Abstrict A method and apparatus for controlling dispensing of a desiccant
material into an interior region of an elongated spacer frame member.
The appropriate desiccant dispensing nozzle is automatically selected
and/or the distance between the desiccant dispensing nozzle and
the elongated spacer frame member is automatically determined based
on a property of the spacer frame member, such as the width of the
spacer frame member.
Claims 1. A method of controlling dispensing of a desiccant material into
an interior region of an elongated spacer frame member, comprising:
a) automatically indexing one of a plurality of nozzles to a delivery
site located along a path of travel of the elongated spacer frame
member; b) moving the elongated spacer frame member along the path
of travel relative to the delivery site at a controlled speed; and
c) delivering controlled amounts of the desiccant material through
the nozzle at the delivery site to the interior region of the elongated
spacer frame member.
2. The method of claim 1 further comprising monitoring a width
of the elongated spacer frame member and automatically indexing
a nozzle based on the monitored width of the spacer frame member.
3. The method of claim 2 wherein the one or more of the plurality
of nozzles is selected to deliver desiccant to a range of elongated
spacer frame widths.
4. The method of claim 1 further comprising vertically adjusting
a nozzle with respect to the path of travel based on a width of
an elongated spacer frame member approaching the delivery site.
5. The method of claim 1 further comprising monitoring a width
of the elongated spacer frame member and automatically vertically
adjusting a nozzle with respect to the elongated spacer frame member
to a distance above the spacer frame member that corresponds to
the width of the spacer frame member.
6. The method of claim 1 further comprising adjusting a width of
the desiccant material applied by the nozzle at the delivery site
to the elongated spacer frame member by adjusting a relative distance
between the spacer frame member and the nozzle at the delivery site.
7. The method of claim 1 further comprising: i) monitoring a width
of the elongated spacer frame member; ii) automatically indexing
a nozzle that corresponds to the width of the spacer frame member;
and iii) automatically vertically adjusting the nozzle that corresponds
to the width of the spacer frame member with respect to the elongated
spacer frame member to a distance above the spacer frame member
that corresponds to the width of the spacer frame member.
8. The method of claim 1 wherein a volume of desiccant material
per unit of spacer frame member length applied by a nozzle is based
on a moisture vapor transfer rate of an insulated glass unit constructed
with the elongated spacer frame member.
9. The method of claim 8 wherein the volume of desiccant material
per unit of spacer frame member length is constant for a range of
spacer frame widths.
10. The method of claim 1 wherein indexing one of the plurality
of nozzles to the delivery site comprises linearly moving a nozzle
carrying plate.
11. The method of claim 1 wherein indexing one of the plurality
of nozzles to the delivery site comprises rotating a turret manifold.
12. A method of controlling dispensing of a desiccant material
into an interior region of an elongated spacer frame member, comprising:
a) monitoring widths of elongated spacer frame members that are
moved along a path of travel; b) moving a first elongated spacer
frame member having a first width along the path of travel relative
to a delivery site at a controlled speed; c) automatically positioning
a first nozzle that corresponds to the first width at the delivery
site; d) delivering controlled amounts of the desiccant material
through the first nozzle at the delivery site to the interior region
of the first elongated spacer frame member; e) moving a second elongated
spacer frame member having a second width along the path of travel
relative to a delivery site at a controlled speed; f) automatically
positioning a second nozzle that corresponds to the second width
at the delivery site; and g) delivering controlled amounts of the
desiccant material through the second nozzle at the delivery site
to the interior region of the second elongated spacer frame member.
13. The method of claim 12 wherein the first nozzle corresponds
to a range of elongated spacer frame widths.
14. The method of claim 12 further comprising automatically vertically
adjusting the first nozzle with respect to the path of travel based
on the first width.
15. The method of claim 12 further comprising adjusting a width
of the desiccant material applied by the first nozzle at the delivery
site to the first elongated spacer frame member by adjusting a relative
distance between the first spacer frame member and the first nozzle
at the delivery site.
16. The method of claim 12 wherein a volume of desiccant material
per unit of spacer frame member length applied by a nozzle is based
on a moisture vapor transfer rate of an insulated glass unit constructed
with the first elongated spacer frame member.
17. The method of claim 16 wherein the volume of desiccant material
per unit of spacer frame member length is constant for a range of
spacer frame widths.
18. The method of claim 12 wherein the first and second nozzles
are positioned by linearly moving a nozzle carrying plate.
19. The method of claim 12 wherein the first and second nozzles
are positioned by rotating a nozzle carrying disk.
20. A method of controlling dispensing of a desiccant material
into an interior region of an elongated spacer frame member, comprising:
a) monitoring widths of elongated spacer frame members that are
moved along a path of travel; b) moving a first elongated spacer
frame member having a first width along the path of travel relative
to a delivery site at a controlled speed; c) automatically positioning
a nozzle at a first distance above the path of travel that corresponds
to the first width; d) delivering controlled amounts of the desiccant
material through the nozzle at the delivery site to the interior
region of the first elongated spacer frame member; e) moving a second
elongated spacer frame member having a second width along the path
of travel relative to a delivery site at a controlled speed; f)
automatically positioning the nozzle at a second distance above
the path of travel that corresponds to the second width; and g)
delivering controlled amounts of the desiccant material through
the nozzle at the delivery site to the interior region of the second
elongated spacer frame member.
21. The method of claim 20 wherein positioning the nozzle above
the path of travel adjusts a width of the desiccant material applied
by the nozzle at the delivery site.
22. The method of claim 20 wherein a volume of desiccant material
per unit of spacer frame member length applied by the nozzle is
based on a moisture vapor transfer rate of an insulated glass unit
constructed with the first elongated spacer frame member.
23. The method of claim 22 wherein the volume of desiccant material
per unit of spacer frame member length is constant for the first
elongated spacer frame member and the second spacer frame member.
24. A method of controlling dispensing of a desiccant material
into an interior region of an elongated spacer frame member, comprising:
a) monitoring widths of elongated spacer frame members that are
moved along a path of travel; b) automatically positioning a nozzle
with respect to the path of travel based on monitored widths of
the elongated spacer frame members; c) moving the elongated spacer
frame member along the path of travel relative to the delivery site
at a controlled speed; d) delivering controlled amounts of the desiccant
material through the nozzle at the delivery site to the interior
region of the elongated spacer frame member.
25. The method of claim 24 wherein automatically positioning the
nozzle with respect to the path of travel comprises vertically adjusting
the nozzle with respect to the path of travel based on a width of
an elongated spacer frame member approaching the delivery site.
26. The method of claim 24 wherein positioning the nozzle with
respect to the path of travel adjusts a width of the desiccant material
applied by the nozzle at the delivery site to the elongated spacer
frame member.
27. The method of claim 24 wherein a volume of desiccant material
per unit of spacer frame member length applied by the nozzle is
based on a moisture vapor transfer rate of an insulated glass unit
constructed with the elongated spacer frame member.
28. The method of claim 27 wherein the volume of desiccant material
per unit of spacer frame member length is constant for a range of
spacer frame widths.
29. A system for controlled dispensing of a desiccant material
into an interior region of an elongated spacer frame member, comprising:
a) a plurality of nozzles for dispensing the desiccant material
into the interior region of the elongated spacer frame member; b)
an actuator for selectively indexing each of the plurality of nozzles
to a delivery site located along a path of travel of the elongated
spacer frame member; c) a conveyor for moving the elongated spacer
frame member along the path of travel relative to the delivery site
at a controlled speed; d) a controller that selects a nozzle indexed
to the delivery site based on a width of an elongated spacer frame
member approaching the delivery site.
30. The system of claim 29 wherein the controller selects a single
nozzle to deliver desiccant to a range of elongated spacer frame
widths.
31. The system of claim 29 wherein the controller vertically adjusts
a nozzle with respect to the path of travel based on a width of
an elongated spacer frame member approaching the delivery site.
32. The system of claim 29 wherein the controller monitors a width
of the elongated spacer frame member and vertically adjusts a nozzle
with respect to the elongated spacer frame member to a distance
above the spacer frame member that corresponds to the width of the
spacer frame member.
33. The system of claim 29 wherein the controller adjusts a width
of the desiccant material applied by the nozzle at the delivery
site to the elongated spacer frame member by adjusting a relative
distance between the spacer frame member and the nozzle at the delivery
site.
34. The system of claim 29 further comprising a linearly moving
nozzle plate controlled by the controller to selectively index one
of the plurality of nozzles to the delivery site.
35. The system of claim 29 further comprising a rotatable nozzle
turret controlled by the controller to selectively index one of
the plurality of nozzles to the delivery site.
36. A system for controlled dispensing of a desiccant material
into an interior region of an elongated spacer frame member, comprising:
a) a nozzle for dispensing the desiccant material into the interior
region of the elongated spacer frame member; b) an actuator for
positioning the nozzle above a delivery site located along a path
of travel of the elongated spacer frame member; c) a conveyor for
moving the elongated spacer frame member along the path of travel
relative to the delivery site at a controlled speed; and d) a controller
that determines a distance between the nozzle and the elongated
spacer frame member at the delivery site based on a width of an
elongated spacer frame member approaching the delivery site.
37. A system for controlled dispensing of a desiccant material
into an interior region of an elongated spacer frame member, comprising:
a) a plurality of nozzles for dispensing the desiccant material
into the interior region of the elongated spacer frame member; b)
an actuator for selectively indexing each of the plurality of nozzles
to a delivery site located along a path of travel of the elongated
spacer frame member; c) a conveyor for moving the elongated spacer
frame member along the path of travel relative to the delivery site
at a controlled speed; d) a controller that monitors widths of elongated
spacer frame members conveyed to the delivery site, selects a nozzle
indexed to the delivery site based on a width of an elongated spacer
frame member conveyed to the delivery site, and determines a distance
between the nozzle and the elongated spacer frame member at the
delivery site based on a width of an elongated spacer frame member
conveyed to the delivery site.
Description FIELD OF THE INVENTION
[0001] The present invention relates to insulating glass units
and, more particularly, to a method and apparatus for applying desiccant
to spacer frame assemblies used in constructing insulating glass
units.
BACKGROUND
[0002] Insulating glass units (IGU's) are used in windows to reduce
heat loss from building interiors during cold weather or to reduce
heat gain in building interiors during hot weather. IGU's are typically
formed by a spacer assembly that is sandwiched between glass lites.
The spacer assembly usually comprises a frame structure that extends
peripherally around the unit, an adhesive material that adheres
the glass lites to opposite sides of the frame structure, and desiccant
in an interior region of the frame structure for absorbing atmospheric
moisture within the IGU. The glass lites are flush with or extend
slightly outwardly from the spacer assembly. The adhesive is disposed
on opposite outer sides of the frame structure about the frame structure
periphery, so that the spacer is hermetically sealed to the glass
lites. An outer frame surface that defines the spacer periphery
may also be coated with sealant, which increases the rigidity of
the frame and acts as a moisture barrier.
[0003] One type of spacer construction employs a U-shaped, roll
formed aluminum or steel elements connected at its end to form a
square or rectangular spacer frame. Opposite sides of the frame
are covered with an adhesive (e.g., a hot melt material) for securing
the frame to the glass lites. The adhesive provides a barrier between
atmospheric air and the IGU interior. Desiccant is deposited in
an interior region of the U-shaped frame element. The desiccant
is in communication with the air trapped in the IGU interior and
removes any entrapped water vapor and thus impedes water vapor from
condensing within the IGU. After the water vapor entrapped in the
IGU is removed, internal condensation only occurs when the seal
between the spacer assembly and the glass lites fails or the glass
lites are cracked.
SUMMARY
[0004] The present invention concerns a method and apparatus for
controlling dispensing of a desiccant material into an interior
region of an elongated spacer frame member. The appropriate desiccant
dispensing nozzle is automatically selected and/or the distance
between the desiccant dispensing nozzle and the elongated spacer
frame member is automatically determined based on a property of
the spacer frame member, such as the width of the spacer frame member.
[0005] In one embodiment of the method, one of a plurality of nozzles
is indexed to a delivery site located along a path of travel of
the elongated spacer frame member. The elongated spacer frame member
is moved along the path of travel relative to the delivery site
at a controlled speed. Controlled amounts of the desiccant material
are dispensed through the nozzle at the delivery site to the interior
region of the elongated spacer frame member. A width of the elongated
spacer frame member may be monitored in a variety of ways and the
nozzle appropriate nozzle can automatically be indexed to the delivery
site based on the monitored width of the spacer frame member.
[0006] In one embodiment of the method, one or more of the nozzles
are used to dispense desiccant material into elongated spacer members
having a range of widths. For example, when a first elongated spacer
frame member having a first width is moved toward the delivery site,
a nozzle is automatically positioned at a first distance above the
path of travel that corresponds to the first width. The nozzle delivers
controlled amounts of the desiccant material to the interior region
of the first elongated spacer frame member. When a second elongated
spacer frame member having a second width is moved toward the nozzle,
the nozzle is automatically positioned at a second distance above
the path of travel that corresponds to the second width. Controlled
amounts of the desiccant material are dispensed through the nozzle
to the interior region of the second elongated spacer frame member.
In one embodiment, the width of the desiccant material applied by
the nozzle at the delivery site to the elongated spacer frame member
is adjusted by adjusting the relative distance between the spacer
frame member and the nozzle at the delivery site.
[0007] In one embodiment, the volume of desiccant material per
unit of spacer frame member length is selected based on a moisture
vapor transfer rate of an insulated glass unit constructed with
the elongated spacer frame member. The volume of desiccant material
per unit of spacer frame member length may be constant for a range
of spacer frame widths.
[0008] One system for controlled dispensing of a desiccant material
into an interior region of an elongated spacer frame member includes
a plurality of nozzles, a nozzle indexing actuator, a conveyor and
a controller. The actuator selectively indexes each of the plurality
of nozzles to a delivery site located along a path of travel of
the elongated spacer frame member. The conveyor moves the elongated
spacer frame members along the path of travel relative to the delivery
site at a controlled speed. The controller selects a nozzle indexed
to the delivery site based on a width of an elongated spacer frame
member approaching the delivery site.
[0009] Another system for controlled dispensing includes a nozzle,
a nozzle adjustment actuator, a conveyor and a controller. The nozzle
adjustment actuator positions the nozzle above a delivery site located
along a path of travel of the elongated spacer frame member. The
controller determines the distance between the nozzle and the elongated
spacer frame member at the delivery site based on a width of an
elongated spacer frame member approaching the delivery site.
[0010] Additional features of the invention will become apparent
and a fuller understanding obtained by reading the following detailed
description in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic representation of a system for applying
desiccant to elongated spacer frame members used in constructing
insulating glass units;
[0012] FIG. 2 is a front elevational view of an elongated spacer
member with adhesive and desiccant applied to it;
[0013] FIG. 3 is a top plan view of an elongated spacer frame member;
[0014] FIG. 4 is a schematic illustration of a plurality of indexable
nozzles positioned above an elongated spacer frame member having
a first width;
[0015] FIG. 5 is a schematic illustration of a plurality of indexable
nozzles positioned above an elongated spacer frame member having
a second width;
[0016] FIG. 6 is a schematic illustration of a nozzle positioned
at a first height with respect to an elongated spacer frame member;
[0017] FIG. 7 is a schematic illustration of a nozzle positioned
at a second height with respect to an elongated spacer frame member;
[0018] FIG. 8 illustrates an insulating glass unit having a first
width;
[0019] FIG. 9 illustrates an insulating glass unit having a second
width;
[0020] FIG. 10A is a perspective view of a nozzle;
[0021] FIG. 10B is a perspective view of a nozzle;
[0022] FIG. 11 illustrates a plurality of nozzles carried by a
nozzle carrying plate;
[0023] FIG. 12 illustrates a plurality of nozzles carried by a
turret;
[0024] FIG. 13 is a perspective view of a system for controlled
dispensing of desiccant;
[0025] FIG. 14 is a perspective view of a system for controlled
dispensing of desiccant;
[0026] FIG. 15 is a perspective view of a multiple station desiccant
dispensing assembly;
[0027] FIG. 16 is a perspective view of a multiple station desiccant
dispensing assembly;
[0028] FIG. 17 is an end elevational view of a multiple station
desiccant dispensing assembly;
[0029] FIG. 18 is a side elevational view of a multiple station
desiccant dispensing assembly;
[0030] FIG. 19 is a plan view of a multiple station desiccant dispensing
assembly.
[0031] FIG. 20 is a side elevational view of a multiple station
desiccant dispensing assembly;
[0032] FIG. 21 is a side elevational view of a multiple station
desiccant dispensing assembly;
[0033] FIG. 22 is an illustration of a guide rail setup screen;
[0034] FIG. 23 is an illustration of a nozzle position setup screen;
[0035] FIG. 24A is an illustration of a desicant amount setup screen;
[0036] FIG. 24B is an illustration of a desicant amount setup screen;
and
[0037] FIG. 25 is an illustration of a nozzle height setup screen.
DETAILED DESCRIPTION
[0038] FIG. 1 schematically illustrates a system 10 for controlled
dispensing of a desiccant 14 into an interior region 22 of elongated
window spacer 16. The system automatically selects an appropriate
desiccant dispensing nozzle 24 and/or automatically determines an
appropriate distance D (FIGS. 6 and 7) between the desiccant dispensing
nozzle 24 and the elongated spacer frame member 16 based on a property
of the spacer frame member 16 such as a width W of the spacer frame
member. The system 10 applies desiccant 14 to the interior region
22 of the elongated window spacer 16. Adhesive 12 is also applied
on the glass abutting walls 18a, 18b to facilitate attachment of
glass lites (FIGS. 2 and 8) of an assembled insulated glass unit.
Adhesive 12 on the outer wall 20 (FIG. 2) strengthens the elongated
window spacer 16 and allows for attachment of external structure.
The desiccant 14 applied to the interior region 22 of the elongated
window spacer 16 captures any moisture that is trapped within an
assembled insulating glass unit.
[0039] The system illustrated by FIG. 1 includes a plurality of
nozzles 24 a nozzle indexing actuator 26 a nozzle height adjusting
actuator 28 a conveyor 30 and a controller 32. An indexed nozzle
25 positioned above a path of travel P selectively opens to dispense
the desiccant material 14 into the interior region 22 of the elongated
spacer frame member. The remainder of the nozzles remain closed
when the indexed nozzle 25 is dispensing desiccant. The nozzle indexing
actuator 26 selectively indexes each of the nozzles 24 to a delivery
site S located along the path of travel of the elongated spacer
frame member. The nozzle height adjusting actuator 28 positions
the nozzle above the conveyor at the delivery site. The conveyor
30 moves the elongated spacer frame member 16 along the path of
travel relative to the delivery site at a controlled speed. The
controller 32 monitors widths W (FIGS. 6 and 7) of elongated spacer
frame members conveyed to the delivery site. The controller selects
the indexed nozzle 25 based on the width W of an elongated spacer
frame member 16 conveyed to the delivery site S. The conveyor also
determines the appropriate distance D between the nozzle and the
elongated spacer frame member 16 at the delivery site based on the
width W of an elongated spacer frame member conveyed to the delivery
site. Details of one acceptable controller 32 are described in U.S.
Pat. No. 6630028 to Briese et al., which is incorporated herein
by reference in its entirety.
[0040] In the embodiment illustrated by FIG. 1 the system 10 includes
a desiccant metering and dispensing assembly 34 a desiccant bulk
supply 36 the conveyor 30 and the controller 32. The desiccant
bulk supply 36 supplies desiccant 14 under pressure to the desiccant
metering and dispensing assembly 34. The desiccant metering and
dispensing assembly 34 monitors pressure of the desiccant 14 supplied
by the desiccant bulk supply 36. The controller 32 regulates the
pressure of the desiccant 14 delivered to the desiccant metering
and dispensing assembly 34 based on the pressures sensed by the
desiccant metering and dispensing assembly 34. The conveyor 30 moves
the elongated window spacer 16 past the desiccant metering and dispensing
assembly 34 at a rate of speed controlled by the controller 32.
[0041] In the exemplary embodiment the desiccant metering and dispensing
assembly 34 includes a desiccant metering pump 76 which is a gear
pump in the exemplary embodiment. The speed of the desiccant dispensing
gear pump 76 is controlled to dispense the desired amount of desiccant
through the indexed nozzle 25 to the interior region 22 of the elongated
spacer member 16. The desiccant metering and dispensing assembly
34 dispenses the desired amount of desiccant 14 into the interior
region 22 of the elongated window spacer 16 as the elongated window
spacer 16 is moved past the desiccant metering and dispensing assembly
34 by the conveyor 32.
[0042] Referring to FIG. 1 the desiccant bulk supply 36 includes
a desiccant reservoir 78 filled with desiccant 14 a shovel pump
mechanism 80 an air motor 82 an exhaust valve 84 an electropneumatic
regulator 86 and a hose 88. One acceptable shovel pump mechanism
for desiccant is model no. MHMP41042SP, manufactured by Glass Equipment
Development. The desiccant electropneumatic regulator 86 regulates
the pressure applied to the desiccant 14 by the desiccant air motor
82. One acceptable electropneumatic regulator 86 is model no. QB1TFEE100S560-RQ00LD,
produced by Proportion-Air. The hose 88 extends from an outlet of
the shovel pump mechanism 80 to an inlet 106 of the desiccant gear
pump 76. In the exemplary embodiment, the desiccant reservoir 78
is a 55 gallon drum filled with desiccant 14. In one embodiment,
the desiccant is heated before it is applied. One acceptable heated
desiccant is HL-5157 produced by H. B. Fuller. In a second embodiment,
the desiccant is applied cold (i.e., at room temperature). One acceptable
cold desiccant is PRC-525 made by PRC-525-DM. The shovel pump mechanism
80 delivers desiccant 14 under pressure to the hose 88. In the exemplary
embodiment, the shovel pump mechanism 80 heats the desiccant 14
to condition it for application by the desiccant metering and dispensing
assembly 34. To stop additional pressure from being applied to the
desiccant 14 the exhaust valve 84 is selectively opened. One acceptable
desiccant shovel pump 80 for supplying heated desiccant is model
no. MHMP41024SP, produced by Glass Equipment Development. One acceptable
pump 80 for supplying cold desiccant is model no. MCFP 1031 SP,
produced by Glass Equipment Development.
[0043] Most manufacturing facilities generate approximately 100
psi of air pressure. The piston diameter ratio of the desiccant
shovel pump mechanism 80 amplifies the air pressure provided by
the manufacturing facility by a factor of 42 to 1. Magnification
of the air pressure provided by the facility enables the shovel
pump mechanism 80 to supply desiccant 14 at a maximum pressure of
4200 psi to the desiccant hose 88.
[0044] In one embodiment, when heated material is used, the desiccant
hose 88 is a 1 inch diameter insulated hose and is approximately
10 feet long. In another embodiment, when cold desiccant is used
a 1 inch diameter non-insulated hose is used. The pressure of the
desiccant 14 as it passes through the hose 88 will drop approximately
1000 psi as it passes through the hose 88 resulting in a maximum
desiccant pressure of 3200 psi at the inlet 106 of the adhesive
metering and dispensing assembly 34.
[0045] In the embodiment illustrated by FIGS. 1 13-18 and 19
the desiccant metering and dispensing assembly 34 includes a desiccant
gear pump 76 a desiccant gear pump motor 98 and a plurality of
desiccant dispensing guns 100 in series. Referring to FIG. 1 desiccant
14 is supplied under pressure by the desiccant bulk supply 36 via
the hose 88 to the inlet 106 of the desiccant gear pump 76. Controlled
rotation of pump gears 107a, 107b of by the desiccant gear pump
motor 98 meters and supplies desiccant 14 to the line of desiccant
dispensing guns 100 through a desiccant gear pump outlet 108.
[0046] In the exemplary embodiment, the desiccant dispensing guns
100 are snuff-back valve-type dispensing guns that utilizes an air
cylinder to apply an upward force on a stem that extends to a nozzle
24 when the needle valve is closed. To dispense desiccant 14 a
solenoid valve of the indexed dispensing gun 100 causes the air
cylinder 110 to move the desiccant stem 112 away from the air cylinder
and a sealing seat of the indexed nozzle 25 allowing desiccant
14 to flow through an open orifice of the nozzle indexed 25. The
remainder of the dispensing guns 100 remain closed. As such, desiccant
is dispensed only through the indexed nozzle 25. In the embodiment
illustrated by FIG. 1 an inlet of a first dispensing gun 100a is
provided with desiccant by an outlet of the metering pump 76 an
inlet of a second dispensing gun 100b is provided with desiccant
by an outlet of the first dispensing gun 100a, an inlet of a third
dispensing gun 100c is provided with desiccant by an outlet of the
second dispensing gun 100b, and an inlet of a fourth dispensing
gun 100d is provided with desiccant by an outlet of the third dispensing
gun 100c. It should be readily apparent that any number of dispensing
guns could be included in the desiccant metering and dispensing
assembly. One suitable desiccant dispensing gun 100 is model no.
2-15266 manufactured by Glass Equipment Development.
[0047] In the exemplary embodiment, each nozzle 24 can be used
to deliver desiccant to a range of elongated spacer frame widths.
For example, a first nozzle may be sized to apply desiccant to elongated
spacer members having widths ranging from 11/32'' to 13/32''. A
second nozzle may be sized to apply desiccant to elongated spacer
members having widths ranging from 1/2'' to 19/32''. A third nozzle
may be sized to apply desiccant to elongated spacer members having
widths ranging from 19/32'' to 21/32''. FIGS. 10A and 10B illustrate
two differently sized nozzles 24. The nozzles illustrated in FIGS.
10A and 10B are single integral members that each include a mounting
plate 300 a guide pin 302 and a dispensing tip 304. The mounting
plate 300 facilitates attachment to a dispensing gun. The guide
pin 302 inhibits significant misalignment of elongated spacer frame
members with respect to the nozzle 24. The dispensing tip 304 includes
an orifice 306 through which the desiccant is dispensed.
[0048] Referring to FIGS. 10A and 10B, the system 10 includes a
variety of differently sized nozzles 24 to accommodate spacers having
various widths. For example, the system may include six nozzles
to accommodate spacers having widths ranging from 7/32'' to 7/8''.
In the exemplary embodiment, the system monitors the widths W of
elongated spacer frame members approaching the delivery site. The
width may be monitored in a variety of ways. For example, a schedule
may be imported to the controller that includes the widths of each
of the elongated spacer frame members that will be processed by
the system, the width of the approaching spacer may be provided
by a machine that forms the elongated spacer frames, and/or the
widths of approaching spacer frame members may be measured. Once
the width of the approaching elongated spacer frame member or group
of elongated spacer frame members is known, the appropriate nozzle
is automatically indexed to the delivery site based on the monitored
width of the approaching spacer frame member(s). For example, a
nozzle that accommodates 1/2'' to 19/32'' wide elongated spacer
frame members would automatically be indexed to the delivery site
when the system 10 determines that a 9/16'' wide spacer frame is
approaching the delivery site.
[0049] Referring to FIGS. 4 and 5 the nozzles 24 are indexed by
the nozzle indexing actuator 26 that is controlled by the controller.
In the illustrated embodiment, the nozzle indexing actuator 26 is
a motor. The nozzle indexing actuator 26 drives an externally threaded
shaft 130 that is coupled to a plate 132. The plate 132 is connected
to the nozzles 24 such that rotation of the shaft 130 by the nozzle
indexing actuator 26 linearly moves the plate 132 and nozzles 24.
In FIG. 4 the indexed nozzle 25 corresponds to the width of the
elongated spacer frame illustrated in FIG. 4. When the width of
the elongated spacer frame member 16 shown in FIG. 5 is sensed,
the nozzle indexing actuator 26 rotates the shaft 130 to index the
nozzle that corresponds to the width of the elongated spacer frame
illustrated in FIG. 5 to the delivery site.
[0050] In the embodiment illustrated by FIGS. 13-21 the dispensing
guns 100 the desiccant metering pump 76 and the desiccant pump
motor 98 are mounted to a carriage 134. The carriage 134 is mounted
to a rail 136 such that the carriage is laterally moveable with
respect to the rail. The plate 132 is fixed to the carriage 134.
The nozzle indexing actuator 26 and a bearing plate 138 (FIGS. 15
and 16) are fixed with respect to the rail 136. The threaded shaft
130 extends from the nozzle indexing actuator 26 through the plate
132 and is supported by a bearing 140 mounted in the bearing plate
138. Rotation of the threaded shaft 130 linearly moves the plate
132 and carriage 134 along the rail. The carriage linearly moves
the dispensing guns 100 the desiccant metering pump 76 and the
desiccant pump motor 98 as a unit to index the appropriate nozzle
24 to the delivery site.
[0051] FIG. 11 illustrates a dispensing gun 112 of an alternate
embodiment. The dispensing gun includes a single valve assembly
114 and a plurality of nozzles 24 carried by an indexable nozzle
carrying plate 116. The valve assembly 114 selectively dispenses
desiccant 14 through an opening 118 that is positioned above the
desiccant delivery site. The nozzle carrying plate 116 can be linearly
moved to position each of the nozzles over the opening 118 at the
delivery site. Once the appropriate nozzle 24 is positioned at the
delivery site, the valve assembly 114 is controlled to dispense
desiccant through the opening 118 and through the indexed nozzle
25 to the delivery site.
[0052] FIG. 12 illustrates a dispensing gun 120 of an alternate
embodiment. The dispensing gun includes a single valve assembly
124 and a plurality of nozzles 24 carried by an indexable turret
manifold 122. The valve assembly 124 selectively dispenses desiccant
14 through an opening 126 that is positioned above the desiccant
delivery site. The turret can be rotated to position each of the
nozzles over the opening 126 at the delivery site. Once the appropriate
nozzle 24 is positioned at the delivery site, the valve assembly
124 is controlled to dispense desiccant through the indexed nozzle
25 to the delivery site. In the exemplary embodiment, the nozzles
are arranged on the turret 122 such that only one nozzle is positioned
in the path P of travel of the elongated window spacers 16 at a
time.
[0053] In the exemplary embodiment, each nozzle 24 can be used
to deliver desiccant to a range of elongated spacer frame widths.
For example, a first nozzle may be sized to apply desiccant to elongated
spacer members having widths ranging from 11/32'' to 13/32''. A
second nozzle may be sized to apply desiccant to elongated spacer
members having widths ranging from 1/2'' to 19/32''. A third nozzle
may be sized to apply desiccant to elongated spacer members having
widths ranging from 19/32'' to 21/32''.
[0054] Referring to FIGS. 6 and 7 the height of the indexed nozzle
25 is vertically adjusted with respect to the path of travel based
the width W of an elongated spacer frame member approaching the
delivery site. In the exemplary embodiment, the width of the elongated
spacer frame member approaching the delivery site is monitored and
the indexed nozzle 25 is automatically vertically adjusted with
respect to the elongated spacer frame member to a distance D above
the spacer frame member that corresponds to the width of the spacer
frame member. As is illustrated by FIGS. 6 and 7 by adjusting the
relative distance between the spacer frame member and the nozzle
at the delivery site, the width of the desiccant material applied
by the nozzle to the elongated spacer frame member is adjusted.
[0055] Referring to FIGS. 6 and 7 the nozzles 24 are vertically
positioned by a nozzle height adjusting actuator 28 that is controlled
by the controller. In the exemplary embodiment, the nozzle height
adjusting actuator 28 is a motor. The nozzle height adjusting actuator
28 drives an externally threaded shaft 150 that is coupled to a
plate 152. The plate 152 is connected to the nozzles 24 such that
rotation of the shaft 150 by the nozzle height adjusting actuator
28 linearly moves the plate 152 and nozzles 24. In FIG. 6 the vertical
position corresponds to the width of the elongated spacer frame
illustrated in FIG. 6. When the width of the elongated spacer frame
member 16 shown in FIG. 7 is sensed, the nozzle height adjusting
actuator 28 rotates the shaft 150 to move the indexed nozzle 25
to a height that corresponds to the width of the elongated spacer
frame illustrated in FIG. 7 to the delivery site.
[0056] In the embodiment illustrated by FIGS. 13-21 lateral rail
136 that supports lateral carriage 134 carrying the dispensing guns
100 the desiccant metering pump 76 and the desiccant pump motor
98 is mounted to a vertical carriage 154. The carriage 154 is mounted
to a pair of rails 156 such that the carriage is vertically moveable
with respect to the rails 156. The plate 152 is fixed to the vertical
carriage 154. The nozzle height adjusting actuator 28 is fixed with
respect to the pair of rails 156. The threaded shaft 150 extends
from the vertically adjusting nozzle height adjusting actuator 28
through the plate 152. Rotation of the threaded shaft 150 linearly
moves the plate 152 and carriage 154 along the pair of rails. The
carriage vertically moves the dispensing guns 100 the desiccant
metering pump 76 and the desiccant pump motor 98 to appropriately
position the indexed nozzle above the delivery site for the approaching
elongated spacer frame member(s).
[0057] In one embodiment, the volume of desiccant material per
unit of spacer frame member length applied by a nozzle 25 is based
on a moisture vapor transfer rate of an insulated glass unit constructed
with the elongated spacer frame member. Referring to FIGS. 8 and
9 the moisture vapor transfer rate is dependant on the length L
of the path from the exterior 142 to the interior 144 of the insulating
glass unit. In the example illustrated by FIGS. 8 and 9 this length
L is dictated by the width of the adhesive 12 applied to the side
walls 18a, 18b. This length L may be approximately the same for
insulating glass units with different spacer frame widths. As a
result, the volume of desiccant material per unit of spacer frame
member length can be constant for a range of spacer frame widths.
In the example illustrated by FIGS. 8 and 9 the length L of the
path from the exterior 142 to the interior 144 is approximately
the same for wider spacer frame member illustrated by FIG. 9 as
the narrower spacer frame member illustrated by FIG. 8. As a result,
approximately the same amount of desiccant 14 can be used in the
insulating glass unit illustrated by FIG. 9 as the insulating glass
unit illustrated by FIG. 8. The height of the indexed nozzle 25
can be adjusted as illustrated by FIGS. 6 and 7 to adjust the width
of the bead of desiccant applied to the elongated spacer members.
In the example of FIGS. 6 and 7 the indexed nozzle 25 is moved
closer to the spacer frame member, such that the same volume of
desiccant material per unit length applied in the narrower spacer
frame member of FIG. 6 is spread out to cover the entire interior
wall 146 of the wider spacer frame member of FIG. 7. The application
of the same volume of desiccant material per unit length to cover
the entire interior wall a wider spacer can also be accomplished
by indexing a larger nozzle to the delivery site.
[0058] The volume of desiccant 14 dispensed by the desiccant metering
and dispensing assembly 34 can be precisely metered by controlling
the speed of the gears 107a, 107b of the desiccant gear pump motor
98. As long as material is continuously supplied to the inlet of
the desiccant gear pump 98 the same volume of desiccant is dispensed
for each revolution of the gears 107a, 107b. In the exemplary embodiment,
the desiccant metering and dispensing assembly 34 includes a manifold
which delivers the desiccant 14 from the hose 88 to the desiccant
gear pump 76 and delivers the desiccant 14 from the desiccant gear
pump 76 to the line of desiccant dispensing guns 100. A known amount
of desiccant 14 is dispensed for every revolution of the desiccant
gear pump 76. In the exemplary embodiment, the desiccant gear pump
76 provides 20 cm.sup.3 of desiccant 14 per revolution of the desiccant
gear pump 76.
[0059] Referring to FIGS. 1 and 13 the conveyor 32 moves elongated
window spacers 16 past the desiccant metering and dispensing assembly
34. The desiccant metering and dispensing assembly 34 applies desiccant
14 to an interior region 22 of the elongated window spacer 16 as
the conveyor 32 moves the elongated window spacer 16 beneath the
indexed nozzle 25. The indexed desiccant dispensing gun 100 is located
at the delivery site, directly above the conveyor 32 allowing desiccant
14 to be dispensed into the interior region 22 of the elongated
window spacer 16 as the elongated window spacer moves past the indexed
desiccant dispensing gun 100.
[0060] Referring to FIG. 1 the system 10 includes first and second
conveyor guides 118a, 118b which guide the elongated window spacer
16 and position the window spacer in the center of the conveyor
32 as the elongated window spacer moves along the conveyor. The
conveyor guides 118a, 118b are automatically moved toward and away
from each other by a servo motor 310 (FIG. 1) based on the width
of the approaching elongated spacer frame member(s). In the exemplary
embodiment, the conveyor guides 118a, 118b are automatically adjust
to accommodate spacers having widths ranging from 7/32'' to 7/8''.
The system 10 illustrated in FIGS. 13 and 14 also includes rolling
guides 119 (some removed to simplify drawing) that hold elongated
spacers 16 firmly against the conveyor 32 as the spacer is moved
along the conveyor. In the exemplary embodiment, the guides include
wheels that are forced toward the conveyor by a spring loaded mechanism.
[0061] Referring to FIG. 1 a pair of desiccant fiber optic sensors
220 is shown mounted in relation to the conveyor 32 at a point along
the path of the conveyor 32 before the delivery site. In the disclosed
embodiment of the invention there are two desiccant fiber optic
sensors. The desiccant fiber optic sensors sense a leading edge
222 gas holes 224 and a trailing edge 226 of an elongated window
spacer 16 (see FIG. 3). The desiccant fiber optic sensors 220 provide
a signal to the controller 32 when the sensor 220 senses a leading
edge, a gas hole or the trailing edge of an elongated spacer 16.
The controller 32 uses this signal to determine when the elongated
spacer member 16 will pass under the nozzle 114 of the desiccant
metering and dispensing assembly 26.
[0062] Referring to FIG. 1 the controller 32 includes a touch
sensitive display 135 for both inputting parameters and displaying
information. During a setup sequence, the user is prompted to enter
a target conveyor speed, to enter the width between the guide rails
118a, 118b for each spacer frame width, to calibrate the vertical
home position of the nozzles, to calibrate the horizontal home position
of each nozzle, to enter the number of active desiccant nozzles,
to assign a nozzle position to each spacer size, to assign an amount
of desiccant per unit length for each spacer size, and to assign
a nozzle height to each spacer size. FIG. 22 illustrates a rail
spacing setup screen 400. A spacer size selection box 402 allows
the user to select each spacer size. A rail spacing selection box
404 allows the user to set the desired rail spacing for the selected
spacer size.
[0063] FIG. 23 illustrates a nozzle position setup screen 410.
A number of nozzles box 412 allows the user to select the number
of active desiccant nozzles 24. A nozzle position box 414 allows
the user to assign a nozzle position to each spacer size.
[0064] FIG. 24A illustrates an amount of desiccant by weight setup
screen 40. A spacer size selection box 422 allows the user to select
each spacer size. A weight of desiccant per unit length input box
424 allows the user to input the weight of desiccant per unit of
spacer frame length for each spacer frame size.
[0065] FIG. 24B illustrates a thickness of desiccant screen 430
which may be used by the user instead of by the weight setup screen
420. A spacer size selection box 432 allows the user to select each
spacer size. A thickness of desiccant box 434 allows the user to
input the designed thickness of desiccant to be applied to the selected
spacer frame width.
[0066] FIG. 25 illustrates a nozzle height setup screen 440. A
nozzle height box allows the user to assign a nozzle height to each
spacer size.
[0067] The controller 32 control the speed of the conveyor 32
the pressure supplied by the desiccant bulk supply 36 the speed
at which the motor 98 turns the desiccant gear pump 76 and the
time at which the indexed desiccant gun 100 dispenses desiccant
as well as other parameters.
[0068] By supplying desiccant 14 to the gear pumps 76 at an appropriate
pressure (typically between 600 psi and 1500 psi) and controlling
the speed at which the motor drives the gear pump, the volumetric
flow rate of desiccant 14 is accurately controlled.
[0069] The required volumetric flow and speed at which the desiccant
motor 98 drives the desiccant pump 76 is calculated by the controller
32. The required volumetric flow of desiccant 14 is equal to the
cross-sectional area of the desiccant applied multiplied by the
velocity of the elongated window spacer 16 along the conveyor 32.
The required pump speed is equal to the required volumetric flow
of desiccant 14 divided by the volume of desiccant flow produced
for each revolution of the desiccant pump 76.
[0070] In the embodiment where the mass or volume of the desiccant
14 per length of window spacer 16 is inputted into the controller
32 via the touch screen 135. The controller 32 calculates the required
volumetric flow of desiccant 14 by multiplying the inputted mass
per elongated window spacer 16 length by the speed of the conveyor
32. The speed at which the desiccant pump 76 must be driven by the
desiccant gear pump motor 98 is equal to the required desiccant
volumetric flow rate divided by the flow created by each revolution
of the desiccant gear pump 76.
[0071] The indexed nozzle 25 is selected, the height of the indexed
nozzle is adjusted, and the distance between the conveyor guides
118a, 118b are adjusted automatically by servo motors based on the
widths of elongated spacer members scheduled to be processed by
the system. An elongated window spacer 16 is placed on the conveyor
32 (either manually or automatically by an automated delivery device
or from a machine that forms elongated spacers from ribbon stock)
with the outer wall 20 in contact with the conveyor 32 and the glass
abutting walls 18a, 18b constrained by the conveyor guides 118a,
118b. The rolling guides 119 hold the elongated spacer 116 firmly
against the conveyor 32 as the spacer is moved along the conveyor.
The conveyor 32 moves the elongated window spacer 16 toward the
desiccant metering and dispensing assembly 34. The leading edge
222 gas holes 224 and trailing edge 226 of the elongated window
spacer pass beneath the desiccant fiber optic sensor 220. The desiccant
fiber optic sensor 220 senses the leading edge, the gas holes 224
and the trailing edge 226 and provides a signal to the controller
32 indicating the time at which the leading edge, gas holes and
trailing edge pass beneath the desiccant fiber optic sensor 120.
The controller 32 uses the input from the desiccant fiber optic
sensor and the speed of the conveyor 32 to calculate the time at
which the leading edge, gas holes and trailing edge of the elongated
window spacer 16 will pass the indexed nozzle 25.
[0072] Referring to FIG. 1 the elongated window spacer 16 is moved
by the conveyor 32 past the desiccant dispensing gun 100. When the
leading edge 222 of the elongated window spacer 16 reaches the indexed
nozzle 25 desiccant 14 is dispensed into the interior region 22
of the elongated spacer beginning at the leading edge. Desiccant
14 is applied to the interior region as the elongated spacer is
moved past the desiccant dispensing gun 100. The desiccant gear
pump motor 98 drives the desiccant gear pump 76 at the required
speed to supply the desired amount of desiccant 14 into the interior
region 22 of the elongated window spacer 16.
[0073] In one embodiment, when a gas hole 224 of the elongated
window spacer 16 passes beneath the desiccant dispensing gun 100
dispensing of desiccant into the interior region 222 is temporarily
stopped, leaving the gas holes 224 open. In the exemplary embodiment,
the controller 32 causes the desiccant dispensing gun 100 to begin
dispensing desiccant again after the gas hole 124 passes the desiccant
dispensing gun 100. In an alternate embodiment, desiccant 14 is
applied over the gas holes 124. In this embodiment, the controller
32 causes the desiccant dispensing gun 100 to continue dispensing
desiccant 14 as each gas hole 124 passes beneath the desiccant dispensing
gun 100. This option of applying desiccant over the gas holes, may
be programmed by the user into the controller 32 via the touch screen
135 during the setup sequence.
[0074] The desiccant dispensing gun 100 continues to dispense desiccant
14 into the interior region 22 until the trailing edge 226 of the
elongated window spacer 16 is reached. In one embodiment, the controller
stops dispensing of desiccant 14 at the trailing edge 126 of the
elongated window spacer 16 based on the position of the trailing
edge 126 sensed by the desiccant fiber optic sensor 120. In an alternate
embodiment, the controller 32 stops dispensing of desiccant 14 into
the interior region 22 based on a length parameter that is inputted
into the controller 32 via the touch screen 135.
[0075] Although the present invention has been described with a
degree of particularity, it is the intent that the invention include
all modifications and alterations falling within the spirit or scope
of the appended claims. |