The present disclosure relates to an insulting glass unit (IGU) sealing system and method, and more particularly, a window sealing assembly and method having tool utilization and spatial recognition for more uniformly sealing portions of the IGU.
Insulating glass units (IGUs) are used in windows to reduce heat loss from building interiors during cold weather. IGUs are typically formed by a spacer assembly sandwiched between glass lites. A spacer assembly usually comprises a spacer frame extending peripherally about the unit, a sealant material adhered both to the glass lites and the spacer frame, and a desiccant for absorbing atmospheric moisture within the unit. The margins or the glass lites are flush with or extend slightly outwardly from the spacer assembly. The sealant extends continuously about the spacer frame periphery and its opposite sides so that the space within the IGUs is hermetic. The sealant provides a barrier between atmospheric air and the IGU interior, which blocks entry of atmospheric water vapor.
Typically, sealant is manually applied around a majority of the spacer frame periphery, while leaving a small opening formed through the spacer frame uncovered, or free from sealant. The atmospheric air is evacuated and an inert gas is inserted into the space within the IGU. A rivet or screw is inserted into the opening, and additional sealant is then applied over the uncovered area. Particulate desiccant is typically deposited inside the spacer frame and communicates with air trapped in the IGU interior to remove the entrapped airborne water vapor, and as such, precludes condensation within the unit. Thus, after the water vapor entrapped in the IGU is removed, internal condensation only occurs if the unit fails. The sealant over the uncovered area is typically where IGUs have failed because atmospheric water vapor infiltrated the sealant barrier, such as when the new or second pass sealant over the uncovered area is not hot enough to create a bond with the previously applied sealant, the new sealant is applied unevenly, and/or the like. Additionally, the sealant may be applied unevenly when edges of the glass lites are not co-planar, or otherwise uneven.
Such sealant issues are discussed in U.S. Pat. Pub. No. 2017/0071030 to Briese et al., which is assigned to the assignee of the present disclosure and is incorporated herein by reference. Sealant dispensing, utilizing a sealant metering pump, is discussed in further detail in U.S. Pat. No. 7,048,964, to McGlinchy et al., which is assigned to the assignee of the present disclosure and is incorporated herein by reference
One example embodiment of the present disclosure includes a window sealing system for use in sealing insulating glass units (IGUs). The sealing system has an articulating arm having a plurality of members and arms to allow movement about multiple axes defined by the articulating arm, and a sealant dispensing apparatus releasably couplable to the articulating arm. The sealant dispensing apparatus comprising a pivotable dispensing element for dispensing sealant onto an IGU, and a vision system, coupled to the sealant dispensing apparatus, for monitoring physical properties of the sealant during sealant application.
Another example embodiment of the present disclosure comprises a method of constructing a window sealing system for use in sealing insulating glass units (IGUs), the method comprising the steps of assembling a sealant dispensing apparatus comprising a releasably couplable element configured to be coupled to an articulating arm and a pivotable dispensing element for dispensing sealant onto an IGU, coupling a vision system to the sealant dispensing apparatus, for monitoring physical properties of the sealant during sealant application, and connecting the vision system, the articulating arm, and the sealant dispensing apparatus to a controller. The controller is configured to receive information from the vision system and instruct the articulating arm based upon the information.
Yet another example embodiment of the present disclosure includes an apparatus for applying a sealant material over an outer surface of an insulating glass unit. The apparatus comprising a source of sealant material, a nozzle for dispensing sealant material from the source onto an outer surface of an insulating glass unit, and a valve for regulating sealant flow from the source to the nozzle. The apparatus further includes a drive for providing relative movement between the nozzle and the insulating glass unit as the nozzle dispenses sealant onto the outer surface, a controller coupled to the drive for adjusting the drive speed to regulate deposition of sealant onto the insulating glass unit, and a sensor for determining a location of the outer surface to appropriately position the nozzle for dispensing of the sealant.
While another aspect of the present disclosure includes an apparatus for applying a sealant material over an outer surface of an insulating glass unit. The apparatus comprises a source of sealant material; a nozzle for dispensing sealant material from the source onto an outer surface of an insulating glass unit; a valve for regulating sealant flow from the source to the nozzle; a drive for providing relative movement between the nozzle and the insulating glass unit as the nozzle dispenses sealant onto the outer surface; a controller coupled to the drive for adjusting the drive speed to regulate deposition of sealant onto the insulating glass unit; a sensor for determining a location of the outer surface to appropriately position the nozzle for dispensing of the sealant; and a smoothing apparatus coupled to the drive, the smoothing apparatus comprising a heating element, wherein the drive provides relative movement between the smoothing apparatus and the insulating glass unit as the heating element interacts with sealant on the outer surface.
The foregoing and other features and advantages of the present disclosure will become apparent to one skilled in the art to which the present invention relates upon consideration of the following description of the invention with reference to the accompanying drawings, wherein like reference numerals refer to like parts unless described otherwise throughout the drawings and in which:
Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present disclosure.
The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.
Referring now to the figures generally wherein like numbered features shown therein refer to like elements throughout unless otherwise noted. The present disclosure relates to an insulting glass unit (IGU) sealing system and method, and more particularly, a window sealing assembly and method having tool utilization and spatial recognition for more uniformly sealing portions of the IGU.
During assembly, applied sealant 200 in a prior operation cures around the entire outer peripheral walls the spacer frame 201 except for a small uncovered area 209. Within the uncovered area 209 is an opening 203 through the spacer frame 201 (see
The window sealing system 10 includes a sealant station 60, comprising an articulating arm 62, a vision system 12, a sealant dispensing apparatus 14, and an optical sensor 16 in communication with a controller 35. The articulating arm 62 is selectively couplable to at least one of the optical sensor 16, the sealant dispensing apparatus 14, or the visions system 12. In one example embodiment, the vision system 12 includes a camera capable of detecting pixel count of a targeted area. The pixel count being analyzed by the controller 35 to perform an operation as would be appreciated by one of ordinary skill in the art. In another example embodiment, the vision system 12 is a laser scanner.
Typically, the optical sensor 16 is actuated (e.g., via the articulating arm 62) to move into various positions relative to different parts of an IGU 100 (see
Views of the sealant station 60 constructed in accordance with one example embodiment of the present disclosure are illustrated in
In the illustrated example embodiment, the articulating arm 62 is a six-axis articulating arm, that is, the arm is capable of translation in the X, Y, and Z axial directions as well rotation about each axis Rx, Ry, Rz, as illustrated by the coordinate system illustrated in
Secured to the third member 112 is a coupling 114 that is mechanically attachable to the tool support assembly 68. The arm 62 rotates about the Y axis, thus rotating the coupling 114 and tool support assembly 68. Each of the selectable couplable components 12, 14, 16 can be oriented to rotate about the Z axis when needed. In one example embodiment, the articulating arm is a six-axis arm manufactured by ABB of Zurich, Switzerland sold under part number ABB-IRB140.
In the illustrated example embodiment, areas with differing topography of the IGU 100 placed at the sealing station 60 are identified by the visual sensor 16. In one exemplary embodiment, the visual sensor 16 includes a laser, which scans along a line of the IGU 100 profile (see
Referring to
Referring to
When the sealant 40 is being dispensed, the sealant valve 28 is opened by the cylinder 23 to allow sealant 40 from the sealant input 20 to flow through a nozzle 26 and from the dispensing apparatus 14 that programmably moved by the controller 35 (while applying the sealant along the uncovered area 209). Once the uncovered area 209 is covered with sealant 40, the sealant valve 28 is closed stopping sealant from going from the sealant input 20 to the nozzle 26. An example of a suitable sealant valve is manufactured by GED Integrated Solutions, Inc. under part number 2-32978 having a nozzle stem under part number 3-33092 and a nozzle seat under part number 3-24754. In one example embodiment, the controller 35 instructs the cylinder 23 when to open or shut the sealant valve 28 responsive to information from the vision system 12. In the illustrated example embodiment, responsive to the cylinder 23 being retracted, the sealant valve 28 is open and sealant 40 is applied at the nozzle 26 and responsive to the cylinder being extended, the sealant valve is closed.
Referring again to
As in the illustrated example embodiment of
Similarly as shown in the illustrated example embodiment of
The dispensing element 22 comprises the front face 24 in which the nozzle opening 26 is defined. In the illustrated example embodiments of
In the illustrated example embodiment of
In the illustrated example embodiment of
During use, and as illustrated in the example method 300 of
At 304, the articulating arm 62 will move the sealant dispensing apparatus 14 such that the front face 24 abuts the IGU 100 over the uncovered area 209 (see
The nozzle 26 is aligned to dispense sealant 40 beginning at the second end 209b (see
In yet another example, if the vision system 12 sends information to the controller 35 that indicates that the temperature of the bead 38 is too low (e.g. for optimal bonding with the solid state sealant 200), the controller will alter the heat being applied by the heating elements 31, 32, 33, increase the flow rate of the sealant 40 (e.g., by increasing the pressure on the sealant in the sealant dispensing apparatus 14), and/or increase the speed at which the sealant dispensing apparatus 14 is moving along the dispensing direction (arrow F). At 310, the controller 35 instructs the sealant dispensing apparatus 14 to stop dispensing sealant 40. The sealant dispensing apparatus 14 stops dispensing sealant 40 gradually, or abruptly, responsive to the information sent to the controller 35. At 311, the sealant dispensing apparatus 14 continues moving along the edges of the first and second lites 210, 212, in the first dispensing direction (arrow F) after the sealant dispensing apparatus has stopped dispensing sealant 40. In one example embodiment, the sealant dispensing apparatus 14 continues moving along the edges of the first and second lites 210, 212 for a predetermined distance (e.g., a distance equal to the length of the dispensing apparatus 22). In another example embodiment, the sealant dispensing apparatus 14 continues moving along the edges of the first and second lites 210, 212 until the controller 35 receives information from the vision system 12 that the bead 38 has shrunk or disappeared. In this way, the dispensing apparatus 22 wipes/cleans itself before returning to step 302.
At 312, the sealant dispensing apparatus is removed from the IGU 100 once the sealant has been dispensed, for example, responsive to the coordinates indicating the sealant dispensing apparatus 14 has reached the first end 209a, the nozzle 26 stops dispensing sealant 40 (e.g., by the controller 34 instructing the cylinder 21 to extend to close the sealant valve 28). In one example embodiment, the front face 24 of the dispensing element 22 maintains contact with the edges of the IGU 100 and continues moving along the dispensing direction (arrow F) until the vision system 12 indicates that the bead 38 is a stop dispensing size (e.g., as indicated by a pre-programmed variable in the controller 35). In this example embodiment, the controller 35 instructs the articulating arm 62 to continue moving the sealant dispensing apparatus 14 along the dispensing direction (arrow F) until receiving a signal from the vision system 12 to remove the sealant dispensing apparatus 14 from contact with the IGU 100. The movement of the sealant dispensing apparatus 14 along the dispensing direction (arrow F) smoothes the remaining sealant 40 to create an even seal. The sealant dispensing apparatus 14 is returned to the home position and uncoupled from the articulating arm 62. It would be appreciated by one having ordinary skill in the art that the sealant dispensing apparatus 14 could be moved from the first end 209a to the second end 209b, such as in a second dispensing direction directly opposed to the dispensing direction (arrow F) to dispense sealant 40.
During use, and as illustrated in a second example method 400 of
At 406, the nozzle 26, once aligned, starts dispensing sealant 40 while maintaining the initial position. As the sealant dispensing apparatus 14 dispenses sealant 40 over the uncovered portion 209 excess sealant 40 forms the bead 38. At 408, the vision system 12 monitors a size of the bead 38 and communicates the size to the controller 35. At 410, responsive to the bead 38 reaching a bead size threshold, the controller 35 instructs the sealant dispensing apparatus 14 to stop dispensing sealant 40. In this embodiment, the sealant dispensing apparatus 14 stops dispensing sealant 40 abruptly, responsive to the information sent to the controller 35.
At 412, the sealant dispensing apparatus 14 starts moving along the edges of the first and second lites 210, 212, maintaining contact with the edges. The sealant dispensing apparatus 14 moves in the first dispensing direction (arrow F) after the sealant dispensing apparatus has stopped dispensing sealant 40. In one example embodiment, the sealant dispensing apparatus 14 continues moving along the edges of the first and second lites 210, 212 for a predetermined distance (e.g., a distance equal to the length of the dispensing apparatus 22). In another example embodiment, the sealant dispensing apparatus 14 continues moving along the edges of the first and second lites 210, 212 until the controller 35 receives information from the vision system 12 that the bead 38 has shrunk or disappeared. In this way, the dispensing apparatus 22 wipes/cleans itself before returning to step 402. At 414, the sealant dispensing apparatus is removed from the IGU 100.
Advantageously, the articulating arm 62 coupled to the sealant dispensing apparatus 14 dispenses the sealant in a reproducible manner. For example, the articulating arm 62 moves the sealant dispensing apparatus 14 at a constant speed, unless the visions system 12 indicates that the speed should be adjusted to achieve a more uniform sealant dispensing. Further, the vision system 12 is able to adjust dispensing factors, such as sealant temperature, sealant dispensing speed, and the speed of the sealant dispensing apparatus 14, during application to prevent dis-uniformity across multiple IGUs. The real-time monitoring by the vision system 12 provides enhanced sealing of the IGUs. During manual sealant application, a user may move the sealant dispensing apparatus 14 too quickly, preventing bonding of the steady state sealant 200 and the sealant 40, or too slowly resulting in overflow of the sealant. The pivotablity of the dispensing element 22 further enhances sealing of the IGUs 100, by allowing the front face 24 of the dispensing element to be flush with the edges of the IGU 100. It should be appreciated that while the IGU 100 is being presented to the sealing system 10 with a first sealant 40 along all sides of the IGU except for the unsealed area 209. The sealing system 10 however has the flexibility and designed in such a way that the system can apply sealant to more than the unsealed area 209 and along all sides of the IGU if desired.
In the foregoing specification, specific embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the disclosure as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present teachings.
The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The disclosure is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued.
Moreover in this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “has”, “having,” “includes”, “including,” “contains”, “containing” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a”, “has . . . a”, “includes . . . a”, “contains . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element. The terms “a” and “an” are defined as one or more unless explicitly stated otherwise herein. The terms “substantially”, “essentially”, “approximately”, “about” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment the terms are defined to be within for example 10%, in another possible embodiment within 5%, in another possible embodiment within 1%, and in another possible embodiment within 0.5%. The term “coupled” as used herein is defined as connected or in contact either temporarily or permanently, although not necessarily directly and not necessarily mechanically. A device or structure that is “configured” in a certain way is configured in at least that way, but may also be configured in ways that are not listed.
To the extent that the materials for any of the foregoing embodiments or components thereof are not specified, it is to be appreciated that suitable materials would be known by one of ordinary skill in the art for the intended purposes.
The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.
The following application is a divisional application claiming priority under 35 U.S.C. § 121 to currently U.S. patent application Ser. No. 15/970,451 filed May 3, 2018 that published as U.S. published patent application number 20180339307 on Nov. 29, 2018, which claims priority under 35 U.S.C. 119(e) to U.S. Provisional Patent Application Ser. No. 62/500,704 filed May 3, 2017 entitled INSULATING GLASS UNIT FINAL SEALING ASSEMBLY AND METHOD, U.S. Provisional Patent Application Ser. No. 62/629,785 filed Feb. 13, 2018 entitled INSULATING GLASS UNIT PLUG AND INSTALLATION METHOD, and U.S. Provisional Patent Application Ser. No. 62/539,779 filed Aug. 1, 2017 entitled INSULATING GLASS UNIT FLUID EXCHANGE ASSEMBLY AND METHOD. The above-identified patent applications are incorporated herein by reference in their entireties for all purposes.
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20210053089 A1 | Feb 2021 | US |
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Parent | 15970451 | May 2018 | US |
Child | 17074130 | US |