Note: Descriptions are shown in the official language in which they were submitted.
lU'~850i
- sackgrouncl o~ the Inven-tion
. - _ _
The present inven-tion generally relates to an apparatus
; and method for making a uni~ary construction element or shape
having an insulating or thermal barrier member therein, commonly
referred to as a thermal barrier or thermobreak extrusion or
shape, which can be employed in the construction of windows,
doorst frames therefor, curtain walls and the like.
The invention particularly relates to an apparatus
for making a unitary construction element, wherein an insulating
ember is joined to a metal member or members by a crimping or
stitching operation.
With the advent of metal construction used in ma~ing
indows, doors, frames therefor, curtain walls and the like,
roblems of heat conduction and water condensation have arisen.
he use of aluminum or other metals caused a greater transfer of
eat between wall elements than had heretofore taken place in
arlier types of construction. To solve this problem, some type
f insulating or thermal break construction was essential.
ccordingly, a variety of thermal barrier or thermobreak
onstructions and methods and apparatuses for making such
onstructions have been developed.
One type of construction which has achieved some
egree of success is one in which the insulating material is
oured, flowed, foamed, and formed in place. U. S. Patents
- ,204,324; 3,332,170; 3,393,487; 3,624,885 ~Re. 28,084 and
e. 28,086); 3,634,565; and 3,823,524 are illustrative of such
ype of construction. Of these, 3,204,324 is representative of
method of making a thermal harrier construction element or
nsulating construction, wherein a metal shape having a generally
-shaped channel therein is filled with a flowinq resinous
nsulating composition; the composition is cured, and subsequently
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a por~ion of the me-tal member or web ~orming the base of the
channel is removed. No. 3,823,52~ rela-tes -to a similar method
but employs a web member whi~h extends convexly be-tween the
structural member forming the channel. Both of these methods
require the use of a liquid resinous composition which is
subsequently cured or hardened. No. 3,393,487 discloses a
somewhat more complicated process for making a thermal insulating
joint construction and also utilizes a liquid plastic material.
In such process, two separate elongated metal shapes are spaced
apar~ and fastened together with a solid first insulatiny member.
The two shapes and the first insulating member provide a channel
in which a second thermal insulating member is flowed therein.
Upon solidification of the latter, the metal and insulating
members are Iocked together as an integral unit.
Of the more common t~pes of thermai barrier
constructions, two metal members are joined together by a solid
insulating rnember. These constructions encompass a wide variety
of insulating and/or plastic shapes and metal shapes.
Illustrative of these are U. S. Patents 2,835,360; 3,093,217,
20 3,099,337; 3,289,377; 3,436,884; 3,~87,580; 3,600,S57; and
3,916,503. In one of the more basic o~ this type of construction,
for example, in 2,835,360, two metal members are joined together
nd spaced apart by an overlapping insulating member. In
,91~,503, simple mechanical means are employed to join the metal
embers with an insulating member. No. 3,600,857 is representativ
. f more complex shapes of insulating and metal members.
; In a pa~ticular type of the foregoing more common
: ype of thermal barrier constructions, metal and insulating
embers are mechanically joined together by deformation of the
etal members or by crimping or stitching the metal members on
he insulating member. Representative oE such a joining method
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are u. s. Patents 3,11~ 17g; 3,~11,'9g5; 3,420,026; 3,517,472; and
3,903,217 and Swiss Patellt 320,~88 (same as British Patent
lo. 768,~99). For example, 3,420,02~ discloses several ~ypes of
thermal insulating members and methods of ma]~ing them. In one
type, two separate metal members ar~ mechanically joined to a
;central insulating member by crimping or deforrnation of groove
means or projections on the metal members. In one particular
type of thermal break construction, the insulating member is in
the s~ape of a ~laltese cross in cross-section. In another
;10 embodiment, the insulating rnember is made from a thermoplastic
material and a portion thereof is heated to cause melting and
flow of the plastic into an associated groove means formed by
the two metal members. Upon cooling of the plastic, the metal
and plastic member are unitarily joined together. No. 3,517,472
also illustrates a mechanical joining process similar to that of
the former and additionally represents the use of a plastic or
nsulating member which expands upon heating. The Swiss patent
discloses several types of window or door frames, one of which
employs a crimp system using two separate metal extrusions having
a pair of flanges thereon which form grooves for receiving a
plastic rod. After the plastic rod or thermal barrier member is
introduced into the yrooves, the flanyes are pressed towards the
plastic rod or crimped thereon so that they are flush with the
sides of the rod.
Other types of thermal break or insulated window or
wall constructions are illustrated by U. S. Patents 2,654,920;
3,055,468; 3,289,377; 3,411,254; and, 3,466,801. For example,
No. 3,411,254 provides a plastic thermobreak which l~tilizes a
plastic locking strip which contains a heat actuated biowing
agent to join two separate metal shapes. After assemhly of the
two metal shapes and the plastic strip, the unit is heated to
expand the plastic into tight engagement with the two metal
members.
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U. S. l?aten~ 3,~15,216 illustrate~ still another
method o~ manufac~uriny a -thermal break ~on~rU~tion el~men~ and
; employs a metal extrusion ~h~ch has a relnovable interior section
which is subse~uently removed to separate the extrusion intG two
metal members. While maintaining the separate metal members
spaced apart, a plastic material is inserted therebetween. The
construction element can be made in a continuous operation.
Of these various types of thermal break constructions,
the system of crimping or stitchiny has enjoyed considerable
commercial success. In such systems, crimping is often done
manuallv or by simple mechanical means. Such means are of course
relatively slow and have limited flexibility. One current
stitching system consists of a feeder for inserting straight
lengths of vinyl or other suitable plastic insulating members
in the metal members. Rollers are employed to provide crimp ng
of the metal flanges on the insulating or plastic member.
Conventionally, two rollers or wheels are required to crimp
the flanges. One roller must actually bend the metal flanges
on the insulating member while the other roller must back-up or
-' 20 hold the metal extrusion in the correct position for joining
metal and plastic members. To accomplish the crimping action,
clear access must be available on both sides of the plastic member
on which crimping of the metal members occurs. In some cases, a
small wheel or support is laterally employed to serve as a
back-up. The size of the support and the forces required to
obtain a tight joint create a number of operating problems The
types of shapes or extrusions which can be used in this method
are extremely limited. Finished parts have to b~e removed by
hand after the stitching or crimping operation is completed.
It is therefore a primary object of the present
invention to provide a crimp or stitching system or method of
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making thermal barrier extrusions which overcomes the dis-
advantages of prior art systems and which can be used with a
wide variety of metal shapes or extrusions.
An important object of the invention is to provide
a complete machinery line assembly or apparatus ~or rapidly
and efficiently manufacturing thermal barrier or thermobreak
extrusions shapes or members.
Another object of the present invention is to
provide a stitcher or crimping machine which can quickly and -:
easily be adjusted to handle a wide variety of rnetal shapes.
Still another object of the invention i5 to :
provide an elongated guide box which is adapted to handle a
large number of metal shapes or extrusions of different
con~igurations.
Other objects and advantages of the present inven
tion will becoine more readily apparent from a consideration of
the description and drawings hereinafter.
Sumrnary of the Invention
The present invention provides a complete machinery
line assembly for manufacturing thermal barrier members or
construction elements, especially those unitary thermal barrier
members or construction elements used to make alurninum windows,
doors, frames there~or and the like, comprising metal members
joined together by an insulating member.
One aspect of the present invention is defined
: as an apparatus for making a unitary thermal break constructionelement comprising a feed means for inserting an insulating
material into metal shapes, adjacent to and following the
- feed means a guide means for position.iny two spaced apart
metal shapes thereon into which the insulat.iny material is to
be inserted, adjacent to and following said yuide means a
crimping means for receiving the -two metal shapes wi-th -the
insulating material therein and for crimpiny each of the
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metal shapes on the insulating material there~y providing
the unitary thermal break ConStrUCtion element, ~he crimping
means including a plurality of crimping sta~ionS and a plur-
ality of guide stakions, with a guide station being positioned
before each crimping station, each guide station positioned
before each crimping station including a removable block
assembly having adjusting means thereon for accommodating
the guide stations to metal shapes of various cross-sectional
configurations, and each of the crimping stations including
an adjusting means for accommodatin~ the crimping stations
to metal shapes of various cross-sectional configurations.
Another aspect of the present invention is defined
as a method of making a unitary thermal barrier construction
element, comprising the steps of: (a) positioning a reel of .
insulating material of a desired cross-sectional configuration
on an unwind stand and inserting one end of the reel of insul-
, ating material into a feeder; (b) positioning in a parallel . : .
spaced apart relationship a pair of metal shapes of a desired
; length and cross-sectional configuration on a guide means
adapted to receive the metal shapes in the desired parallel
spaced apart relatlonship, the metal shapes having an opening
formed therebetween for receiving a section of the reel o
insulating material and each of the metal shapes having a
portion thereof adapted to be crimped on the section of insul-
. ating material; (c) positioning the pair of parallel spaced
apart metal shapes into position relative to the feeder for
receiving the section of the insulating material into the open- :.
ing therefor between the parallel spaced apart metal shapes and
. maintaining the metal shapes in the parallel spaced apart
~; 30 receiving position.until insertion of the section o
insulating material is accomplished; ~d) feeding a section
of the reel of insulating material into the opening therefor
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between the parallel spaced apart me-tal shapes un-til a
desired length of the insulating rnaterial has been inserked
into the openiny; (e) severing the section o insulation
material inserted into the opening therefor between the parallel
spaced apart metal shapes from the reel of insulating material;
(f) transferring the pair o~ parallel spaced apart metal shapes
with the section of insulating material therein to a crimping
apparatus; and, (g) crimping the pair of parallel spaced apart
metal shapes on the section of the insulating material to
thereby form a unitary thermal barrier construction element.
Brief Description of *he- DraWings
The features and advantages of this invention will
be more readily apparent in the following detailed description
of illustrated embodiments which i5 to be read in connection
with the accompanying drawings, wherein:
Fig. 1 is a front view of the complete machinery
line assembly of the invention illustrating the various
components thereof and their positions relative to each other;
Fig. 2 is an enlarged front view of the unwind strand
or reel support of the assembly line machinery of Fig. l;
Fig. 3 is a side view of the unwind strand of
Fig. 2;
Fig. 4 is an enlarged top view of the thermal
barrier feeder of the assembly line machinery of Fig. l;
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Fi~. 5 is a ront view o~ the feeder of Fic3 . 4;
Fig. 6 is an enlarrJed front view of the guide bo~ and
support frame of the assembl~ line rnachinery of Fig. l;
Fig. 7 is a section along line 7-7 of Fig. 6 and shows
the configuration or cross-sectional shape of the metal members
to be joined with an insulating member and the position of the
metal members in the guide box;
Fig. 8 is an enlarged front view of the stitcher or
crimping machine of the assembly line machinery of Fig. 1,
Fig. 9 is an enlarged top view of the take-off unit
of the assembly line machinery of Fig. l;
Fig. 10 is a front view of the take-o~f unit of Fig. 9;
Fig. 11 is an enlarged perspective view of a reel
support arm;
Fig. 12 is a sectional view taken along line 12-12 of
Fig. 5 illustrating the measuring means or section of the thermal
barrier feeder;
Fig. 13 is a sectional view taken along line 13-13 of
Fig. 5 illustrating the drive means or section of the thermal
barrier feeder;
Fig. 14 is a sectional view taken along line 14-14
f Fig. 8 illustrating a stitching or crimping means or station
; f the stitcher or crimping machine;
Fig. 15 is a sectional view taken along line 15-15
of Fig. 8 illustrating a guide means or station of the stitcher
or crimping machine;
Fig. 16 is an end view taken along line 16-16 of
Fig~ 10 illustrating the dump arm mechanism of the take-off unit
( ith a finished thermal barrier extrusion or member thereon in
: 30 position just prior to activation; and,
, Fig. 16A is a view similar to that oE Fig. 16, but with
the dump arm in a raised position to discharge the finished thermal
barrier member.
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Descr; p~i~r of the Pr~fe~d ~mb~imAnt
.~
Rcferring now -to the drawings, especially Fig. 1, the
various components or units comprising the complete machinery
line assembly or apparatus and their relative position or relation
to each other are illustrated. Each of the various units is in
alignment with the other so as to provide the basIs for a
continuous operation. The assembly comprises five basic units, a
reel or unwind stand 20, a reel or thermal barrier feeder 30, a
guide box unit 40, a stitcher or crimping unit 50, and a take-off
unit 60. The machinery is especially adapted to install a thermal
barrier or insulating material in a]uminum extrusions or shapes
to provide a unitary thermal barrier shape or thermal break
construction element. The apparatus is particularly adapted to
make a type of thermobreak construction wherein the thermal
barrier is stitched or crimped in place. Such an element is
especially useful in the manufacture of aluminum windows ! doors,
frames therefor, curtain walls and the like.
In the operation of the apparatus, a reel of thermal
barrier material 21 is positioned on the unwind stand 20. One
nd of the reel 21 is inserted in the feeder 30. The thermal
~Q arrier insulating material is preferably a vinyl or foamed PVC.
ny other suitable type of material may be used. The cross-
section shape of the material is of a size and shape to be
eceived by or inserted in a pair of appropriately designed
etal shapes 70 and 71. For most operations, two separate metal
shapes, preferably extruded alur,linum shapes are employed. In
some instances, it may be desirable to use a single metal shape
in which a portion thereof is removed therefrom after the
: peration is complete. A single metal shape would have an
ppropriately constructed opening therein for receiviny the
barrier ox insulating material.
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Two rnet~l ~r aluminu~ sllapes 70 and 71 are properly
positioned on a guide bo~ 41 of ~he ~3uide bo~ unit 40 by ~n
operator. Th~ met~l shapes a~e -then ~lid lnto the feeder 30 and
properly positioned therein to receive the thermal barrier
material. Shapes are customarily about sixteen feet in len~th,
but may be of any length desired. A foot switch (not shown)
actuates a clamp 31 which holds the alurninum shapes 70 and 71 in
position. ~ pair of drive wheels 32 and 33 are actuated and
feed the barrier portion 21a into the shapes 70 and 71. The
length of the material or barrier 21a inserted is controlled by
a pre-set or pre-determined setting on a counter connected to a
measuring wheel 34 riding on the barrier. The barrier or
insulating material comes off the reel as it travels through the
feeder until the pre-set length is reached. The drive wheels
then stop and a knife 35 is actuated which cuts or separates the
barrier section 21a in the aluminum shapes 70 and 71 from the
reel 21 and the clamp 31 is released. The operator then inserts
he combination of metal shapes 70 and 71 and barrier section
21a into the stitcher 50. A first stitch or crimp station 51 of
he stitcher 50 causes the metal on one side of the barrier 21a
o be crimped thereon. The cambination is continued through
he stitcher without any further help from the operator. As the
ombination passes through a second stitch station 52, the metal
n the other side of the barrier 21a is crimped thereon. The
ompleted thermal barrier construction element or shape T is
oved or driven in the direction indicated by arrow A where it
is received by the take-of-f unit 60. As the finished part or
lement T clears the stitcher 50, an electric eye (not shown)
ocated between the stitcher 50 and the take-off unit 60
ctuates dump arms 61 and 62 causiny the arms to raise and slide
he finished part T into a basket or other suitable receptacle.
Once the operation has been started, the operator does not have
to move from the one location by the feeder. As soon as -the
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combination cle~rs the quide bo~ into -the stitch~r, the operator
places another pair of metal shapes on the yui~e box and slides
them into the feeder ~o provide a substantially continuous
operation.
S ~lthough the operation is described employing two
metal shapes, a single metal shape can be used. I~hen using a
single metal shape, the procedure is substantially the same except
after the part T is transferred to the receiving basket, the
part must be subjected to the further operation of removing a
pre-determined portion of the metal shape therefrom to thereby
provide the thermal barrier or break in the finished part. The
details of the various components of the assembly are described
in more detail hereinafter.
Referring now to Figs. 2 and 3 of the drawings, the
reel stand or unwind stand 20 basically comprises a frame 22,
a shaft 23 mounted thereon, a guide arm mounting plate 24
mounted on one end of the shaft 23, a plurality of guide arms 25
mounted on the guide arm mounting plate 2~, a reel support arm
26 mounted on each guide arm 26, a guide rod 27 pivotally
mounted on each reel support arm 26 and a brake aisc 28 mounted
on the other end of the shaft 23. The frame 22 comprises a
plurality of frame mer~ers welded or otherwise joined together
including a pair of spaced apart base members 22a, four vertical
frame members 22b and, a pair of base frame members 22c parallel-
edly spaced apart and joined together with vertical supportmembers 22b and upper side frame members 22c. It can be
appreciated that the frame 22 may be varied in construction and
that the particular frame illustrated is merely~e~emplary.
The shaft 23 is mounted on the fra~le 22 by means of
a pair of pillow bloc~.s or bearings 29 mounted on each of the
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shaft support frame members 22d. The s~lat is fr~ely ro~atable
¦within the bearinys. The caliper digc break 2~ includes a disc
¦hub 28a, break disc 2~b and break caliper 28c. Any suitable
¦caliper disc break may be used. The guide rods 27 are pivotally
5 ¦mounted on the reel support arms 26 by means of a hinged pin 26a.
¦The arms 26 also include a positioning pin 26b which enables the
¦rods 27 to be locked in either a horizontal position as illustrated
or a vertical position ninety degrees from the horizontal one.
¦Figs. 2 and 3 of the drawings illustrate the guide rods 27 in
10 ¦position for receiving a reel of insulating material 21. After
¦the insulating reel has been positioned on the arms 26, the rods
127 are raised to a vertical position and locked in place as seen
¦in Fig. 1.
¦ Referring to Fig. 11, a portion of reel support arm 26
lis illustrated showing a guide rod 27 pivotally mounted therein.
¦The reel support arm 26 has an opening 26c cut therein for
¦receiving the rod 27. The member 26 is conveniently a channei
¦mem~er, and the portion 26c removed therefrom is removed from
¦the web of the member 26. Other types of construction are of
¦course suitable. The reel support arm 26 also has suitable
¦openings therein in the flanges thereof for receiving the hinge
¦pin 26a and the positioning pin 26b. The rod 27 also has suitable
¦holes or openings therein for receiving pins 26a and 26b,
respectively. The rod 27 is pivotally mounted on the hinge pin
~ 25 26a so it may be raised from a horizontal position to a vertical
; position in the direction of the arrow E. A nut 26d secures the
hinge pin 26a on the arm 26. When the positioning pin 26b is in
the position illustrated in Fig. 11, the rod 26~is locked in a
horizontal or longitudinal position with the guide support arm
26. To Place a reel of insulating matexial on the unwind stand
20, each of the rods 27 are placed in the position as illustrated
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in Fig. 11. ~ter the reel has becn placed on the support arms 26,
the positioning 2in 26h is withdrawn and the rod ~7 moved in th~
direction of the arrow E to -the vertical posi~ion shown in
Fig. 11. The positioning pin is then inserted in the holes in
the arm 26 from which i-t was previously removed, thus locking
the rod in a vertical position and thus maintaining the reel 21 on
the unwlnd stand 20. Any other suitable reel support mechanism or
apparatus may be used as desired.
~ The details of the feeder 30 are seen in Figs. 4 and 5.
The feeder includes a frame 36, a motor 37 mounted thereon, a speed
reducer 38 mounted on the motor with a suitable sprocket and
chain assembly for driving the upper and lower drive wheels 32
and 33, respectively, an input guide 39, measuring wheel 3~,
drive wheels 32 and 33, a knife 35 and a clamp 31, all of which
are suitably mounted on the frame 36. The frame 36 includes four
vertical support members 36a on which are mounted a front plate
36b, a rear plate 36cj a base plate 36d and connecting bars 36e.
Any other suitable framing mechanism may be used to provide the
support for the various components of the Feeder 30.
The clamp assembly 31 includes clamp air cylinder
31aj a cylinder rod 31b, a jam nut 31c, a clamp 31d, a clamp
guide 31e, an extrusion or shape support 31f and an extrusion
r shape positioning plate 31g. The angle iron extrusion
support member 31f has a pair of slots 31h therein and is
ounted on the front plate 36b by means of a plurality of socket
head cap screws 31i or other suitable fasteners. The extrusion
support 31f may be moved vertically to a desired position to
support the base of the extrusions 70 and 71 in~a desired
position. The extrusion positioning plate 31g is in a ~ixed
position and so located between the kni~e unit 35 and clamp
assembly 31 that when the shapes 70 and 71 are abutted
thereagainst, the shapes are in a proper position for receiving.
~ 10'~859i
the insulatiny membex 21a. The ~ir cylinder 31a ~c-tu~tes the
¦ cylinder rod 31b so that the cl~mp 31d and clamp yui~e 31e
thereon are moved into holding contact wlth -the shapes 70 and
71 to hold them in the desired position during the insertion
¦ operation. The air cylinder 31a has an air line 31j (partially
¦ shown) for connecting the air cylinder to a suitable valve and
¦air supply.
The knife or knife assembly 35 includes an air cylinder
135a, a block 35b for holding same, a cylinder actuatiny rod 35c,
10 la jam nut 35d and a jam nut 35e positioned on the rod 35c, a
¦knife holder 35f mounted on the end of the rod 35c and a knife
¦35g position~d in the knife holder 35f. The air cylinder block
~35b is mounted on the front plate 36b. A cutting block 35h is
¦also mounted on the front plate 36d. An air line 35i (partially
15 ¦shown) connected to a suitable valve and air supply provides air
Ito the air cylinder 35a for actuating the knife blade 35g for
Icutting or severing the insulating barrier 2ia when an
¦appropriate signal is given thereto.
¦ The base plate 36d has an opening 36d for receiving a
20 ¦drive chain 32a connecting the drive wheels 32 and 33 with the
motor 37.
The lower drive wheel 33 is mounted on a shaft 32b
positioned in bearing blocks 32c and 32d fixed on rear plate
36c and front plate 36b, respectively. A drive sprocket 32e
is mounted on the drive shaft 32b for receiving the drive chain
32a. The lower drive wheel 33 is mounted on the end of the
shaft 32b which extends through a suitable opening therefor
in the front plate 36b. ~,
The upper drive wheel 32 is mounted on axle 32f
mounted in front plate 36b. The upper drive wheel 32 :is
adjustable so as to accommodate various sizes of in~ulatiny
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~1 - 1078591
material or barriers. Such rnechanism inclides a hol~ h~lder 32g
mounted on the front plate 3~b and a bolt 32h, a glide block 32i
and slides 32 j suitably positioned thereon. The drive wheels 32
and 33 advance the barrier member 21a in the direction of the
arrow B so as to insert the member 21a into the shapes 70 and 71.
Additional details of the drive wheels 32 and 33
are seen in Fig. 13. Upper drive wheel or drive unit 32 is
mounted on the plate 36b. Lower drive wheel or drive unit 33
is mounted on the shaft 32b which extends through an opening in
the plate 36b. The unit 32 includes a drive gear 32k having
teeth 32k' thereon which is mounted on bushing 32m in which
axle bolt 32f is positioned therethrouyh and inserted into
movable slide block 32i. Slide block 32i is slidably mounted
in slide 32j which is fixed to plate 36b. A thrust bearing 32n
15 i5 also positioned on the axle 32E between the head of axle 32f
and drive gear 32k. Barrier drive wheel 32p having teeth 32pl
thereon is fixcd to the drive gear 32k so as to move therewith.
The bolt holder 32g is fixed to the plate 36b above the slide
32j and has an opening 32g' therein for receiving the bolt 32h.
The bolt 32h also extends into and is fixed to the movable slide
block 32i. Nuts 32q are appropriately positioned on the bolt 32h
so as to retain the bolt in a desired position on the bolt holder
and in the slide block. By adjusting the nuts 32q, the slide
block 32i may be moved vertically within the slide 32j so that
he drive wheel 32p will be in an appropriate position for
driving the insulating barrier material 26a on the top side
thereof.
The drive shaft 32b has a hub 33a th~reon positioned
in a bushing 33b in a bushinc3 support member or bearing 32d
ounted on plate 36b. A drive gear 33d having teeth 33d'
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thereon is mounted on the hub 33a on ~haft 32b ancl mcshes with
gear 32k 80 as to drive the gear 32k. Drive wheel 33d on hub
33a and having teeth 33d' thereon moves or rotates shaft 32b
and drives the underside of barrier 26a.
The measuring wheel 34 is also mounted on the front
plate 36b in a suitable manner on a shaft 34a connected to a
suitable electrical pulse generator 34b, also mounted on the
front plate 36b. The input guide 39 is also mounted on the
front plate 36b. The input guide 39 ls also mounted on the
front base plate 36b in a suitable manner.
Referring now to Fig. 12, the details of the measuring
wheel 34 are illustrated. A pulse generator mounting block 34c
is affixed to front side plate 36b by means of a bolt 34d
through suitable openings in the plate 36d and mounting block
lS 34c, respectively. The pulse yenerator 34b having a shaft 34a
is mounted on the mounting block 34b. A shaft extender 34a' is
affixed to the shaft 3~a and held in place thereon by means of a
set screw 34e. The plate 36b has an opening 36b' therein for
receiving the shaft extender 34a'. The measuring wheel 34 is
positioned on the shaft extender 34a'. A movable guide block 34f
is mounted on the plate 36b below the measuring wheel 34 by
means of a pivot bolt 34g and a pivot bolt nut 34h. The side
plate 36b has a suitable opening 36b'' for receiving the pivot
bolt 34g. The movable guide block 34f has an opening 34f'
therethrough sufficiently large to permit vertical movement of
the block 34f when the nut 34h is loosened. The block may be
moved to accommodate a particular size of insulating material or
barrier. The block 34f also has a suitable opening 34f'' for
receiving the barrier or insulating rnaterial 26a. Also mounted
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o~ the plate 36b belo~ the ~uide blocl. 3~ is a spring holdlng
block 34i. The block 34i has an opening 34i' ~or receiviny
the spring bolt 34 j . A spring 34k is mounted on the bolt 34j'.
~uts 34m retain the bolt 34j in the block 3~i . The spring 34k
urges the bolt 34j into contact with movable guide block 34f so
as to urge the vinyl material 26a therein against the measuring
¦wheel 34.
Any other suitable feeder may be used. The feeder
hould have some type of means to receive and feed the barrier
aterial into the metal member or members and to stop the feeding
pe~ation when an appropriate lenyth of insulating material has
been inserted into the metal member or members.- Preferably, the
eeder also contains a clamping means for holding metal members
n place during insertion operations and a knife means for cutting
r severing the inserted barrier material from the reel of barrier
¦material. The clamping means and knife means can each be separate
omponents and not made specifically a part of the feeder unit.
In some instances, such clamping or holding and cutting operations
can be conducted manually, although this would not be as efficient
~0 as the automatic operation disclosed.
Referring to Figs. 6 and 7, the guide box 40 with
metal shapes 70 and 71 thereon is illustrated in more detail.
The guide box unit 40 includes a guide box 41 mounted on a frame
42. The frame 42 includes vertical guide box support members 43
joined together and spaced apart by base frame members 44 and
top frame members 45. Brackets 46 are fixed to the support members
43 for supportiny the guide box 41. It can be appreciated that
any other suitable structure may be used for ho~ding the guide
box 41. The guide box 41 is a longitudinally extending wooden
ember or board which has grooves 41a and 41b therein for
eceiving portions of the shapes 70 and 71, respectlvely, as
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illustrated in Fiy. 7. q'he guide box 41 is merel~ illustrative
¦of a very simple type o~ guide box. It may be made o'c wood or
any other suitable material, e.g., metal and plastic. For
norrnal operations, a guide box having a multiplicity of grooves
¦for receiving a variety of types of shapes would be employed.
¦A11 that is necessary is that the guide box hold the metal shapes
¦in a suitable position for receivinc3 the barrier material.
¦Shapes 70 and 71 are relatively simple shapes and are shown in
¦their position for receiviny the thermal barrier 21a in the
¦opening 80 between members 70 and 71. The opening 80 is of a
¦size and shape so as to readily receive a somewhat similarly
¦shaped, in cross-section, thermal barrier material. The flanges
or portions 70a and 71a of the members 70 and 71, respectively,
~are in their pre-crimping or pre-stitching position. The metal
¦shapes are therefore illustrated in the shape in which they are
¦normally extruded or otherwise prepared.
¦ Referring now to Fig. ~, the stitcher or crimping
¦machine 50 includes a first stitch station or unit 51, a second
¦stitch station or unit 52, a plurality of guide block assemblies
53' 54 and 55 and an ejector station 56 mounted OII side plates
57 and 57' moun-ted on a base plate 57'' mounted on support
members 58. Additionally, the stitcher 50 includes a combination
motor and reducer unit 59 suitably mounted on the underside of
the base plate 57 " with a drive chain 59a. The chain tensior.er
59b is also mounted on the base 57 by means of a mounting block
59c.
The ejector station 56 includes a toothless drive
wheel 56a and a lower idler wheel 56b and adjus-~iny screws 56c.
The ejector station 56 receives the metal members with barrier
crimped therein and ejects the extrusion or ~i.nished part T
out of the ~titcher 50 and also straic3htens the element T.
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L0'~1~591
The guide blocks 53, 54 and 55 are substantially
identical and are made for a particular shape. The guide blocks
are removable and an additional series of guide blocks may be
placed in the stitcher for accommodating shapes of configurations
other than those illustrated. The stitch stations 51 and 52 are
fixed in the machine and remain the same for eac'n identical
operation. The stitch stations are adjustable to accommodate
particular shapes. Details of the stitch stations and guide
stations are seen in Figs. 14 and 15.
Referring now to Fig. 14, a sti-tch station is
illustrated in detail. Stitch station 51 is ~ounted on side
plates 57 and 57' and base plate 57'' of the stitcher 50. The
stitch station 51 includes an upper fixed portion 51a and a
lower movable portion 51b. The upper portion 51a includes a
drive shaft 51c which has a drive sprocket 51d on one end thereof
for receiving the chain 59a. rrhe shaft 51c has a stitch or
crimping wheel 51e fixed thereto with spacers 51f and 51f' on
either side thereof. Bearings 51g and 51g' support the shaft in
the stitcher and are mounted in side plates 51h and 51h',
espectively. A pair of snap rings 51r and 51r' are positioned
n the shaft 51c adjacent bearings 51g and 51g', respectively.
olding bars 51i and 51i' hold the upper portion 51a in position
o the stitcher 50. The lower movable portion or backup block
51b includes side plates 51j and 51j' in which are mounted
earings 51k and 51k' for supporting the backup wheel shaft 511
ackup wheel 51m having hub 51m' is mounted on the shaft 511 and
fixed thereon by means of shaft key 51n. A pair of snap rings
51p and 51p' are also positioned on the shaft 511 adjacent
earing~ 51k and 51k', respectively. A cross brace 51q connects
or joins the side plates 51j and 51j'. The lowe~ or backup
heel 51m is movable and controlled by means of an air cylinder
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S~l ~
51r mounted on the sti-tcher base plate 57'' by means of bolts
¦ 57a or other suitable means. The plate 57 " has an opening 57b
l therein for receiving the air cylinder shaft 51r' which is
¦ mounted to a cross plate 51s. As the air cylinder shaft 51r' is
5 ¦ actuated up or down, the block 51b is moved therewith so that
¦ an operator may vary the backup force for a particular stitching
or crimping operation depending upon the particular metal members
being stitched or crimped. The stitch wheel and backup wheel are
l both hardened steel rollers with the stitch wheel having teeth
10 ¦ thereon. The stitch wheel 51e is grooved or so constructed that
only one metal member or one side of a metal member is crimped as
the metal members 70 and 71 pass therethrough.
¦ The stitch station 52 is similarly constructed to the
¦stitch station Sl, except that the wheel 51e is so constructed
15 ¦that the other side of the metal member or metal members is
¦crimped. As illustrated in Fig. 14, the stitch wheel 51e is
¦shown crimping the flange 51a of the member 71. ~rhe flange 70a
¦is crimped by the stitch station 52.
¦ The guide station or guide box assembly 53 is seen in
¦detail in Fig. 15. ~he guide station is also mounted in side
¦plates 57 and 57' and base plate 57 " of the stitcher 50. The
¦guide stations are made as a separate block unit and each
¦station has an upper block 53a and a lower block 53b. The upper
¦block 53a includes a pair of side plates 53c and 53c' joined
¦together in a spaced apart relationship by cross brace 53d. The
¦shaft 53e is mounted in bearings 53f and 53f' positioned in side
plates 53c and 53c', respectively. A pair of snap rings 53y and
53y' are positioned on the shaft 53e adjacent bearings 53f and
53f', respectively. A pair of guide wheels 53g and 53h are
mounted on the shaft 53e. A key 53i enables the guide wheels to
be locked ln a predetermined position on khe shaft 53e. A pair
of spring guide posts or pin.s 53j and a pair of spring guide
posts or pins 53j' are mounted on the top of side plates 53c and
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10 78591
53c', respectively. Ilold~ny bars 53k and 53k' are also positioned
on side plates 53c and 53c', respectively Each yuide post ha.s a
¦spring 531 thereupon. The guide posts or pins are not connected
to the holding bars, but are positioned therein ~hrough holes in
5 ¦the holding bars therefor. The pins pass through the holding
¦bars when the block 53a is raised. The springs are held in
¦position by the pins and act to push the upper block downwardly.
¦AS the metal shapes pass through the machine, the upper block is
Iraised slightly, compressing the springs.
lO ¦ The lower block 53b includes side plates 53m and
~53m' joined together by cross brace 53n. A shaft 53p i5 mounted
¦in bearings 53q and 53q', respecti.vely, mounted in the side
¦plates 53m and 53m', respectively, .~ pair of lower guide wheels
¦53r and 53s are mounted on the shaft 53p and spaced apart
15 ¦therefrom each other and retained in a predetermined position
¦by means of key 53t. A fixed side guide yolk 53u is mounted on
¦the inside Or side plate 53m' and includes an a~le 53u' on
¦which roller 53u'' is positioned thereon. A rnovable side guide
¦yolk 53v is mounted on guide bolt 53'' positioned in a suitable
20 ¦opening therefor in side plate 53m. Yolk 53v includes an axle
53w on which a wheel 53w' is positioned thereon. A spring 53x
¦mounted on the guide bolt 53v' urges the yolk 53v and the wheel
153w' thereon against the shape 71 which in turn urges the shape
¦71 and shape 70 against the wheel 53u " . Snap rings 53y and 53y'
are also positioned on the shaft 53p adjacent bearings 53q and
53q', respectively. The guide blocks are readily removable and
perrnit a rapid change out from one shape to another. The guide
blocks position the metal shapes in a proper location for
stitching or crimping.
The guide wheels are illustrative of one particular
type. It can be appreciated that they may be of any suitable
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type as desired, Such ~heels are prefer~bly madr of a material
such as a phenolic resin, vinyl or other sui-ta~le material ~,~hich
does not damage thê metal shapes. The various guide wheels also
have set screws therein for fixing the ~heels to their respective
shafts in a predetermined position.
Guide stations 54 and 55 are similarly constructed
to guide station 53 and are also removable from the stitcher 50.
For any particular operation, all of the guide stations are of
identical construction and have their ~7heels set in a similar
position.
The guide stations before each stitching station hold
the metal shapes and barrier therebetween in proper alignment for
each successive crimping or stitching operation. Guide stations
and stitch stations can be so constructed and assembled that
stitching or crimping can be conducted on whicllever metal member
or side of metal member desired. The last guide station guides
the metal shapes w,ith barrier material locked therein or
therebetween into the ejector station or unit. The ejector
station not only ejects the finished part from the stitcher or
stitcher assembly to the take-off unit but also straightens the
finished part thereby correcting any distortion which may have
occurred during the stitching operation.
Referring to Figs. 9 and 10, the take-off unit 60
includes dump arms 61 and 62 mounted on a shaft 63 held by
bearings 6~, conveniently mounted on frame support members 65
and 55. In addition to the vertical support members 65 and 66,
frame 60' includes end vertical support members 67 and horizontal
joining framing members 68 and additional horizontal joining
members 69 and 69'. A roller, conveyor 60" is mounted on the
support mel~ers 68 and 67. An air rotary actuator 90 is mounted
on a motor base plate 91 mounted on vertical support members 66
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:LI~'7l3591
of the frame 60'. The rotary actuator 90 h~s a shaft soa eY~tendiny
¦therefrom on which is mounted a gear 92 which drives a gear g3
~ounted on the shaft 63. An air valve g4 is also mounted on the
~late 91. The roller conveyor operates in the customary manner,
¦and some of the rollers are further spaced apart than others to
¦provide an area for pivotal movement of the dump arms 61 and 62.
¦The dump arms 61 and 62 are affixed to the shaft 63; and, as
¦the shaft is rotated when appropriately actuated or driven by the
¦actuator 90, and raises the arms from a horizontal position to a
¦raised position so that a member T thereon will slide off of the
¦unit 60 and into a suitable receptacle.
¦ Referring now to Figs. 16 and 16A, a completed thermal
¦barrier shape T is illustrated in position on the take-off unit
160 prior to activation of the dump arms and in position after
¦the dump arms have been activated. Dump arm 62 is shown in a
¦raised position in Fig~ 16A wherein the finished part T is moved
¦from the position shown in Fig. 16 to the position shown in
¦Fig. 16A and hence into a basket or other suitable container.
~ump arm 62, as well as dump arm 61, is raised or lowered by
~eans of gear 60a fixed to the shaft 63 which is caused to rotate
¦in the direction of the arrow C by action of the smaller gear
¦60b rotated in the direction of the arrow D and fixed to the air
¦rotary actuator shaft or rod 9Oa actuated by the air valve 94.
~ he air valve 94 is connected to a suitable air supply source by
means of lines 95 and 95'. It can be appreciated that the frame
of the take-off unit or the take-off unit itself can be of
arious constructions. It is only essential that rollers or
ther suitable means be provided for moving a finished part
thereon and that a dumping meçhanism or some other means be
rovided for removing the finished part from the takc-off unit.
Although a take-off unit of some type is preEerred,
the finished parts can be manually handled, if desired. Such a
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manual operation would no~ be as efficiellt and would pro~,ably
require the services of an additional person to réceive the
finished parts as they are ejected from the stitcher.
~etal shapes are preferably ex-truded aluminum shapes,
but any other suitable metal o~ various made metal shapes May be
used. The term aluminum includes all aluminum and aluminum
alloys employed or capable of being employed in thé manufacture
of windows, doors, frames therefor, curtain walls, and the like
and in the building or construction industry in general. Such
metal shapes may be of various lengths, and may be of any desired
configuration in cross-section as long as they are so constructed
as to receive a barrier material and have portions thereof ~hlch
can be crimped onto the barrier material after it has been
inserted.
The insulating material or barrier is preferably made
of plastic. Any other suitable materials may be used which have
the desired characteristic of thermal conductivity, strength,
and rigidity. Although a material of sufficient flexibility that
it can be made into reels or rolls is preEerred, material of
greater rigidity can be used. In such case, lengths of barrier
material would have to be fed into the feeder by hand or sor,le other
suitable means.
The foregoing disclosure and description of the
invention is illustrative and explanatory thereof, and various
~5 changes in the size, shape, and materials, as well as in the
details of the illustrated construction may be made within the
scope of the appended claims without departing from the spirit
of the invention.
