Automatic machine for versatile and alternative application of at least two types of sealant along the perimetric rim of an insulating glazing unit

Abstract

An automatic machine for versatile and alternative application of at least two types of sealant along the perimetric rim of an insulating glazing unit, whose spacer frame is constituted preferably but not exclusively by a continuous strip of expanded synthetic material. In particular, the machine allows simple and quick switching from one sealant to another, since the path of the plurality of sealants which starts from their feed, be they of the hot and/or cold extruded type, uses a plurality of ducts which reach the extrusion nozzles that are active proximate to the perimetric rim of the insulating glazing unit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

Further characteristics and advantages of the invention will become better apparent from the description of a preferred but not exclusive embodiment of the invention illustrated by way of non-limiting example in the accompanying drawings, wherein:

FIGS. 1A-1E are schematic views of the peripheral portion of the insulating glazing unit 3 in an exemplifying but not exhaustive series of possible constructive combinations: FIG. 1A: normal, FIG. 1B: triple glazing unit, FIG. 1C: offset glass panes, FIG. 1D: normal outer pane and low-emissivity inner pane, FIG. 1E: tempered reflective outer pane and laminated low-emissivity inner glass pane. FIGS. 1A, 1B, 1C show the traditional spacer frame 1 and the two types of sealant used: in black, the butyl sealant (PIB) 1001, which acts as an initial binder among the components and as a seal (first seal) and is applied between the lateral surfaces of the frame and the glass panes; in broken lines, the polysulfide (PS) or polyurethane (PU) or silicone (SI) sealant 1002, which has a mechanical strength function (second sealing) and is applied between the outer surface of the frame and the faces of the glass panes up to their edge. FIGS. 1D, 1E illustrate the spacer frame obtained by means of an innovative spacer profile 1′ and 1″ made of expanded synthetic material covered with adhesive (as a replacement of the first seal). In the case of FIG. 1D, the sealant (HM) that constitutes the second seal 1002 is shown with hachures, and the cross-hatching indicates the spacer profile made of expanded synthetic material, which is of the so-called Super Spacer normal type with a rectangular cross-section 1′. In the case of FIG. 1E, the sealant (PIB) which constitutes the second seal 1002 is highlighted in black lines (the first seal 1001 being assigned, albeit without expectations of tightness but rather as a coupling function, to the acrylic adhesive as mentioned earlier and being shown in FIG. 1E in closely hatched lines); the sealant (PS, PU or SI, but typically SI for structural glazing units) which constitutes the third seal 1003 is shown in normal hatching and the spacer profile made of expanded synthetic material is of the special type known as TriSeal with a contoured cross-section 1″, so as to have lateral compartments for accommodating the PIB sealant.

The inner/outer orientation is identified visually by means of icons which represent the sun (outer side) and the radiator (inner side). Said figures clearly show the importance of the spacer frame 1, 1′, 1″ in the composition of the insulating glazing unit 3, especially in embodiments in which the thicknesses of the glass panes 2 are considerable and therefore so is the weight (as in the case of laminated glazing units), and therefore the use of the spacer profile 1′, 1″ made of expanded synthetic material, the lateral faces of which are covered with highly effective acrylic adhesive, turns out to be particularly valid, since it allows the instantaneous coupling of the glass panes to the spacer, differently from the butyl sealant according to the background art.

FIGS. 2, 3, 4 illustrate the machine according to the invention, in several views (a general front view, showing the horizontal axis H for the movement of the insulating glazing unit and of the vertical axis V for moving the extrusion head, and with the arrangement of the insulating glazing unit 3, complete with the identification of its sides in the typical progression of the steps of the sealing process; a general side view, with identification of the vertical axis V and of the rotation axis Θ for the orientation of the extrusion nozzles, a complete rear view exemplifying the presence of two PIB/HM dosage units, of the PIB melting unit, the one for the HM being similar, and of an electrical panel).

FIGS. 5A and 5B represent in perspective views the main components of the machine, divided into assemblies, designated according to the numbering logic: the 100 series of numerals for the horizontal track, with a sucker-fitted carriage 100 for moving the insulating pane 3 along the horizontal axis H; the 200 series for the vertical track with the extrusion head supporting carriage for moving the extrusion head along the vertical axis V; the 300 series for the assembly for actuating the rotation of the head about the rotation axis Θ; the 400 series for the dosage unit assembly; the series 500 for the assembly with several of the inventive features to which the present application mainly, but not exclusively, relates.

FIGS. 6A and 6B illustrate specifically the assembly (an extrusion head assembly), of the 500 series.

FIG. 7 is a perspective view of details of the assembly of the 500 series.

FIG. 8 is a perspective view of the mechanisms for allowing the switching of the orientation of the extrusion nozzles.

FIGS. 9A and 9B illustrate the details of the extrusion nozzles mated with the perimetric part of the insulating glazing unit 3 during an extrusion step.

FIGS. 10A and 10B are views of the production line of the insulating glazing unit 3 (in the elevation and plan views) with the machine according to the invention, and includes in the plan view melting units for PIB 11, a melting unit for HM 12, an electrical/electronic panel 13, a control column 14 and protection devices 15.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

We now provide the detailed description of a preferred but not exclusive way of carrying out the invention.

Description of a preferred but not exclusive embodiment of the invention is made hereinafter with reference to FIGS. 1A-1E, 2, 3, 4, 5A, 5B, 10A, 10B for the general configuration and to FIGS. 6A, 6B, 7, 8, 9A, 9B for the description of the details. For the purposes of the description, it is assumed that parts that correspond to FIGS. 2, 3, 4, 5A, 5B are known and therefore do not require a detailed description but only a brief one, since both the previously described prior art and the knowledge of the person skilled in the art do not require particular clarifications for the manufacture of such parts.

Single-digit reference numerals refer to the material being processed, whereas, as already set forth earlier in the description, three-digit reference numerals refer to the components of the machine and reference numerals which end with two zeros refer to each assembly of the machine. Four-digit reference numerals refer to the machines that belong to the production line of the insulating glazing unit 3, in which the machine 1000 is the one to which the present application particularly relates.

In particular, the reference numerals 1′, 1″ designate a spacer profile made of expanded synthetic material, without excluding operation of the machine also with spacer profiles made of a different material, so long as said material is compatible with the mechanisms described hereinafter; the reference numeral 2 designates a glass pane, equally the one directed toward the operator and the one that lies opposite and another intermediate pane or other intermediate panes (in the case of an insulating glazing unit composed of more than two glass panes) affected by the application of the PIB and/or HM sealant); the reference numeral 3 designates an insulating glazing unit. These reference numerals have already been used in the previous description.

Two-digit reference numerals are also used as follows: the reference numeral 11 designates a melting unit for the PIB sealant; the reference numeral 12 designates a melting unit of the sealant AM; the reference numeral 13 designates an electrical/electronic panel, the reference numeral 14 designates a control column, and the reference numeral 15 designates protective structures, which can be mechanical barriers or optical barriers or laser barriers or electrically sensitive mats et cetera, since particular attention is dedicated not only to the functional, economic and ergonomic aspects that are specific to the content of the present invention but also to aspects related to accident prevention.

One preferred way of carrying out the invention is the one described hereafter; the listing of the various components whereof, albeit not numerous, is to be considered in the context of the flow of the sealants along the paths (pipes and components) to travel from the melting units 11, 12 to the perimeter of the insulating glazing unit 3.

The terms used herein are intended to have the significance indicated hereinafter: “vertical”, “substantially vertical” or “pseudovertical”, it is understood to refer to a slight inclination with respect to the vertical, (in the range of about 6°), since the transport of the glass pane 2 or of the insulating glazing unit 3 along the entire production line occurs on conveyors whose supporting surface is inclined by approximately 6° with respect to the vertical plane.

Likewise the lower transport/support parts and rollers have an axis which is inclined by approximately 6° with respect to the truly horizontal plane. Accordingly, when using the term “horizontal”, this will be understood to mean a slight inclination, in the order of about 6°, with respect to the horizontal.

The insulating glazing unit 3, in the processing step in which it is composed of at least two glass panes and at least one spacer frame but is not yet provided with the second and third sealants as defined earlier, is fed from a previous processing machine, typically a coupling/pressing unit 6000 or a gas filling unit 7000, or is fed manually or by means of a loading unit, onto the known input conveyor of the machine 1000 according to the present invention, the machine comprising a body structure F that bears a pseudovertical support 600 that supports the glazing unit 3 to be processed. The glazing unit 3 advances, conveyed by support and advancement rollers or belts, but kept in step by means of a synchronous actuation. The actuation is constituted by a horizontal carriage 100 actuated by a synchronous motor 101 by means of a reduction unit 102 and belts drive 103 and other known components. The unit 3 advances up to a sucker 104 which mates with the glass pane on the operator side, and up to a slowing sensor and a directly subsequent stop device, both of which are known, so as to position such insulating glazing unit 3 in the correct arrangement, onto the support system 600, with respect to an extrusion head 500 and allow the beginning of the process for applying the PIB sealant or the HM sealant.

Previously, the head assembly 500, which can move vertically since it is applied to a vertical carriage 200, supported so as to be guidingly movable on the body structure F of the machine (see FIGS. 5A-5B), by way of the action of a synchronous motor 201 and a reduction unit 202 and other known components, all of which control the vertical motion of the head assembly 500, has been arranged in the condition for beginning the process. The head assembly 500 is also provided with a rotary motion, about a rotation axis Θ which is actuated by a rotation assembly 300 rotatable about the axis Θ by means of a synchronous motor 301, a reduction unit 302, a toothed pinion 303 and a ring gear 304, which act on the center bearings for centering and supporting the hollow shaft (components the structure whereof is known and which are referenced here as containing internally and in a cantilever fashion the devices that belong to the assembly 500).

At this point, the synchronized motions, the horizontal one of the insulating glazing unit 3 by means of the mechanisms and actuations of the section 100, the vertical one of the head assembly 500 by means of the mechanisms and actuations of the section 200, the rotary one of the head assembly 500 by means of the mechanisms and actuations of the series 300 (which act to turn through 90° in order to switch the orientation of a nozzle 503h or of a nozzle 503p so as to interface with the vertical side or with the horizontal side of the rectangular insulating glazing unit, or to perform finite or progressive rotations to interface a nozzle 503h or a nozzle 503p or other nozzles with the perimeter region of the insulating glazing unit when it has non-rectangular shapes), in their interaction, initially bring into contact the perimetric region or rim of the insulating glazing unit with the extrusion nozzle and retain it along the entire path, mating with its shape, be it rectangular or non-rectangular. There is no need to delve more in detail with the description of the mechanisms involved that are of a conventional construction, known to the one skilled in the art. Likewise, the elements related to the distribution of the sealant starting from storage up to the extrusion nozzle are known and belong to the background art which is nevertheless repeated here for completeness of the description also as regards the known part, i.e., the part related to a single sealant (be it of the hot type or of the cold type and in this second case of the single- or two-component type).

In the case of a hot sealant (in the current art, only of the single-component type, for example the hot melt (HM) type), its path begins from a melting unit 401h (part of the dosage assembly 400), which is constituted by a heated parallelepipedal compartment into which the product, generally a so-called cake S also shaped like a parallelepiped, is introduced manually through a hopper 402h (part of the dosage assembly 400). Once melted, melting being in any case progressive and therefore the part that has remained for longer having melted, a gear pump 403h (part of the dosage assembly 400) transfers it to a dosage unit 404h of the known type; by being provided with its own axis Dh which is actuated by a synchronous motor whose actuation is interpolated with the information that arrives from a detector 501 for sensing depth (distance between the outer wings of the glass panes and retracting position of the spacer frame 1, 1′, 1″), which is also of a known type, and from a device for measuring the distance between the glass panes 502 (not shown), which is also known, and from the actuation systems which move the axes H or V, or H and V combined in the case of contoured insulating glazing units, said dosage unit doses the stoichiometric quantity of sealant, which flows along a pipe 405h for feeding to a rotary coupling 406h which is connected to the section 500. Up to this point, a description of the machine was provided with reference to the assemblies and devices inherent to its generic construction-operation. The specific features that enable putting into effect of the invention are comprised mainly by the section-assembly 500. A plate 305 is rigidly coupled to the gear 304 and therefore can rotate with it and accommodates an articulation 504h (where the index h stands for HM). This articulation receives the HM sealant through the rotary coupling and conveys it through a rotary coupling 505h to a duct 506h. All this can be seen in FIG. 6b, which also includes the details 504p, 505p, 506p, the index p of which stands for PIB, which will be described hereinafter. Conveniently, the articulation 504h in combination with the articulation 504p, through the inside of which the sealants pass, constitute a fulcrum for the ducts 506h and 506p, which therefore can oscillate about the oscillation axis p by using a counterweight 507 to balance the cantilever extensions that pass through the hollow shaft which begins with the gear 304 and arrive at the extrusion nozzles 503h, 503p, of which 503h is the point of arrival of the FM sealant.

In the case of an alternative sealant, again of the hot PIB (polyisobutylene) type, its path begins from a melting unit 401p, constituted by a heated parallelepipedal block in the cylindrical continuation 402p of which the product, generally a so-called cake S which also is cylindrical, is introduced manually. Melting is in any case progressive and the part of the product that has remained stationary for longer is melted. Once the melt product is obtained, a pusher 403p transfers it to a dosage unit 404p, of the known type, which is provided with its own axis Dp actuated by a synchronous motor and doses the PIB sealant, as explained earlier for the HM sealant. In the same manner as in the description of the path for the HM sealant, the PIB sealant can reach the extrusion nozzle 503p through the components 404p, 405p, 406p, 504p, 505p, 506p.

The combination of these two sealant path descriptions is clearly illustrated in FIG. 7, which also shows the wires for supplying power to the heating resistors 507h and 507p for heating the ducts, since the products discussed so far in the description are of the hot type; said figure illustrates one of the preferred embodiments, and the other ones can be constituted by the following combinations:

a heated duct such as 506p for the PIB product and an unheated duct such as 506f (f stands for “cold”, i.e., ambient temperature) for feeding a cold single-component product;

a duct such as 506p for the PIB product and a known mixing unit, which has similar dimensions to the duct, for feeding a cold two-component product, two pipes such as 405f converging to said mixing unit on two rotary couplings such as 406f, the sealant being composed of a base product and a catalyst product, as known;

two unheated ducts such as 506f for feeding two cold single-component products;

two known mixers, whose space occupation is similar to that of the ducts 506f, for feeding two cold two-component products, and at which pipes such as 405f and rotary couplings such as 406f converge, the sealants being each composed of a base product and a catalyst product as known;

all the possible combinations of three sealant products among the eight available: HM, PIB, single-component PS, single-component PU, single-component SI, two-component PS, two-component PU, two-component SI.

FIG. 8 illustrates the mechanisms for allowing switching of the product, in order to draw either the one that arrives from the duct 506h or the one that arrives from the duct 506p; this is obtained by loosening screws 508, turning a plate 509 and tightening the screws 508 again and, since the nozzles 503h, 503p can be switched, by acting on a three-way, two-position cock 510. Of course, other combinations can provide the same result, for example the use of a plate 509 which again is able to rotate and is provided with double holes, each hole being connected to a single nozzle, and by resorting to the blocking of the product that is not used upstream of the ducts such as 506.

The description given above and the corresponding figures refer to a sealing machine 1000, with respect to which the source machine (gas filler 7000 or coupling unit 6000) is arranged to the left and the destination machine, if any (a possible additional sealing machine for additional combinations of products), is arranged to the right thereof (with reference to the flow of the process); it is easy to imagine a description and corresponding figures in the case of mirror-symmetrical or otherwise different arrangements.

Of course, all the movements linked to the steps of the cycle are mutually interlocked with the aid of a logic system which is parallel but always active in order to avoid, during the process, conditions of mutual interference between actuator elements and the material being processed.

As is readily available to those skilled in the art, the machine allows simple and quick switching from one sealant to another since the paths of the plurality of sealants that start from their feeds, be they of the hot- and/or cold-extruded type, use multiple ducts which reach the extrusion nozzles which are active proximate to the perimetric rim of the insulating glazing unit.

The present invention is susceptible of numerous constructive variations (with respect to what can be deduced from the drawings, the details of which are evident and eloquent), all of which are within the scope of the appended claims; this applies, for example, to the mechanical solutions to allow the switching of the nozzles (503h, 503p), for extrusion, to the switching means which can be electrical, electric-electronic, pneumatic, hydraulic and/or combined, et cetera, to the control means, which can be electronic or fluid-operated and/or combined, et cetera.

The constructive details can be replaced with other technically equivalent ones. The materials and the dimensions may be any according to requirements in particular arising from the dimensions (base and height) of the glass panes 2.

The industrial application and the advantages of the invention are important, since machines for automatic sealing are widespread. Known machines handle a single sealant or two sealants by resorting to replacements of the final feed path, with an abnormal expenditure of time. Introduction of an innovation whose scope has been described here provides instead two great possibilities: implementing the device invention on existing machines, provided that they have a sufficiently spacious hollow part of the extrusion head, and marketing directly automatic sealing machines of the versatile type, already provided according to the invention.

Moreover, the insulating glazing unit market is continuously evolving and expanding, since in recent years it has been increased by the need for higher thermal insulation at the spacer frame, hence the onset of the spacer profile made of expanded synthetic material 1′, 1″ which requires, for an equal plant for the production of the insulating glazing unit, the second sealing 1002 with hot HM or the second sealing 1002 with hot PIB and the third sealing 1003 with a cold sealant. This can be done in the same machine and therefore in the same line only with the machine and method of the present invention.

In addition, the spread of shapes which are non-rectangular because they are polygonal or curvilinear or mixed, enhances even further the importance of the present invention, since it can be applied also in automatic machines which seal insulating glazing units which have non-rectangular shapes, for example polygonal and curvilinear ones.

Application of the present invention in an insulating glazing unit production line is illustrated in FIGS. 10A and 10B (perspective view and plan view), clearly demonstrating the assured success in industrial application.

The disclosures in Italian Patent Application No. TV2006A000187 from which this application claims priority are incorporated herein by reference.

Claims

1. An automatic sealing machine for sealing a perimetric rim of an insulating glazing unit formed by at least two glass panes joined to each other by interposition of at least one spacer frame, the machine comprising: a body structure;a pseudovertical support system for supporting the glazing unit;a horizontal carriage for conveying the glazing unit synchronously along a horizontal axis onto said support system, said carriage being provided with a sucker that is coupleable to an outer face of one of the glass panes;a vertical carriage that is supported so as to be guidingly movable, along a substantially vertical axis, on said body structure;a rotation assembly, supported at said body structure for rotation about a rotation axis;an extrusion head assembly that is supported on said vertical carriage for vertical movement along said substantially vertical axis, said extrusion assembly being further actuatable by said rotation assembly for rotary motion about said rotation axis;at least one extrusion nozzle that is supported on said extrusion head assembly so as to have an orientation that is switchable by way of said rotation assembly to selectively interface with a perimeter region of a vertical or of a horizontal side of the glazing unit to be treated;a volumetric dosage assembly, supported on said body structure, for dosing and transferring to said at least one nozzle hot and/or cold sealant in a required amount, established as a function of a cross-section of the glazing unit to be filled and of the relative speed between the perimetric region to be treated and said at least one nozzle;

2. The automatic machine of claim 1, wherein it comprises switching valves provided along the sealant feed path for selection of the product to be fed to the at least one extrusion nozzle.

3. The automatic machine of claim 1, wherein selective feeding is provided among more than two sealant products.

4. The automatic machine of claim 2, comprising a hollow part which is identified with a face of the extrusion head assembly that is provided with a plurality of feed ducts, acting as end parts of the feed paths for at least two sealants.

5. The automatic machine of claim 4, wherein in the hollow part which is identified with the face of the extrusion head assembly, a plurality of mixing units are provided acting as end parts of the feed paths of at least two sealants.

6. The automatic machine of claim 4, wherein in the hollow part which is identified with the face of the extrusion head assembly at least one feed duct and one mixer are provided acting as end parts of the feed paths of at least two sealants.

7. The automatic machine of claim 5, wherein said feed ducts and mixing units are pivoted in a region of said extrusion head assembly which is located far from the insulating glazing unit arranged for treatment on said support system.

8. The automatic machine of claim 7, wherein said region is located externally with respect to a gear of the rotation assembly of the extrusion head assembly on an opposite side with respect to an arrangement of the insulating glazing unit on said support system.

9. The automatic machine of claim 5, comprising a counterweight and at least two nozzles, said feed ducts or mixers and said at least two extrusion nozzles being balanced statically by means of said counterweight.

10. The automatic machine of claim 1, comprising a sealant selection valve located proximate to said at least one extrusion nozzle.

11. The automatic machine of claim 10, wherein said selection valve is manually or automatically actuatable.

12. The automatic machine of claim 1, wherein said at least one nozzle for extrusion of the sealant has a shape that is provided selected as a function of a distance between the two glass panes and of the distance between the spacer frame and wings of the glass panes.

13. The automatic machine of claim 12, wherein said at least one extrusion nozzle is coupled to said extrusion head assembly like a slider for easy replaceability and convertibility.

14. A method for sealing a perimetric rim of an insulating glazing unit formed by at least two glass panes joined to each other by interposition of at least one spacer frame, on a machine as set forth in claim 1, the method comprising the steps for: actuating a horizontal carriage for conveying a glazing unit along a horizontal axis and onto a support system;actuating a vertical carriage to move in a guided manner along a substantially vertical axis on a body structure of the machine, whereby to move vertically, along said substantially vertical axis, an extrusion head assembly;actuating a rotation assembly supported on the body structure of the machine to rotate the extrusion head assembly, along with at least one extrusion nozzle supported thereon, about a rotation axis;actuating a volumetric dosage assembly supported on the body structure of the machine to dose and transfer to the at least one nozzle hot and/or cold sealant, in a required amount, said dosage step comprising establishing of a required amount of sealant as a function of a cross-section of the glazing unit to be filled and of the relative speed between a perimetric region of the glazing unit to be treated and the at least one nozzle;