Thermal barrier stitching apparatus

An apparatus or complete machinery line assembly is provided for stitching or crimping an insulating or thermal barrier member in a metal member or members. The assembly comprises a reel or unwind stand for holding and supplying insulating or thermal barrier material, a reel feeder for receiving the barrier material from the reel and feeding or inserting it into the metal member or members, a guide box for holding a metal member or members in position during feeding or insertion operations, a stitcher or crimping machine for crimping the metal members and barrier member together and a take-off or run-out table for receiving thermal barrier shapes from the crimping operation. The unwind stand, feeder, stitcher, guide box and take-off table are positioned in a line one after the other to form a continuous production line for making a unitary thermal barrier or thermal break construction element. The stitcher or crimping machine comprises a plurality of guide stations and crimping or stitching stations arranged alternately and adjacent each other. Each guide station is made as a removable block unit having an upper and lower block. The guide block units are made for handling particular metal shapes. The crimping or stitching stations are fixed and can accommodate an unlimited number of shapes. Preferably, a first stitch station crimps one side of a metal member and a second stitch station crimps the other side of the metal member or one side of another metal member.

BACKGROUND OF THE INVENTION 
The present invention generally relates to an apparatus and method for 
making a unitary construction element or shape having an insulating or 
thermal barrier member therein, commonly referred to as a thermal barrier 
or thermobreak extrusion or shape, which can be employed in the 
construction of windows, doors, frames therefor, curtain walls and the 
like. 
The invention particularly relates to an apparatus for making a unitary 
construction element, wherein an insulating member is joined to a metal 
member or members by a crimping or stitching operation. 
With the advent of metal construction used in making windows, doors, frames 
therefor, curtain walls and the like, problems of heat conduction and 
water condensation have arisen. The use of aluminum or other metals caused 
a greater transfer of heat between wall elements than had heretofore taken 
place in earlier types of construction. To solve this problem, some type 
of insulating or thermal break construction was essential. Accordingly, a 
variety of thermal barrier or thermobreak constructions and methods and 
apparatuses for making such constructions have been developed. 
One type of construction which has achieved some degree of success is one 
in which the insulating material is poured, flowed, foamed, and formed in 
place. U.S. Pat. Nos. 3,204,324; 3,332,170; 3,393,487; 3,624,885 (Re. 
28,084 and Re. 28,086); 3,634,565; and 3,823,524 are illustrative of such 
type of construction. Of these, 3,204,324 is representative of a method of 
making a thermal barrier construction element or insulating construction, 
wherein a metal shape having a generally U-shaped channel therein is 
filled with a flowing resinous insulating composition; the composition is 
cured, and subsequently a portion of the metal member or web forming the 
base of the channel is removed. No. 3,823,524 relates to a similar method 
but employs a web member which extends convexly between the structural 
member forming the channel. Both of these methods require the use of a 
liquid resinous composition which is subsequently cured or hardened. No. 
3,393,487 discloses a somewhat more complicated process for making a 
thermal insulating joing construction and also utilizes a liquid plastic 
material. In such process, two separate elongated metal shapes are spaced 
apart and fastened together with a solid first insulating member. The two 
shapes and the first insulating member provide a channel in which a second 
thermal insulating member is flowed therein. Upon solidification of the 
latter, the metal and insulating members are locked together as an 
integral unit. 
Of the more common types of thermal barrier constructions, two metal 
members are joined together by a solid insulating member. These 
constructions encompass a wide variety of insulating and/or plastic shapes 
and metal shapes. Illustrative of these are U.S. Pat. Nos. 2,835,360; 
3,093,217; 3,099,337; 3,289,377; 3,436,884; 3,487,580; 3,600,857; and 
3,916,503. In one of the more basic of this type of construction, for 
example, in 2,835,360, two metal members are joined together and spaced 
apart by an overlapping insulating member. In 3,916,503, simple mechanical 
means are employed to join the metal members with an insulating member. 
No. 3,600,857 is representative of more complex shapes of insulating and 
metal members. 
In a particular type of the foregoing more common type of thermal barrier 
constructions, metal and insulating members are mechanically joined 
together by deformation of the metal members or by crimping or stitching 
the metal members on the insulating member. Representative of such a 
joining method are U.S. Pat. Nos. 3,114,179; 3,411,995; 3,420,026; 
3,517,472; and 3,903,217 and Swiss Pat. No. 320,988 (same as British Pat. 
No. 768,499). For example, 3,420,026 discloses several types of thermal 
insulating members and methods of making them. In one type, two separate 
metal members are mechanically joined to a central insulating member by 
crimping or deformation of groove means or projections on the metal 
members. In one particular type of thermal break construction, the 
insulating member is in the shape of a Maltese cross in cross-section. In 
another embodiment, the insulating member is made from a thermoplastic 
material and a portion thereof is heated to cause melting and flow of the 
plastic into an associated groove means formed by the two metal members. 
Upon cooling of the plastic, the metal and plastic member are unitarily 
joined together. No. 3,517,472 also illustrates a mechanical joining 
process similar to that of the former and additionally represents the use 
of a plastic or insulating member which expands upon heating. The Swiss 
patent discloses several types of window or door frames, one of which 
employs a crimp system using two separate metal extrusions having a pair 
of flanges thereon which form grooves for receiving a plastic rod. After 
the plastic rod or thermal barrier member is introduced into the grooves, 
the flanges are pressed towards the plastic rod or crimped thereon so that 
they are flush with the sides of the rod. 
Other types of thermal break or insulated window or wall constructions are 
illustrated by U.S. Pat. Nos. 2,654,920; 3,055,468; 3,289,377; 3,411,254; 
and 3,446,801. For example, No. 3,411,254 provides a plastic thermobreak 
which utilizes a plastic locking strip which contains a heat actuated 
blowing agent to join two separate metal shapes. After assembly of the two 
metal shapes and the plastic strip, the unit is heated to expand the 
plastic into tight engagement with the two metal members. 
U.S. Pat. No. 3,815,216 illustrates still another method of manufacturing a 
thermal break construction element and employs a metal extrusion which has 
a removable interior section which is subsequently removed to separate the 
extrusion into two metal members. While maintaining the separate metal 
members spaced apart, a plastic material is inserted therebetween. The 
construction element can be made in a continuous operation. 
Of these various types of thermal break constructions, the system of 
crimping or stitching has enjoyed considerable commercial success. In such 
systems, crimping is often done manually or by simple mechanical means. 
Such means are of course relatively slow and have limited flexibility. One 
current stitching system consists of a feeder for inserting straight 
lengths of vinyl or other suitable plastic insulating members in the metal 
members. Rollers are employed to provide crimping of the metal flanges on 
the insulating or plastic member. Conventionally, two rollers or wheels 
are required to crimp the flanges. One roller must actually bend the metal 
flanges on the insulating member while the other roller must back-up or 
hold the metal extrusion in the correct position for joining metal and 
plastic members. To accomplish the crimping action, clear access must be 
available on both sides of the plastic member on which crimping of the 
metal members occurs. In some cases, a small wheel or support is laterally 
employed to serve as a back-up. The size of the support and the forces 
required to obtain a tight joint create a number of operating problems. 
The types of shapes or extrusions which can be used in this method are 
extremely limited. Finished parts have to be removed by hand after the 
stitching or crimping operation is completed. 
It is therefore a primary object of the present invention to provide a 
crimp or stitching system or method of making thermal barrier extrusions 
which overcomes the disadvantages of prior art systems and which can be 
used with a wide variety of metal shapes or extrusions. 
An important object of the invention is to provide a complete machinery 
line assembly or apparatus for rapidly and efficiently manufacturing 
thermal barrier or thermobreak extrusions shapes or members. 
Another object of the present invention is to provide a stitcher or 
crimping machine which can quickly and easily be adjusted to handle a wide 
variety of metal shapes. 
Still another object of the invention is to provide an elongated guide box 
which is adapted to handle a large number of metal shapes or extrusions of 
different configurations. 
Other objects and advantages of the present invention will become more 
readily apparent from a consideration of the description and drawings 
hereinafter. 
SUMMARY OF THE INVENTION 
The present invention provides a complete machinery line assembly for 
manufacturing thermal barrier members or construction elements, especially 
those unitary thermal barrier members or construction elements used to 
make aluminum windows, doors, frames therefor and the like, comprising 
metal members joined together by an insulating member. The apparatus or 
machinery comprises a reel or unwind stand for holding and supplying 
insulating or thermal barrier material, such as a reel of vinyl of a 
predetermined size and cross-section; a feeder for receiving the 
insulating material from the reel and inserting it into metal members or 
shapes for joining relationship therewith; a guide box for receiving and 
holding in place the metal members or shapes which are to be joined with 
an insulating member; a stitcher or crimping machine for crimping the 
metal members on an insulating member; and, a take-off unit or run out 
table for receiving finished parts or thermal barrier shapes from the 
crimping or stitching operation. The unwind stand, feeder, stitcher, 
guide-box and take-off table are positioned or located in a line one after 
the other to form a continuous production line for making unitary thermal 
barrier construction elements or members from an insulating member and a 
metal member or members. 
The stitcher or crimping machine comprises a plurality of guide stations 
and crimping stations arranged alternately and adjacent each other. Each 
guide station comprises a removable block unit having an upper and lower 
block. A guide block unit is so constructed as to handle a particularly 
shaped or configured (in cross-section) metal member. The crimping 
stations are fixed and are adapted to accommodate a wide variety of 
shapes. Preferably, there are at least two stitch stations, with a first 
stitch station for crimping one side of a metal member and a second stitch 
station for crimping one side of another metal member or another side of 
the same metal member.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring now to the drawings, especially FIG. 1, the various components or 
units comprising the complete machinery line assembly or apparatus and 
their relative position or relation to each other are illustrated. Each of 
the various units is in alignment with the other so as to provide the 
basis for a continuous operation. The assembly comprises five basic units, 
a reel or unwind stand 20, a reel or thermal barrier feeder 30, a guide 
box unit 40, a stitcher or crimping unit 50, and a take-off unit 60. The 
machinery is especially adapted to install a thermal barrier or insulating 
material in aluminum extrusions or shapes to provide a unitary thermal 
barrier shape or thermal break constructions element. The apparatus is 
particularly adapted to make a type of thermobreak construction wherein 
the thermal barrier is stitched or crimped in place. Such an element is 
especially useful in the manufacture of aluminum windows, doors, frames 
therefor, curtain walls and the like. 
In the operation of the apparatus, a reel of thermal barrier material 21 is 
positioned on the unwind stand 20. One end of the reel 21 is inserted in 
the feeder 30. The thermal barrier insulating material is preferably a 
vinyl or foamed PVC. Any other suitable type of material may be used. The 
crosssection shape of the material is of a size and shape to be received 
by or inserted in a pair of appropriately designed metal shapes 70 and 71. 
For most operations, two separate metal shapes, preferably extruded 
aluminum shapes are employed. In some instances, it may be desirable to 
use a single metal shape in which a portion thereof is removed therefrom 
after the operation is complete. A single metal shape would have an 
appropriately constructed opening therein for receiving the barrier or 
insulating material. 
Two metal or aluminum shapes 70 and 71 are properly positioned on a guide 
box 41 of the guide box unit 40 by an operator. The metal shapes are then 
slid into the feeder 30 and properly positioned therein to receive the 
thermal barrier material. Shapes are customarily about sixteen feet in 
length, but may be of any length desired. A foot switch (not shown) 
actuates a clamp 31 which holds the aluminum shapes 70 and 71 in position. 
A pair of drive wheels 32 and 33 are actuated and feed the barrier portion 
21a into the shapes 70 and 71. The length of the material or barrier 21a 
inserted is controlled by a pre-set or pre-determined setting on a counter 
connected to a measuring wheel 34 riding on the barrier. The barrier or 
insulating material comes off the reel as it travels through the feeder 
until the pre-set length is reached. The drive wheels then stop and a 
knife 35 is actuated which cuts or separates the barrier section 21a in 
the aluminum shapes 70 and 71 from the reel 21 and the clamp 31 is 
released. The operator then inserts the combination of metal shapes 70 and 
71 and barrier section 21a into the stitcher 50. A first stitch or crimp 
station 51 of the stitcher 50 causes the metal on one side of the barrier 
21a to be crimped thereon. The combination is continued through the 
stitcher without any further help from the operator. As the combination 
passes through a second stitch station 52, the metal on the other side of 
the barrier 21a is crimped thereon. The completed thermal barrier 
construction element or shape T is moved or driven in the direction 
indicated by arrow A where it is received by the take-off unit 60. As the 
finished part or element T clears the stitcher 50, and electric eye (not 
shown) located between the stitcher 50 and the take-off unit 60 actuates 
dump arms 61 and 62 causing the arms to raise and slide the finished part 
T into a basket or other suitable receptacle. Once the operation has been 
started, the operator does not have to move from the one location by the 
feeder. As soon as the combination clears the guide box into the stitcher, 
the operator places another pair of metal shapes on the guide box and 
slides them into the feeder to provide a substantially continuous 
operation. 
Although the operation is described employing two metal shapes, a single 
metal shape can be used. When using a single metal shape, the procedure is 
substantially the same except after the part T is transferred to the 
receiving basket, the part must be subjected to the further operation of 
removing a pre-determined portion of the metal shape therefrom to thereby 
provide the thermal barrier or break in the finished part. The details of 
the various components of the assembly are described in more detail 
hereinafter. 
Referring now to FIGS. 2 and 3 of the drawings, the reel stand or unwind 
stand 20 basically comprises a frame 22, a shaft 23 mounted thereon, a 
guide arm mounting plate 24 mounted on one end of the shaft 23, a 
plurality of guide arms 25 mounted on the guide arm mounting plate 24, a 
reel support arm 26 mounted on each guide arm 26, a guide rod 27 pivotally 
mounted on each reel support arm 26 and a brake disc 28 mounted on the 
other end of the shaft 23. The frame 22 comprises a plurality of frame 
members welded or otherwise joined together including a pair of spaced 
apart base members 22a, four vertical frame members 22b and, a pair of 
base frame members 22c paralleledly spaced apart and joined together with 
vertical support members 22b and upper side frame members 22c. It can be 
appreciated that the frame 22 may be varied in construction and that the 
particular frame illustrated is merely exemplary. 
The shaft 23 is mounted on the frame 22 by means of a pair of pillow blocks 
or bearings 29 mounted on each of the shaft support frame members 22d. The 
shaft is freely rotatable within the bearings. The caliper disc break 28 
includes a disc hub 28a, break disc 28b and break caliper 28c. Any 
suitable caliper disc break may be used. The guide rods 27 are pivotally 
mounted on the reel support arms 26 by means of a hinged pin 26a. The arms 
26 also include a positioning pin 26b which enables the rods 27 to be 
locked in either a horizontal position as illustrated or a vertical 
position ninety degrees from the horizontal one. FIGS. 2 and 3 of the 
drawings illustrate the guide rods 27 in position for receiving a reel of 
insulating material 21. After the insulating reel has been positioned on 
the arms 26, the rods 27 are raised to a vertical position and locked in 
place as seen in FIG. 1. 
Referring to FIG. 11, a portion of reel support arm 26 is illustrated 
showing a guide rod 27 pivotally mounted therein. The reel support arm 26 
has an opening 26c cut therein for receiving the rod 27. The member 26 is 
conveniently a channel member, and the portion 26c removed therefrom is 
removed from the web of the member 26. Other types of construction are of 
course suitable. The reel support arm 26 also has suitable openings 
therein in the flanges thereof for receiving the hinge pin 26a and the 
positioning pin 26b. The rod 27 also has suitable holes or openings 
therein for receiving pins 26a and 26b, respectively. The rod 27 is 
pivotally mounted on the hinge pin 26a so it may be raised from a 
horizontal position to a vertical position in the direction of the arrow 
E. A nut 26d secures the hinge pin 26a on the arm 26. When the positioning 
pin 26b is in the position illustrated in FIG. 11, the rod 26 is locked in 
a horizontal or longitudinal position with the guide support arm 26. To 
place a reel of insulating material on the unwind stand 20, each of the 
rods 27 are placed in the position as illustrated in FIG. 11. After the 
reel has been placed on the support arms 26, the positioning pin 26b is 
withdrawn and the rod 27 moved in the direction of the arrow E to the 
vertical position shown in FIG. 11. The positioning pin is then inserted 
in the holes in the arm 26 from which it was previously removed, thus 
locking the rod in a vertical position and thus maintaining the reel 21 on 
the unwind stand 20. Any other suitable reel support mechanism or 
apparatus may be used as desired. 
The details of the feeder 30 are seen in FIGS. 4 and 5. The feeder includes 
a frame 36, a motor 37 mounted thereon, a speed reducer 38 mounted on the 
motor with a suitable sprocket and chain assembly for driving the upper 
and lower drive wheels 32 and 33, respectively, an input guide 39, 
measuring wheel 34, drive wheels 32 and 33, a knife 35 and a clamp 31, all 
of which are suitably mounted on the frame 36. The frame 36 includes four 
vertical support members 36a on which are mounted a front plate 36b, a 
rear plate 36c, a base plate 36d, and connecting bars 36e. Any other 
suitable framing mechanism may be used to provide the support for the 
various components of the Feeder 30. 
The clamp assembly 31 includes clamp air cylinder 31a, a cylinder rod 31b, 
a jam nut 31c a clamp 31d, a clamp guide 31e, an extrusion or shape 
support 31f and an extrusion or shape positioning plate 31g. The angle 
iron extrusion support member 31f has a pair of slots 31h therein and is 
mounted on the front plate 36b by means of a plurality of socket head cap 
screws 31i or other suitable fasteners. The extrusion support 31f may be 
moved vertically to a desired position to support the base of the 
extrusions 70 and 71 in a desired position. The extrusion positioning 
plate 31g is in a fixed position and so located between the knife unit 35 
and clamp assembly 31 that when the shapes 70 and 71 are abutted 
thereagainst, the shapes are in a proper position for receiving the 
insulating member 21a. The air cylinder 31a actuates the cylinder rod 31b 
so that the clamp 31d and clamp guide 31e thereon are moved into holding 
contact with the shapes 70 and 71 to hole them in the desired position 
during the insertion operation. The air cylinder 31a has an air line 31j 
(partially shown) for connecting the air cylinder to a suitable valve and 
air supply. 
The knife or knife assembly 35 includes an air cylinder 35a, a block 35b 
for holding same, a cylinder actuating rod 35c, a jam nut 35d and a jam 
nut 35e positioned on the rod 35c, a knife holder 35f mounted on the end 
of the rod 35c and a knife 35g positioned in the knife holder 35f. The air 
cylinder block 35b is mounted on the front plate 36b. A cutting block 35h 
is also mounted on the front plate 36d. An air line 35i (partially shown) 
connected to a suitable valve and air supply provides air to the air 
cylinder 35a for actuating the knife blade 35g for cutting or severing the 
insulating barrier 21a when an appropriate signal is given thereto. 
The base plate 36d has an opening 36d for receiving a drive chain 32a 
connecting the drive wheels 32 and 33 with the motor 37. 
The lower drive wheel 33 is mounted on a shaft 32b positioned in bearing 
blocks 32c and 32d fixed on rear plate 36c and front plate 36b, 
respectively. A drive sprocket 32e is mounted on the drive shaft 32b for 
receiving the drive chain 32a. The lower drive wheel 33 is mounted on the 
end of the shaft 32b which extends through a suitable opening therefor in 
the front plate 36b. 
The upper drive wheel 32 is mounted on axle 32f mounted in front plate 36b. 
The upper drive wheel 32 is adjustable so as to accommodate various sizes 
of insulating material or barriers. Such mechanism inclides a bolt holder 
32g mounted on the front plate 36b and a bolt 32h, a slide block 32i and 
slides 32j suitably positioned thereon. The drive wheels 32 and 33 advance 
the barrier member 21a in the direction of the arrow B so as to insert the 
member 21a into the shapes 70 and 71. 
Additional details of the drive wheels 32 and 33 are seen in FIG. 13. Upper 
drive wheel or drive unit 32 is mounted on the plate 36b. Lower drive 
wheel or drive unit 33 is mounted on the shaft 32b which extends through 
an opening in the plate 36b. The unit 32 includes a drive gear 32k having 
teeth 32k' thereon which is mounted on bushing 32m in which axle bolt 32f 
is positioned therethrough and inserted into movable slide block 32i. 
Slide block 32i is slidably mounted in slide 32j which is fixed to plate 
36b. A thrust bearing 32n is also positioned on the axle 32f between the 
head of axle 32f and drive gear 32k. Barrier drive wheel 32p having teeth 
32p' thereon is fixed to the drive gear 32k so as to move therewith. The 
bolt holder 32g is fixed to the plate 36b above the slide 32j and has an 
opening 32g' therein for receiving the bolt 32h. The bolt 32h also extends 
into and is fixed to the movable slide block 32i. Nuts 32q are 
appropriately positioned on the bolt 32h so as to retain the bolt in a 
desired position on the bolt holder and in the slide block. By adjusting 
the nuts 32q, the slide block 32i may be moved vertically within the slide 
32j so that the drive wheel 32p will be in an appropriate position for 
driving the insulating barrier material 26a on the top side thereof. 
The drive shaft 32b has a hub 33a thereon positioned in a bushing 33b in a 
bushing support member or bearing 32d mounted on plate 36b. A drive gear 
33d having teeth 33d' thereon is mounted on the hub 33a on the shaft 32b 
and meshes with gear 32k so as to drive the gear 32k. Drive wheel 33d on 
hub 33a and having teeth 33d' thereon moves or rotates shaft 32b and 
drives the underside of barrier 26a. 
The measuring wheel 34 is also mounted on the front plate 36b in a suitable 
manner on a shaft 34a connected to a suitable electrical pulse generator 
34b, also mounted on the front plate 36b. The input guide 39 is also 
mounted on the front plate 36b. The input guide 39 is also mounted on the 
front base plate 36b in a suitable manner. 
Referring now to FIG. 12, the details of the measuring wheel 34 are 
illustrated. A pulse generator mounting block 34c is affixed to front side 
plate 36b by means of a bolt 34d through suitable openings in the plate 
36d and mounting block 34c, respectively. The pulse generator 34b having a 
shaft 34a is mounted on the mounting block 34b. A shaft extender 34a' is 
affixed to the shaft 34a and held in place thereon by means of a set screw 
34e. The plate 36b has an opening 36b' therein for receiving the shaft 
extender 34a'. The measuring wheel 34 is positioned on the shaft extender 
34a'. A movable guide block 34f is mounted on the plate 36b below the 
measuring wheel 34 by means of a pivot bolt 34g and a pivot bolt nut 34h. 
The side plate 36b has a suitable opening 36b" for receiving the pivot 
bolt 34g. The movable guide block 34f has an opening 34f' therethrough 
sufficiently large to permit vertical movement of the block 34f when the 
nut 34h is loosened. The block may be moved to accommodate a particular 
size of insulating material or barrier. The block 34f also has a suitable 
opening 34f" for receiving the barrier or insulating material 26a. Also 
mounted on the plate 36b below the guide block 34f is a spring holding 
block 34i. The block 34i has an opening 34i' for receiving the spring bolt 
34j. A spring 34k is mounted on the bolt 34j'. Nuts 34m retain the bolt 
34j in the block 34i. The spring 34k urges the bolt 34j into contact with 
movable guide block 34f so as to urge the vinyl material 26a therein 
against the measuring wheel 34. 
Any other suitable feeder may be used. The feeder should have some type of 
means to receive and feed the barrier material into the metal member or 
members and to stop the feeding operation when an appropriate length of 
insulating material has been inserted into the metal member or members. 
Preferably, the feeder also contains a clamping means for holding metal 
members in place during insertion operations and a knife means for cutting 
or severing the inserted barrier material from the reel of barrier 
material. The clamping means and knife means can each be separate 
components and not made specifically a part of the feeder unit. In some 
instances, such clamping or holding and cutting operations can be 
conducted manually, although this would not be as efficient as the 
automatic operation disclosed. 
Referring to FIGS. 6 and 7, the guide box 40 with metal shapes 70 and 71 
thereon is illustrated in more detail. The guide box unit 40 includes a 
guide box 41 mounted on a frame 42. The frame 42 includes vertical guide 
box support members 43 joined together and spaced apart by base frame 
members 44 and top frame members 45. Brackets 46 are fixed to the support 
members 43 for supporting the guide box 41. It can be appreciated that any 
other suitable structure may be used for holding the guide box 41. The 
guide box 41 is a longitudinally extending wooden member or board which 
has grooves 41a and 41b therein for receiving portions of the shapes 70 
and 71, respectively as illustrated in FIG. 7. The guide box 41 is merely 
illustrative of a very simple type of guide box. It may be made of wood or 
any other suitable material, e.g., metal and plastic. For normal 
operations, a guide box having a multiplicity of grooves for receiving a 
variety of types of shapes would be employed. All that is necessary is 
that the guide box hold the metal shapes in a suitable position for 
receiving the barrier material. Shapes 70 and 71 are relatively simple 
shapes and are shown in their position for receiving the thermal barrier 
21a in the opening 80 between members 70 and 71. The opening 80 is of a 
size and shape so as to readily receive a somewhat similarly shaped, in 
cross-section, thermal barrier material. The flanges or portions 70a and 
71a of the members 70 and 71, respectively, are in their pre-crimping or 
pre-stitching position. The metal shapes are therefore illustrated in the 
shape in which they are normally extruded or otherwise prepared. 
Referring now to FIG. 8, the stitcher or crimping machine 50 includes a 
first stitch station or unit 51, a second stitch station or unit 52, a 
plurality of guide block assemblies 53, 54 and 55 and an ejector station 
56 mounted on side plates 57 and 57' mounted on a base plate 57" mounted 
on support members 58. Additionally, the stitcher 50 includes a 
combination motor and reducer unit 59 suitably mounted on the underside of 
the base plate 57" with a drive chain 59a. The chain tensioner 59b is also 
mounted on the base 57 by means of a mounting block 59c. 
The ejector station 56 includes a toothless drive wheel 56a and a lower 
idler wheel 56b and adjusting screws 56c. The ejector station 56 receives 
the metal members with barrier crimped therein and ejects the extrusion or 
finished part T out of the stitcher 50 and also straightens the element T. 
The guide blocks 53, 54 and 55 are substantially identical and are made for 
a particular shape. The guide blocks are removable and an additional 
series of guide blocks may be placed in the stitcher for accommodating 
shapes of configurations other than those illustrated. The stitch stations 
51 and 52 are fixed in the machine and remain the same for each identical 
operation. The stitch stations are adjustable to accommodate particular 
shapes. Details of the stitch stations and guide stations are seen in 
FIGS. 14 and 15. 
Referring now to FIG. 14, a stitch station is illustrated in detail. Stitch 
station 51 is mounted on side plates 57 and 57' and base plate 57" of the 
stitcher 50. The stitch station 51 includes an upper fixed portion 51a and 
a lower movable portion 51b. The upper portion 51a includes a drive shaft 
51c which has a drive sprocket 51d on one end thereof for receiving the 
chain 59a. The shaft 51c has a stitch or crimping wheel 51e fixed thereto 
with spacers 51f and 51f' on either side thereof. Bearings 51g and 51g' 
support the shaft in the stitcher and are mounted in side plates 51h and 
51h', respectively. A pair of snap rings 51r and 51r' are positioned 
respectively. on the shaft 51c adjacent bearings 51g and 51g', 
respectively. Holding bars 51i and 51i' hold the upper portions 51a in 
position to the stitcher 50. The lower movable portion or backup block 51b 
includes side plates 51j and 51j' in which are mounted bearings 51k and 
51k' for supporting the backup wheel shaft 51l. Backup wheel 51m having 
hub 51m' is mounted on the shaft 51l and fixed thereon by means of shaft 
key 51n. A pair of snap rings 51p and 51p' are also positioned on the 
shaft 51l adjacent bearings 51k and 51k', respectively. A cross brace 51q 
connects or joins the side plates 51j and 51j'. The lower or backup wheel 
51m is movable and controlled by means of an air cylinder 51r mounted on 
the stitcher base plate 57" by means of bolts 57a or other suitable means. 
The plate 57" has an opening 57b therein for receiving the air cylinder 
shaft 51r' which is mounted to a cross plate 51s. As the air cylinder 
shaft 51r' is actuated up or down, the block 51b is moved therewith so 
that an operator may vary the backup force for a particular stitching or 
crimping operation depending upon the particular metal members being 
stitched or crimped. The stitch wheel and backup wheel are both hardened 
steel rollers with the stitch wheel having teeth thereon. The stitch wheel 
51e is grooved or so constructed that only one metal member or one side of 
a metal member is crimped as the metal members 70 and 71 pass 
therethrough. 
The stitch station 52 is similarly constructed to the stitch station 51, 
except that the wheel 51e is so constructed that the other side of the 
metal member or metal members is crimped. As illustrated in FIG. 14, the 
stitch wheel 51e is shown crimping the flange 51a of the member 71. The 
flange 70a is crimped by the stitch station 52. 
The guide station or guide box assembly 53 is seen in detail in FIG. 15. 
The guide station is also mounted in side plates 57 and 57' and base plate 
57" of the stitcher 50. The guide stations are made as a separate block 
unit and each station has an upper block 53a and a lower block 53b. The 
upper block 53a includes a pair of side plates 53c and 53c' joined 
together in a spaced apart relationship by cross brace 53d. The shaft 53e 
is mounted in bearings 53f and 53f' positioned in side plates 53c and 
53c', respectively. A pair of snap rings 53y and 53y' are positioned on 
the shaft 53e adjacent bearings 53f and 53f', respectively. A pair of 
guide wheels 53g and 53h are mounted on the shaft 53e. A key 53i enables 
the guide wheels to be locked in a predetermined position on the shaft 53 
e. A pair of spring guide posts or pins 53j and a pair of spring guide 
posts or pins 53j' are mounted on the top of side plates 53c and 53c', 
respectively. Holding bars 53k and 53k' are also positioned on side plates 
53c and 53c', respectively. Each guide post has a spring 531 thereupon. 
The guide posts or pins are connected to the holding bars, but are 
positioned therein through holes in the holding bars therefor. The pins 
pass through the holding bars when the block 53a is raised. The springs 
are held in position by the pins and act to push the upper block 
downwardly. As the metal shapes pass through the machine, the upper block 
is raised slightly, compressing the springs. 
The lower block 53b includes side plates 53m and 53m' joined together by 
cross brace 53n. A shaft 53p is mounted in bearings 53q and 53q', 
respectively, mounted in the side plates 53m and 53m', respectively, A 
pair of lower guide wheels 53r and 53s are mounted on the shaft 53p and 
spaced apart therefrom each other and retained in a predetermined position 
by means of key 53t. A fixed side guide yolk 53n is mounted on the inside 
of side plate 53m' and includes an axle 53n on which roller 53n" is 
positioned thereon. A movable side guide yolk 53v is mounted on guide bolt 
53n" positioned in a suitable opening therefor in side plate 53m. Yolk 53v 
includes an axle 53w on which a wheel 53w' is positioned thereon. A spring 
53x mounted on the guide bolt 53v' urges the yolk 53v and the wheel 53w' 
thereon against the shape 71 which in turn urges the shape 71 and shape 70 
against the wheel 53n". Snap rings 53y and 53y' are also positioned on the 
shaft 53p adjacent bearings 53q and 53q', respectively. The guide blocks 
are readily removable and permit a rapid change out from one shape to 
another. The guide blocks position the metal shapes in a proper location 
for stitching or crimping. 
The guide wheels are illustrative of one particular type. It can be 
appreciated that they may be of any suitable type as desired. Such wheels 
are preferably made of a material such as a phenolic resin, vinyl or other 
suitable material which does not damage the metal shapes. The various 
guide wheels also have set screws therein for fixing the wheels to their 
respective shafts in a predetermined position. 
Guide stations 54 and 55 are similarly constructed to guide station 53 and 
are also removable from the stitcher 50. For any particular operation, all 
of the guide stations are of identical construction and have their wheels 
set in a similar position. 
The guide stations before each stitching station hold the metal shapes and 
barrier therebetween in proper alignment for each successive crimping or 
stitching operation. Guide stations and stitch stations can be so 
constructed and assembled that stitching or crimping can be conducted on 
whichever metal member or side of metal member desired. The last guide 
station guides the metal shapes with barrier material locked therein or 
therebetween into the ejector station or unit. The ejector station not 
only ejects the finished part from the stitcher or stitcher assembly to 
the take-off unit but also straightens the finished part thereby 
correcting any distortion which may have occurred during the stitching 
operation. 
Referring to FIGS. 9 and 10, the take-off unit 60 includes dump arms 61 and 
62 mounted on a shaft 63 held by bearings 64, conveniently mounted on 
frame support members 65 and 55. In addition to the vertical support 
members 65 and 66, frame 60' includes end vertical support members 67 and 
horizontal joining framing members 68 and additional horizontal joining 
members 69 and 69'. A roller conveyor 60" is mounted on the support 
members 68 and 67. An air rotary actuator 90 is mounted on a motor base 
plate 91 mounted on vertical support members 66 of the frame 60'. The 
rotary actuator 90 has a shaft 90a extending therefrom on which is mounted 
a gear 92 which drives a gear 93 mounted on the shaft 63. An air valve 94 
is also mounted on the plate 91. The roller conveyor operates in the 
customary manner, and some of the rollers are further spaced apart than 
others to provide an area for pivotal movement of the dump arms 61 and 62. 
The dump arms 61 and 62 are affixed to the shaft 63; and, as the shaft is 
rotated when appropriately actuated or driven by the actuator 90, and 
raises the arms from a horizontal position to a raised position so that a 
member T thereon will slide off of the unit 60 and into a suitable 
receptacle. 
Referring now to FIGS. 16 and 16A, a completed thermal barrier shape T is 
illustrated in position on the take-off unit 60 prior to activation of the 
dump arms and in position after the dump arms have been activated. Dump 
arm 62 is shown in a raised position in FIG. 16A wherein the finished part 
T is moved from the position shown in FIG. 16 to the position shown in 
FIG. 16A and hence into a basket or other suitable container. Dump arm 62, 
as well as dump arm 61, is raised or lowered by means of gear 60a fixed to 
the shaft 63 which is caused to rotate in the direction of the arrow C by 
action of the smaller gear 60b rotated in the direction of the arrow D and 
fixed to the air rotary actuator shaft or rod 90a actuated by the air 
valve 94. The air valve 94 is connected to a suitable air supply source by 
means of lines 95 and 95'. It can be appreciated that the frame of the 
take-off unit or the take-off unit itself can be of various constructions. 
It is only essential that rollers or other suitable means be provided for 
moving a finished part thereon and that a dumping mechanism or some other 
means be provided for removing the finished part from the take-off unit. 
Although a take-off unit of some type is preferred, the finished parts can 
be manually handled, if desired. Such a manual operation would not be as 
efficient and would probably require the services of an additional person 
to receive the finished parts as they are ejected from the stitcher. 
Metal shapes are preferably extruded aluminum shapes, but any other 
suitable metal or various made metal shapes may be used. The term aluminum 
includes all aluminum and aluminum alloys employed or capable of being 
employed in the manufacture of windows, doors, frames therefor, curtain 
walls, and the like and in the building or construction industry in 
general. Such metal shapes may be of various lengths, and may be of any 
desired configuration in cross-section as long as they are so constructed 
as to receive a barrier material and have portions thereof which can be 
crimped onto the barrier material after it has been inserted. 
The insulating material or barrier is preferably made of plastic. Any other 
suitable materials may be used which have the desired characteristic of 
thermal conductivity, strength, and rigidity. Although a material of 
sufficient flexibility that it can be made into reels or rolls is 
preferred, material of greater rigidity can be used. In such case, lengths 
of barrier material would have to be fed into the feeder by hand or some 
other suitable means. 
The foregoing disclosure and description of the invention is illustrative 
and explanatory thereof, and various changes in the size, shape, and 
materials, as well as in the details of the illustrated construction may 
be made within the scope of the appended claims without departing from the 
spirit of the invention.