element550, such as still wound on a spool or not separated from a remainder of the spacer material. When the first end328of the spacer106is aligned with the first corner568of the sheet102, the spacer106will already have the first notch332cut. However, in some embodiments, when the first end328of the spacer106is aligned with the first corner568of the sheet102, the spacer106will not have one or more of the second notch or third notch cuts made.FIG. 12represents the configuration of the spacer106and the sheet102once the first end328is aligned with the first corner568, and before the spacer106and the sheet102have been fed through the front carriage564and the rear carriage566. In various embodiments, the first end328can be disposed between the front carriage564and the rear carriage566in the configuration ofFIG. 12.

FIG. 13is a schematic view of the spacer106and the sheet102fromFIG. 12after the first portion has passed between the front carriage564and the rear carriage566resulting in a first adhered portion1392and an unadhered portion1394of the spacer106.

After the first portion1392is adhered to the sheet102, the system can rotate, or rotate and translate, the sheet102in preparation for a second portion of the spacer106to be adhered between the second corner570and the third corner572. In some embodiments, as the sheet102is rotated, or rotated and translated, the spacer106is further fed in the +X direction to keep the spacer106aligned with sheet102.

In reference now toFIG. 14, a front view of the system500for applying a spacer is shown in accordance with various embodiments herein. In various embodiments, as soon as possible after the components are in a clear to rotate state, such as after a translation in the +X direction, the robot558can start to rotate the sheet102about the second corner570. The second corner570can continue to move in the +X direction at the constant speed at which the spacer106is exiting the adhesive application element552. The robot558can rotate the sheet102at a rate (relative to the movement in +X direction) that keeps the third corner572in a safe zone, such that the third corner572does not contact or hit any other components, such as the adhesive application element552. In some embodiments, the rotation of the sheet102can be performed in an efficient manner such that the base560can remain stationary. In other embodiments, the base560can travel along the X-axis as needed. In some embodiments, the robot558can keep the sheet102a small distance away, such as in the −Z direction as shown as gap986inFIG. 9, from the second notch334of the spacer106, such as to avoid smearing the adhesive that is disposed on the spacer106.

In reference now toFIG. 15, a front view of the system500for applying a spacer is shown in accordance with various embodiments herein. When the robot558is nearing the completion of rotating the glass about the second corner570, the robot558can continue to move the sheet102in the +X direction at the constant speed. The front carriage564can be positioned to attach the beginning of the next leg of the spacer106, such as the portion of the spacer106between the second notch334and the third notch336. The third corner572and the third notch336can be aligned as soon as possible without the third corner572rotating into any other components or into a safe boundary.

In reference now toFIG. 16, a front view of the system500for applying a spacer is shown in accordance with various embodiments herein. In various embodiments, the robot558can have finished rotating the sheet102around the second corner570. The robot558, the second corner570, the third corner572, and/or the spacer106can be traveling in the +X direction at the same constant speed. The front carriage564can once again travel in the −X direction applying 75%-80% of the spacer106to the sheet102, while the other components continue to travel in the +X direction. In some embodiments, the front carriage546travels in the −X direction for at least 50% of the length of the leg of the spacer106being applied to the sheet102and not more than 90% of the length of the leg. After the front carriage546completes its travel in the −X direction, the robot558can start locating a new tool center at the third corner572. The steps shown inFIGS. 6, 11, and 14-16can be repeated until all of the legs of the spacer are attached to the glass, such as shown inFIGS. 17-22. In various embodiments, once the second end330of the spacer exits the adhesive application element552, the robot558no longer needs to match the same speed at which the spacer106was exiting the adhesive application element552.

FIG. 17shows a schematic view of the spacer106and the sheet102with the second notch334aligned with the third corner572prior to feeding the portion of the spacer106between the first notch332and the second notch334and the portion of the sheet102between the front carriage564and the rear carriage566.FIG. 18shows a view ofFIG. 17after the second adhered portion1896has been formed.

FIG. 19shows a schematic view of the spacer106and the sheet102with the third notch336aligned with the fourth corner574prior to feeding the portion of the spacer106between the second notch334and the third notch336and the portion of the sheet102between the front carriage564and the rear carriage566.FIG. 20shows a view ofFIG. 19after the third adhered portion2098has been formed.

FIG. 21shows a schematic view of the spacer106and the sheet102with the second end330aligned with the first corner568prior to feeding the portion of the spacer106between the third notch336and the second end330and the portion of the sheet102between the front carriage564and the rear carriage566.FIG. 22shows a view ofFIG. 21after the fourth adhered portion2200has been formed to close the spacer frame105.

The final corner of the spacer can be closed in various different manners. In some embodiments, the robot558can complete another 90° rotation of the frame around the first corner568until the starting leg between the first corner568and the second corner570is parallel with the conveyor or transport mechanism to bend the tail338, such as by using the conveyor780to press the corner closed. In various embodiments, a surface or roller on the second rear carriage, in combination with robot558moves to close the fourth corner of the spacer frame. In some embodiments, a clamp can be used to close and hold the fourth corner closed. In some embodiments, the fourth corner can use a miter joint on a flat leg of the spacer106. Other joints can also be used to close the final corner of the spacer frame105

In various embodiments, after the spacer106has been completely adhered to the sheet102, a second sheet104can be adhered to the opposite side of the spacer106, such as to form the window assembly100shown inFIG. 1. In some embodiments, adhesive for attaching the second sheet104can be applied to the spacer106after the spacer106is adhered to the first sheet102. In some embodiments, adhesive for attaching the second sheet104can be applied to the spacer106simultaneously with adhesive for attaching the spacer106to the first sheet102.

Triple Pane

FIGS. 23-28show various embodiments related to triple pane windows. A triple pane window2300can include a first sheet2302, a second sheet2304and a third sheet2306. It should be understood that the sheets2302,2304,2306can be equivalent to the sheets102,104discussed above.

The second sheet2304can be disposed between the first sheet2302and the third sheet2306. The first sheet2302can be separated from the second sheet2304with a spacer106. Similarly, the second sheet2304can be separated from the third sheet2306with a second spacer106. Generally, the spacers106can be adhered to a sheet2302,2304,2306as discussed above.

FIG. 24shows a schematic side view of a manufacturing step of a triple pane IGU in accordance with various embodiments herein. In some embodiments, the spacers106are both adhered to the middle or second sheet2304. In some embodiments, both spacers106can be applied to the second sheet2304simultaneously. In various embodiments, the first sheet2302and the third sheet2306can be adhered to the respective spacers106after the spacers have been adhered to the second sheet2304.

FIGS. 25-27show schematic side views of manufacturing steps of a triple pane IGU in accordance with various embodiments herein. In some embodiments, a spacer106is adhered to a first sheet2302in the manner discussed above, shown inFIG. 25. A second sheet2304can be adhered to the opposite side of the spacer106as the first sheet2302, shown inFIG. 26. A second spacer106can be adhered to the opposite side of the second sheet2304in the manner discussed above, shown inFIG. 27. The third sheet2306can be adhered to the opposite side of the spacer106from the second sheet2304.

FIG. 28shows a schematic side view of a manufacturing step of a triple pane IGU in accordance with various embodiments herein. In some embodiments, a spacer106can be adhered to a first sheet2302, and a second spacer106can be adhered to the third sheet2306. The second sheet2304can be adhered to both spacers106to dispose the second sheet between the spacers106and the sheets2302,2306.

Methods

Many different methods are contemplated herein, including, but not limited to, methods of making, methods of using, and the like. Aspects of system/device operation described elsewhere herein can be performed as operations of one or more methods in accordance with various embodiments herein.

FIG. 29shows a flowchart of a method of applying a spacer to a planar substrate in accordance with various embodiments herein. In some embodiments, the method for applying a spacer to a planar substrate, includes preparing a spacer to be adhered to the planar substrate2902. In some embodiments, the method includes applying an adhesive to a first side of the spacer2904. In some embodiments, the method includes translating the spacer in a longitudinal direction2906. In some embodiments, the method includes aligning a first end of the spacer with a first corner of the planar substrate2908. In some embodiments, the method includes feeding the spacer and the planar substrate between a front carriage and a rear carriage2910, such as along a longitudinal axis of an unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, a portion of the spacer between a first end and a first notch and a portion of the planar substrate between the first corner and a second corner is fed between the front carriage and the rear carriage resulting in a first adhered length of the spacer. In some embodiments, the method includes rotating, with a six-axis robot, the planar substrate and the first adhered portion of the spacer to bend the spacer at the first notch2912. The first notch can be aligned with the second corner of the planar substrate.

It should be understood that the feeding step2910and the rotating step2912can be repeated for each side or edge of the planar sheet. For example, a method for a rectangular planar substrate would further include feeding the spacer and the planar substrate between the front carriage and the rear carriage along the longitudinal axis of the unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, wherein a portion of the spacer between the first notch and a second notch and a portion of the planar substrate between the second corner and a third corner is fed between the front carriage and the rear carriage resulting in a second adhered length of the spacer. The method would further include rotating, with a six-axis robot, the planar substrate, the first adhered portion of the spacer, and the second adhered portion of the spacer to bend the spacer at the second notch, wherein the second notch is aligned with the third corner of the planar substrate. The method would further include feeding the spacer and the planar substrate between the front carriage and the rear carriage along the longitudinal axis of the unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, wherein a portion of the spacer between the second notch and a third notch and a portion of the planar substrate between the third corner and a fourth corner is fed between the front carriage and the rear carriage resulting in a third adhered length of the spacer. The method would further include rotating, with a six-axis robot, the planar substrate, the first adhered portion of the spacer, the second adhered portion of the spacer, and the third adhered portion of the spacer to bend the spacer at the third notch, wherein the third notch is aligned with the fourth corner of the planar substrate. The method would also include feeding the spacer and the planar substrate between the front carriage and the rear carriage along the longitudinal axis of the unadhered portion of the spacer while pressing the spacer against the planar substrate to adhere a portion of the spacer being pressed by the front carriage to the planar substrate, wherein a portion of the spacer between the third notch and a second end of the spacer and a portion of the planar substrate between the fourth corner and the first corner is fed between the front carriage and the rear carriage resulting in a fourth adhered length of the spacer.

In some embodiments, preparing the spacer to be adhered to the planar substrate, comprises: unwinding a length of spacer material from a spool of spacer material, straightening the length of spacer material that has been unwound from the spool, defining the first notch, the second notch, and the third notch in the length of spacer material, and separating the length of spacer material from the remainder of the spacer material on the spool to form the spacer that has the first end and the second end, and that is equivalent in length to a final spacer perimeter.

In some embodiments, the method further includes applying an adhesive to a first side of the spacer further comprises applying the adhesive to a second side of the spacer.

In some embodiments, the method further includes aligning the first end of the spacer with the first corner of the planar substrate results in the first end of the spacer being adjacent to or inset from the first corner of the planar substrate.

In some embodiments, the method further includes rotating the planar substrate and an adhered portion of the spacer comprises a rotation of 90°.

In some embodiments, the method further includes applying the adhesive to the first side of the spacer at least partially overlaps in time with feeding the spacer and the planar substrate between the front carriage and the rear carriage.

In some embodiments, the method further includes feeding the spacer and the planar substrate between the front carriage and the rear carriage, comprises moving the front carriage along the longitudinal axis of the unadhered spacer.

In some embodiments, the method further includes feeding the spacer and the planar substrate between the front carriage and the rear carriage, comprises moving the planar substrate and spacer along the longitudinal axis of the unadhered spacer.

In some embodiments, the method further includes at least one of the rotations of the planar substrate includes a translation and a rotation of the planar substrate.

In some embodiments, the method further includes the translation of the planar substrate involves feeding the planar substrate between the front carriage and the rear carriage.

As used herein, the recitation of numerical ranges by endpoints shall include all numbers subsumed within that range (e.g.,2to8includes 2.1, 2.8, 5.3, 7, etc.).

The headings used herein are provided for consistency with suggestions under 37 CFR 1.77 or otherwise to provide organizational cues. These headings shall not be viewed to limit or characterize the invention(s) set out in any claims that may issue from this disclosure. As an example, although the headings refer to a “Field,” such claims should not be limited by the language chosen under this heading to describe the so-called technical field. Further, a description of a technology in the “Background” is not an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Summary” to be considered as a characterization of the invention(s) set forth in issued claims.