Patent Application
20220098923
The present invention relates to devices for distributing a sealant material, such as for distributing a sealant material onto the sides of a spacer for an insulating glazing unit, as well as methods of using the devices, spacers formed therefrom, and insulated glazing units formed with the spacers.
Insulated glass units (IGU's) are formed from two or more plies of glass separated by one or more spacers to form an air gap between the plies of glass. Sealant materials are applied to the spacers to bond the plies of glass to the spacer while also providing a gas and liquid barrier to prevent gas, such as air, and liquids, such as water, from flowing into and out of the air gap. The amount, placement, size, and shape of the sealant materials applied to the spacer contribute to the effectiveness of the sealant material as well as the resulting IGU.
Considerable efforts have been expended to develop methods and devices for forming IGU's, including devices and methods for preparing spacers. While current devices and methods can provide spacers with sealant materials for use in IGU's, there is a need for an improved system to apply sealant materials that can provide better performance in the final IGU, a faster overall application process, improved weathering properties, and the like.
Thus, it is desirable to provide an improved device and method of applying sealant materials, which can be used in preparing spacers for IGU's.
The present invention includes a device for delivering a sealant material. The device includes a first nozzle comprising a first nozzle head, and a second nozzle comprising a second nozzle head. The first and second nozzle heads each independently have an outlet, an inlet opposite the outlet, and an open channel that extends through a body of the nozzle heads from the inlet to the outlet. The first nozzle is spaced apart from the second nozzle, such that the outlet of the first nozzle head faces the outlet of the second nozzle head with a space formed between the nozzle heads to allow a component to enter a first side of the device and exit a second side of the device while passing by the first and second nozzle heads. A notch is formed through the body of each of the first and second nozzle heads at a side where the component exits the device to distribute a sealant material onto each side of the component.
The present invention is also directed to a method of applying a sealant material onto a spacer for an insulating glass unit. The method includes passing an elongated spacer through the space formed between the first and second nozzle heads of the previously described device; and applying a sealant material to a first side of the spacer with the first nozzle and to a second opposite side of the spacer with the second nozzle as the spacer is passed through the device.
The present invention further includes a spacer comprising sealant material formed from the previously described method, as well as an insulating glass unit comprising such a spacer formed between opposing glass plies.
The present invention is also directed to the following clauses:
A first aspect is directed to a device for delivering a sealant material, comprising: a first nozzle comprising a first nozzle head; and a second nozzle comprising a second nozzle head, the first and second nozzle heads each independently comprising an outlet, an inlet opposite the outlet, and an open channel that extends through a body of the nozzle heads from the inlet to the outlet, wherein the first nozzle is spaced apart from the second nozzle such that the outlet of the first nozzle head faces the outlet of the second nozzle head, with a space formed between the nozzle heads to allow a component to enter a first side of the device and exit a second side of the device while passing by the first and second nozzle heads, and wherein a notch is formed through the body of each of the first and second nozzle heads at a side where the component exits the device to distribute a sealant material onto each side of the component.
A second aspect is directed to the device of the first aspect, wherein the notches extend through a portion of the body of each nozzle head in a longitudinal direction from the outlet toward the inlet.
A third aspect is directed to the device of the first or second aspects, wherein a height of the notches at the outlets of the nozzle heads are greater than a height of the notches where the notches end within the body of the nozzle heads.
A fourth aspect is directed to the device of any of the preceding aspects, wherein a thickness of the notches extends laterally through the body of the nozzle heads in a direction from a second side of the nozzle heads to the first side of the nozzle heads, and wherein the thickness of the notches extends past the open channels to a point before the first side of the nozzle heads.
A fifth aspect is directed to the device of any of the preceding aspects, wherein the notches extend longitudinally at a distance of no more than half of the length of the body of the nozzle heads.
A sixth aspect is directed to the device of any of the preceding aspects, wherein the first and second nozzles each independently comprise a single nozzle.
A seventh aspect is directed to the device of any of the preceding aspects, wherein the notches are triangular shaped.
An eighth aspect is directed to the device of the seventh aspect, wherein the triangular shaped notches have three points, and wherein a first point of the triangular shaped notches extend through the body of each nozzle head in a longitudinal direction, and a second point and third point of the triangular notches extend through the body of each nozzle head in opposite vertical directions.
A ninth aspect is directed to the device of any of the preceding aspects, further comprising at least one pump that distributes sealant material through the first and second nozzles heads.
An tenth aspect is directed to the device of any of the preceding aspects, further comprising a controller in operable communication with the at least one pump, and one or more computer-readable storage mediums in operable communication with the controller and containing programming instructions that, when executed, cause the controller to distribute the sealant material through the first and second nozzle heads.
An eleventh aspect is directed to the device of any of the preceding aspects, wherein the outlets of the nozzle heads are spaced apart at a distance to apply the sealant material onto opposite sides of an elongated spacer for an insulating glass unit.
A twelfth aspect is directed to a method of applying a sealant material onto a spacer for an insulating glass unit, the method comprising: passing an elongated spacer through the space formed between the first and second nozzle heads of the device according to any one of the first through eleventh aspects; and applying a sealant material to a first side of the spacer with the first nozzle and a sealant material to a second opposite side of the spacer with the second nozzle as the spacer is passed through the device.
A thirteenth aspect is directed to the method of the twelfth aspect, wherein the first and second nozzle heads are spaced at a distance such that the outlets of the first and second nozzle heads are substantially flush with the first and second sides of the spacer.
A fourteenth aspect is directed to the method of the twelfth or thirteenth aspects, wherein the notches extend through a portion of the body of each nozzle head in a longitudinal direction from the outlet toward the inlet.
A fifteenth aspect is directed to the method of the fourteenth aspect, wherein the notches extend longitudinally at a distance of no more than half of the length of the body of the nozzle heads.
A sixteenth aspect is directed to the method of any one of the fourteenth or fifteenth aspects, wherein a thickness of the notches extend laterally through the body of the nozzle heads in a direction from a second side of the nozzle heads to the first side of the nozzle heads, and wherein the thickness of the notches extends past the open channels to a point before the first side of the nozzle heads.
A seventeenth aspect is directed to the method of any one of the twelfth through sixteenth aspects, wherein the device comprises at least one pump that distributes the sealant material through the first and second nozzles heads.
An eighteenth aspect is directed to the method of the seventeenth aspect, wherein the pump moves the sealant material to create an upstream line pressure in a range of from 400 psi to 1200 psi.
A nineteenth aspect is directed to the method of the seventeenth or eighteenth aspects, wherein the device further comprises a controller in operable communication with the at least one pump, and one or more computer-readable storage mediums in operable communication with the controller and containing programming instructions that, when executed, cause the controller to distribute the sealant material through the first and second nozzle heads, and wherein the method comprises automatically applying the sealant material to the first side of the spacer with the first nozzle and the sealant material to the second side of the spacer with the second nozzle as the spacer is passed through the device.
A twentieth aspect is directed to a spacer comprising sealant materials formed from the method of any one of the twelfth through nineteenth aspects.
A twenty-first aspect is directed to an insulating glass unit comprising the spacer of the twentieth aspect formed between opposing glass plies.
For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “lateral”, “longitudinal”, and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the specification, are simply exemplary embodiments of the invention. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.
Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of “1 to 10” is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.
In this application, the use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. In addition, in this application, the use of “or” means “and/or” unless specifically stated otherwise, even though “and/or” may be explicitly used in certain instances.
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The open channels 34 that extend through the body 36 of the nozzle heads 14 and 18 can have various shapes and sizes provided that the open channels 34 are able to receive and deliver sealant materials out of the nozzles 12 and 16 and onto a component such as, for example, a spacer for an insulating glass unit (IGU). It is appreciated that the open channels 34 are sized to distribute a sufficient amount of sealant materials to provide the desired sealant properties between the component and one or more surfaces that the component is attached.
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The notches 60 can have various shapes and sizes formed through the nozzle heads 14 and 18 to provide a desired shape and amount of sealant material 46 onto the surfaces of opposing sides 44 of the component 42 (e.g. a channel-shaped spacer) as shown in
The notches 60 can also be sized to provide a desired volume of sealant onto a selected area of the component 42. For example, the notches 60 can be sized to provide an amount of sealant of from 0.006 to 0.010 cubic inches per linear inch of component 42 per side 44 of the component 42, such as about 0.008 cubic inches per linear inch of component 42 per side 44 of the component 42.
Referring to
The notches 60 can also form a desired shape including, but not limited to, a triangular shape, a trapezoid shape, and the like. For example, and as shown in
As previously described, the opposing sides 44 of the component 42 pass by the outlets 30 of the first and second nozzle heads 14 and 18 at a selected distance to receive the sealant material 46 exiting the open channels 34. For instance, the opposing sides 44 of the component 42 can be spaced at a distance from the outer face 38 of the outlets 30 so that the opposing sides 44 are flush or substantially flush with the outer face 38 of the outlets 30 to form enclosed cavities. As sealant material 46 is distributed through the open channels 34, the sealant material 46 fills the cavities of the notches 60. Because the outer face 38 and portion of the body 36 at the second sides 52 of the nozzles heads 14 and 18 is removed by the notches 60, sealant material 46 is formed onto the sides 44 of the component 42 as the component 42 exits the space 40 formed between the nozzle heads 14 and 18. It is appreciated that the sealant material 46 formed on the sides 44 of the component 42 will be in the shape of the notches 60.
The device 10 can also have additional components. For example, and as shown in
Referring to
Non-limiting examples of other components that can be used with the device 10 include sensors (not shown) that detect various parameters and conditions within the nozzles 12 and 16, nozzle heads 14 and 18, and/or space 40 formed between the nozzle heads 14 and 18. The sensors can be used to detect parameters and conditions including temperature, pressure, sealant flow rate, and/or the presence of sealant material 46 within the nozzle head bodies 36, open channels 34, and/or space 40 formed between the nozzle heads 14 and 18, for example. For instance, the nozzle heads 14 and 18 can have thermocouples for measuring sealant temperature as well as pressure transducers for maintaining consistent dispensing pressure.
Additionally, the device 10 can also include temperature control components to heat or cool the temperature within the open channels 34, fluid passages 21, and/or conduits 22 in fluid communication with the containment apparatus 24. For example, the nozzles 12 and 16 can be heated through conduction such as by using a manifold having heating elements (e.g. heater rods) and thermocouples.
Additionally, referring to
The controller 110 and one or more computer-readable storage mediums can be used to automatically control the device 10. As used herein, the term “automatic control” refers to the absence of substantial participation of a human operator during normal operations of the device 10 without manually controlling the controllable components. As such, the device 10 can be controlled without an operator monitoring or adjusting the various parameters of the device 10 during normal operations.
As indicated, the component 42 that receives the sealant material 46 can comprise a spacer for use in an insulating glass unit (IGU). As such, the present invention includes a method of applying a sealant material onto a spacer (e.g. a channel-shaped elongated spacer) for an IGU. The method includes passing component 42 comprising the spacer through the space 40 formed between the first and second nozzle heads 14 and 18 of the device 10. The spacer enters the space 40 at the first side 50 of the nozzle heads 14 and 18. The spacer of component 42 moves through the space 40 with opposing sides 44 of the spacer of component 42 passing by the outlets 30 of the nozzle heads 14 and 18 as sealant material 46 is being distributed through the nozzle heads 14 and 18.
Each side 44 of the spacer of component 42 is spaced at a distance from the respective first and second nozzle heads 14 and 18 to receive the sealant material 46. For example, the distance between the nozzle heads 14 and 16 can be selected to form a space 40 in which the opposing sides 44 of the spacer of component 42 are flush or substantially flush with the outer face 38 of the outlets 30 (e.g. to provide a clearance distance between the sides 44 of the spacer of component 42 and outer faces 38 of the outlets 30 of from 0.005 to 0.010 inches). As the spacer of component 42 moves past the second sides 52 of the nozzle heads 14 and 18 and exits the space 40, a sealant material 46, such as a triangular shaped sealant material 46, is formed onto the sides 44 of the spacer of component 42.
The method can be automatically controlled using the controller 110 in operable communication with the one or more computer-readable storage mediums containing programming instructions that, when executed, cause the controller 110 to distribute the sealant material 46 through the first and second nozzle heads 14 and 18. The controller 110 can automatically operate the pump(s) 90 to control the flow rate and pressure at which the sealant material 46 is delivered. For example, the controller 110 can automatically operate the pump(s) 90 to move the sealant material at an upstream line pressure in a range of from 400 psi to 1200 psi. The controller 110 can also operate the temperature within the nozzles 12 and 16 such as, for example, within a range of from 140° F. to 360° F.
As previously described, the method can be used to form a spacer of component 42 having sealant material 46, for example triangular shaped sealant material 46, on the opposing sides 44 of the spacer of component 42. Referring to
It will be appreciated that the spacer of component 42 can have various shapes, designs, and configurations that the sealant material 46, for example triangular shaped sealant material 46, can be applied with device 10. For example, and as shown in
It was found that the previously described device 10 provides additional benefits downstream in a manufacturing process. Specifically, the device 10 makes it possible to obtain better accelerated weathering test results and to operate post-heating oven/roll press equipment at lower temperatures and higher speeds, for example at 14% lower sealant temperatures and 30% to 50% faster line speeds for triple IGUs, as compared to currently known devices and methods of applying sealant materials. The resulting sealant material 46 also provides improved bonding, particularly when applied to the sides of a spacer of component 42 for forming an IGU. The previously described spacer of component 42 was also found to provide a good liquid and gas barrier to prevent liquid and gas, such as air, from flowing into and out of an air gap formed in the IGU.
It is appreciated that the previously described device 10 and method can be utilized in various system for forming a spacer and/or for forming an IGU. Non-limiting examples of such systems are described in the following U.S. patents and which are incorporated by reference herein in their entireties: U.S. Pat. Nos. 7,275,570; 7,445,682; 7,448,246; 7,610,681; 7,802,365; 7,866,033; 7,901,526; 8,056,234; 8,474,400; 8,720,026; 8,904,611; 9,212,515; 9,279,283; 9,428,953; 9,765,564; 10,156,515; 10,184,290; 10,267,083; 10,316,578; 10,352,090; 10,352,091; 10,369,617; 10,533,367; and 10,577,856. The device 10 can be incorporated into various portions of such systems.
Whereas particular embodiments of this invention have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present invention may be made without departing from the invention as defined in the appended claims.
This application claims the benefit of U.S. Provisional Application No. 63/084,122, filed Sep. 28, 2020, which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63084122 | Sep 2020 | US |
