Note: Descriptions are shown in the official language in which they were submitted.
his is a division of Canadian Patent Application Serial
' No. 278,164 filed May 11, 1977 and assigned to the present assignee.
BACKGROUND OF THE INVENTION
:- I .
I The present invention generally relates to an apparatus
¦ and method for makin~ a unitary construction element or shape
having an insulating or thermal barrier member therein, commonly
¦ referred to as a thermal barrier or ther~obreak extrusion or
¦ shape, which can be employed in the construction of windows,
¦ doors, frames therefor, curtaill walls and the li~e.
; 10 ¦ The invention particularly relates to an apparatus
for making a unitary construction element, wherein an insulatlng
¦ ember is joined to a metal member or members by a crimping or
stitching operation.
I With the advent of metal construction used in ~a~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 barrier construction element or
nsulating construction, wherein a metal shape having a generally
-shaped channel therein is filled with a flowing resinous
nsulating composition; the composition is cured, and subsequently
1079938
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079938
portion of the metal member or web forming the base of the
channel is removed. No. 3,823,524 relates to a similar method
but employs a web member whi~h extends convexly between 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
apart and fastened togetller with a solid first insulating member.
The two shapes and the ~irst insulating member provide a channel
in which a second therma] insulating member is flowed therein.
Upon solidification of the latter, the metal and insulating
I members are locked together as an integral ~nit.
Of the more common types of thermai barrier
constructions, two metal members are joined together by a solid
insulating member. 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; 3,487,580; 3,600,857; and
¦ 3,916,503. In one of the more basic of this type of construction,
. ¦ for example, in 2,835,360, two ~etal members are joined together
¦ and spaced apart by an overlapping insulating member. In
I 3,916,503, simple mechanical means are employed to join the metal
25 ¦ members with an insulating member. No. 3,600~857 is representative
of more complex shapes of insulating and metal members.
I In a particular type of the foregoing more common
¦ type of thermal barrier constructions, metal and insulating
embers are mechanically ioined together by deformation of the
metal members or by crimping or stitching the metal members on
the insulating member. ~epresentative of such a joining method
"
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` ~079938
re U. S. Patents 3,114,179; 3,411,995; 3,420,026; 3!517,472; and
3,903,217 and Swiss Patent 320,988 (same as British Patent
r~o. 768,~99). For example, 3,420,026 discloses several types of
thermal insulating members and methods of mal;ing them. In one
type, two separate metal members are mechanically joined to a
central insulating member by crimping or deforrnation of groo~e
means or projections on the metal members. In one particular
type of thermal break construction, the insulating member is in
the shape of a rlaltese cross in cross-section. In another
embodiment, the-insu]atin-3 member is made from a thermoplastic
material and a-portion l:llcreof is heated to cause melting and
flow of the plastic int:o an associated groove means formed by
the two metal members. Upon cooling of the plastic, the metal
and plastic member are unitarily ioined 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
¦insulating member which expands upon heating. The Swiss patent
¦discloses several types of window or door frames, one of which
Iemploys 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 grooves, the flanges are pressed towards the
¦plastic rod or crimped thereon so that they are flush with the
sides of the rod.
25 ¦ 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,~11,254; and, 3,466,801. For example,
No. 3,411,254 provides a plastic thermobreak which t~tilizes a
plastic locking strip which contains a heat actuated blowing
agent to join two separate metal shapes. After assembly 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.
ll 1079938
U. S. Patent 3,815,216 ilIust~ates still another
¦method Or manufacturing a thermal break construction e]ement and
¦ernploys a ~etal extrusion which has a relnova)~le interior sec~ion
¦which is subsequently removcd to separate the extrusion intG two
Imetal members. While maintaining the separatc metal members
¦spaeed apart, a plastic material is inserted therebet~een. The
¦eonstruetion element can be made in a eontinuous operation.
¦ Of these various types of thermal break constructions,
Ithe system of crimping or stitehing has enjoyed eonsiderable
10 ¦eommereial suecess. In ;uch systems, crimping is often done
¦manually or by simple mecllanical means. Such means are of course
relatively slow and have limited ~lexibility. One current
stitching system consists of a feeder for inserting straight
lengths of vinyl or other suitable plastie insulating members
lin the rnetal members. Rollers are employed to provide erimplng
¦ of the metal flanges on the insulating or plastie member.
¦ Conventionally, two rollers or wheel~ are re~luired to crimp
the flanges. One roller must aetually bend the metal flanges
I on the insulating member while the other roller must baek-up or .
20 ¦ ho~d the metal extrusion in the eorrect position for joining
¦ metal and plastic members. To aceomplish t~e crimpiny aetion,
¦ elear aeeess must be available on both sides of the plastie member
on whieh erim ing of the metal members oeeurs. In some cases, a
small wheel or support is laterally employed to serve as a
back-up. The size of the support and the forees required to
obtain a tight joint ereate 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 be removed by
hand after the stitching or erimping operation is eompleted.
.
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10'7993~
:
-; The present invention relates to one aspect, the
crimping apparatus, of the invention disclosed in the assignee's
aforementioned Canadian patent application.
The present invention is defined as an apparatus for
~- crimping two spaced apart metal shapes on an insulating member
to thereby provide a unitary thermal barrier construction
element, comprising a frame, a crimping means on the frame,
a guide means on the frame, and a drive means on the frame for
driving the crimping meclns, the crimping means comprising a first
crimping station for crimling a first metal shape on an insulating
~ ., ,
member, a second crimpirlg station for crimping a second metal
shape on the insulatin~J member, adjusting means on the crimping
stations for accommodating the crimping stations to metal shapes
of various cross-sectional configurations, the guide means
;
comprising at least one guide station positioned before the
first crimping station for guiding the two metal shapes with
insulating member therein into a desired position for crimping
operations, and the guide station comprising removable block
assembly having adjusting means thereon for accommodating the
20 guide station to metal shapes of various cross-sectional
configurations.
BRIEF DESCRIPTION OF THE DRAWINGS
~ ..... . .
' The features and advantages of this invention will
be more readily apparent in the following detailed description
of illustrated embodiments which is 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 lllustrating the various com-
;~ ponents 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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. 11 1079938
Fig. 5 is a front view of the feeder of Fig. 4;
Fig. 6 is an enlargcd front view of the guide box and
support frame of the assembl~ line machinery of Fig. l;
Fig. 7 is a section along line 7-7 of Fig. 6 and snows
, the configuration or cross-sectional shape of the metal members
to be joined ~ith an insulating member and the position of thc
metal members in the guide box;
Fig. 8 is an enlar~ed front view of the stitcher or
crimping machine of the assembly line machinery of Fig. l;
lC Fig. 9 is an enlal~3e<l top view of the take-off unit
of the assembly line machillety o~ Fig. l;
Fig. 10 is a front, v;ew of the take-off unit of Fig. ~;
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
of Fig. 8 illustrating a stitching or crimpin,g means or station
~ of 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
with a finished thermal barrier extrusion or member thereon in
3~ position just prior to activation; and,
Fig. 16A is a view similar to that of Fig. 16, but with
the dump arm in a raised position to discharge the finished thermal
barrier member.
¦¦ 107993B
~ I ~escripti^n of the Prcferred E~odiment
.. .
¦ Refe~ring now to the drawings, especially Fig. 1, the
¦various components or units comprising the comple,e machinery
- ¦line assembly or apparatus and their relative position or relation
Ito each other are illustrated. ~ach of the various units is in
; lalignment with the other so as to provide the basis for a
~continuous operation. The assemblv comprises five basic units, a
reel or unwind stand 20, a reel or thermal barrier feeder 30, a
guide box unit ~0, a stitcher or crimping unit 50, and a take-off
unit 60. The machinery is especially adapted to install a thermal
1~ barrier or insulating mat:erial in a]uminum extrusions or shapes
to provide a unitary thermal ~arrier shape or thermal break
construction element. he 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
¦ end of the reel 21 is inserted in the feeder 30. The thermal
~Q ¦ barrier insulating material is preferably a vinyl or foamed ~VC.
. J Any other suitable type of material may be used. The cross-
section shape of the material is of a size and shape to be
received by or inserted in a pair of appropriately designed
metal shapes 70 and 71. For most operations, two separate metal
shapes, preferably extruded alur,~inum 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
operation is complete. A single metal shape would have an
appropriately constructed opening therein for receiving the
barrier or insulating material.
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1~ 1079938
Two metal o~ aluminum shapes ,0 and ,1 are properly
¦positioned on a guide bo~ 4] of the guide box unit 40 by an
¦operator. The metal shapes are then slid into the feeder 30 and
Iproperly positioned therein to receive the thermal barrier
¦material. Shapes are customarily about sixteen feet in length,
¦but may be of any length desired. A foot switch (not shown)
actuates a clamp 31 which holds the aluminum shapes 70 and 71 in
position. ~ pair of drive wheels 32 and 33 are actuated and
Ifeed the barrier portion 21a into the shapes 70 and 71. The
10 ¦length of the material or barrie~ 21a inserted is controlled by
la pre-set or pre-determined setl;ng on a counter connected to a
¦measuring ~7heel 3~ riding on ~}le barrier. The barrier or
insulating material comes off the reel as it travels through the
I 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
¦ the combination of metal shapes 70 and 71 and barrier section
,' ¦ 21a into the stitcher 50. A first stitch or crimp station 51 of
20 ¦ the stitcher 50 causes the metal on one side of the barrier 21a
to be crimped thereon. The combination is continued through
;, the stitcher ~ithout any further help from the operator. As the
combination passes through a second stitch station 52, the metal
on the other side of the barrier 21a is crimped thereon. The
, completed thermal barrier construction element or shape T is
moved or driven in the direction indicated by arrow A where it
is received by the take-off unit 60. As the finished part or
element T clears the stitcher 50, an electric eye (not shown)
located between the stitcher 50 and the take-off unit 60
actuates dump arms 61 and 62 causing the arms to raise and slide
the 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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Il 1079938
ombination clears the quidc box into the stitcher, the operator
places another pair of metal shapes on the guide box and slides
them into the feeder to provide a substantially continuous
operation.
~lthough the operation is described employing two
. metal shapes, a single metal shape can be used. ~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 ~he further operation of removing a
pre-determined portion oE the metal shape therefrom to thereby
provide the thermal barr;er or break in thc finished part. The
details of the various components of the assembly are described
i 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
20 ¦mounted on each reel support arm 26 and a brake disc 28 mounted
on the other end of the shaft 23. The frame 22 comprises a
plurality of fra~e mernbers welded or otherwi$e joined together
¦including a pair of spaced apart base members 22a, four vertical
I frame members 22b and, a pair of base frame members 22c parallel-
¦ edly spaced apart and ioined together with vertical support
¦ members 2Zb 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 exemplary.
The shaft 23 is mounted on the frame 22 by means of
30 a pair of pillow blocks or bearings 29 mounted on each of the -
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; - 1079938
-haft support frame members 22d. The shaft is freely rotatable
¦within the bearings. The caliper disc break 28 includes a disc
Ihub 2~a, break disc 28b and break caliper 28c. ~ny suitable
¦caliper disc ~reak may be used. The guide rods 27 are pivotally
I mounted on the reel support arms 26 by means of a hinged pin 26a.
- I The arms 26 also include a positioning pin 26b which enables the
¦ rods 27 to be locked in either a horizontal position as illustrate
or a vertical position ninety degrees from the horizontal one.
Flgs. 2 and 3 of the drawings illustrate the guide rods 27 in
position for receiving a reel o~ insulating material 21. After
the insulatiny reel has beell positioned on the arms 26, the rods
27 are raised to a vertical position and locked in place as seen
in Fig. 1.
Referring to Fig. 11, a portion o reel support arm 26
is illustrated showing a guide rod 27 pivotally mounted therein.
he reel support arm 26 has an opening 26c cut therein for
receiving the rod 27. The member 26 is conveniently a channei
ember, and the portion 26c removed therefrom is removed from
the web of the member 26. Other types of construction are of
ourse suitable. The reel support arm 26 also has suitable
, penings therein in the flanges thereof for receiving the hinge
in 26a and the positioning pin 26b. The rod 27 also has suitable
oles or openings therein for receiving pins 26a and 26b,
espectively. The rod 27 is pivotally mounted on the hinge pin
6a so it may be raised from a horizontal position to a vertical
osition in the direction of the arrow E. A nut 26d secures the
inge pin 26a on the arm 26. When the positioning pin 26~ is in
: he position illustrated in Fig. 11, the rod 26 is locked in a
orizontal or longitudinal position with the guide support arm
6. To place a reel of insulating material on the unwind stand
0, each of the rods 27 are placed in the position as illustrated
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1~ 1079938
_n Fig. 11. After the reel has becn placed on the support arms 26,
the positioning pin 2~b is withdrawn and the rod 27 moved in the
direction of the arrow E to the vertical position shown in
~ig. 11. The positioning pin is then inserted in the holes in
the arm 26 from which it was previously removed, thus locking
the rod in a vertical position and thus maintaining the reel 21 on
the unwind stand ~0. Any otl~er suitable reel support mechanism or
ap~aratus may be used as desired.
The details of the feeder 30 are seen in Figs. 4 and 5.
The feeder includes a frame 3G, 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 34,
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 36c, 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.
~- 20 The clamp assembly 31 includes clamp air cylinder
31a, a cylinder rod 31b, a jam nut 31c, a clamp 31d, a clamp
guide 31e, an extrusion or shape support 31f and an extrusion
or shape positioning plate 31g. The angle iron extrusion
support member 31f has a pair of slots 31h therein and is
; mounted on the front plate 36b by means of a plurality of soc~et
head cap screws 31i or other suitable Lasteners. 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 fixed
- 30 position and so located between the knife 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.
,.
~ ~1 1079938
-~he insulating member 21a. The air cylinder 31a actuates the
j cylinder rod 31b so that the clamp 31d and clamp guide 31e
¦ thereon are moved into holding contact with the shapes 70 and
71 to hold them in the desired position during the insertion
I 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
¦ 35a, a block 35b for hold;llg same, a cylinder actuating rod 35c,
a jam nut 35d and a jam llUt: 35e positioned on the rod 35c, a
knife holder 35f mount-ed on the end of the rod 35c and a knife
; 35g positioned in the kn;le 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
shown) connected to a suitable valve and air supply provides air
to the air cylinder 35a for actuating the knife blade 35g for
cutting or severing the insulating barrier 21a when an
appropriate signal is given thereto.
.,'- . . .
The base plate 36d has an opening 36d fo~ receiving a
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
; J. 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
ounted in front plate 36b. The upper drive wheel 32 is
¦¦adjust e so as to accommodate various sizes of lnsulating
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j
' 11 ~07ss38
. aterial or barriers. Such mechanism inclides a bolt holder 32g
~mounted on the front plate 36b and a bolt 32h, a slide block 32i
sj ¦and slides 32j suitably positioned thereon. The drive wheels 32
¦and 33 advance the barrier member 21a in the direction of the
~i~ ¦arrow B so as to insert the member 21a into the shapes 70 and 71.
I Additional details of the drive wheels 32 and 33
¦are seen in Fig. 13. Upper drive wheel or drive unit 32 is
., Imounted on the plate 36b. Lower drive wheel or drive unit 33
¦is mounted on the shaft 32b which extends through an opening in
~ 10 ¦the plate 36b. The unit 32 includes a drive gear 32k having
i Iteeth 32k' thereon whicll is mounted on bushing 32m in which
~, ¦axle bolt 32f is posi1:ioned therethrough and inserted into
¦ movable slide block 32i. Slide block 32i is slidably mbunted
,~ ¦ in slide 32j which is fixed to plate 36b. A thrust bearing 32n
is also positioned on the axle 32f between the head of axle 32f
and drive gear 32k. Barrier drive wheel 32p having teeth 32p'
thereon is fixed 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 holderand in the slide block. By adjusting the nuts 32q, the slide
block 32i may be moved vertically within the slide 32j so that
the drive wheel 32p will be in an appropriate position for
driving the insulating barrier material 26a on the top side
hereof.
The dri~e shaft 32b has a hub 33a the-reon positioned
n a bushing 33b in a bushing support member or bearing 32d
30 ounted on plate 36b. A drive gear 33d having teeth 33d'
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1079938
;'hereon is mounte~ on the hub 33a on sha~t 32b and meshes with
l qear 32k so a.-: 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 moun'ted on the
front plate 36b. The inp~lt guide 39 is also mounted on the
front plate 36b. The input guide 39 is also mounted on the
front base plate 36b in a suit:ab]e manner.
; Referring now t~ l'ig. 12, the details of the measuring
wheel 34 are illustrated. ~ pt.llse generator mounting bloc}; 34c
is affixed to front side plate 36b by means of a bolt 34d
through suitable openings in the plate 36d and mounting block
34c, respectively. The pulse generator 34b having a shaft 34a
s mounted on the mounting block 34b. A shaft extender 34a' is
ffixed to the shaft 34a and he1d in place thereon by means of a
¦ set screw 34e. The plate 36b has an opening 36b' therein for
J ¦ receiving the shaft extender 34a'. The measuring wheel 34 is
'i 20 1 positioned on the shaft extender 34a'. A movable guide block 34f -
; I 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 3~g. 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
arrier. The block 34f also has a suitable opening 34f'' for
eceiving the barrier or insulating material 26a. Also mounted
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. 1~ 1079938 -
.. . .
~ n the plate 36b below ~he guide bloc~i 3~1f is a spring holding
block 34i. The block 34i has an opening 34i' for receiving
the spring bolt 34j. A spring 34k is mounted on the bolt 34;'.
~uts 34m retain the bolt 34j in the block 34i. The spring 34k
urges the bolt 39j into contact with movable guide block 34f so
as to urge the vinyl material 26a therein against the measuring
wheel 34.
~ ny other suitable feeder rnay be used. The feeder
should have some type of means to receive and feed the barrier
material into the metal meltll~er or members and to stop the feeding
operation when an appropri.ltc! :Lellgth of insulating material has
been inserted into the meta] ~ncrnber or members. Preferably, the
feeder also contains a clamping means for holding metal members
in place during insertion operations and a knife means for cutting
or 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
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 merl~ers 43
ioined together and spaced apart by base frame members 44 and
- op frame members 45. Brackets 46 are fixed to the support mer.~ers
43 for supporting the guide box 41. It can be appreciated that
any other suitable structure may be used for holding the guide
. ox 41. The guide box 41 is a longitudinally extending wooden
ember or board which has grooves 41a and 41b therein for
receiving portions of the shapes 70 and 71, respectivelyj as
1 1079938 -
illustrated in Fig. 7. The guide bo~ ~1 is merely illustrative
¦of a very simple type of guide box. It may be made of wood or
any other suitable material, e.g., metal and plastic. For
normal operations, a guide box having a multiplicity of grooves
for receiving a variety of types of shapes would be employed.
All that is necessary is that the guide box hold the metal sh~pes
in a suitable position for receiving 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 me~bers 70 and 71. The opening 80 is of a
size and shape so as to ~eadily receive a somewhat similarly
shaped, in cross-section, ~hermal 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. 8, the stitcher or cri~ping
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 on side plates
57 and 57' mounted on a base plate 57'' mounted on support
embers 58. Additionally, the stitcher 50 includes a combination
otor 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~ing screws 56c.
he ejector station 56 receives the metal members with barrier
rimped therein and ejects the extrusion or finished part T
ut of the stitcher 50 and also straightens the element T.
79938 -
The c3uide blocks 53, 54 and 55 are substantiallv
identical and are made for a particular shape. The yuide 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 each identical
operation. The stitch stations are adjustable to accon~odate
particular shapes. Details of the stitch stations and guide
stations are seen in Fic3~. 14 and 15.
Referring no~ to Fig. 14, a stitch station is
; illustrated in detail. Stitch station Sl is mounted 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
15 1 drive shaft 51c which has a drive sprocket 51d on one end thereof
- for receiving the chain 59a. The 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',
20 ¦respectively. A pair of snap rings 51r and 51r' are positioned
lon the shaft 51c adjacent bearings 51g and 51g', respectively.
¦Holding bars 51i and 51i' hold the upper portion 51a in position
; Ito the stitcher 50. The lower movable portion or backup block
¦51b includes side plates 51j and 51j' in which are mounted
s 25 ¦~earings 51k and Sl~' for supporting the backup wheel shaft 511.
¦Backup 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
bearings 51k and 51k', respectively. A cross brace 51q connects
30 or joins the side plates 51j and 51j'. The lower or backup
wheel 51m is movable and con~rolled by means of an air cylinder
ll ~ 1079938 --
;lr mounted on the stitcher base plate 57'' by means of bolts
157a or other suitable means. The plate 57'' has an opening 57b
¦therein for receiving the air cylinder shaft 51r' which is
¦mounted to a cross plate 51s. As the air cylinder shaft 51r' is
¦actuated up or down, the block 51b is moved therewith so that
lan operator may vary the bacXup forcc for a particular stitching
¦ or crimping operation depending upon the particular metal members
being stitched or crimped. Tl~e stitch wheel and backup wheel are
I both hardened steel rollcrs ~lith the stitch wheel having teeth
,~ 10 1 thereon. The stitch wheel 5le i.s grooved or so constructed that
- I only one metal member or OllC` s;.dc 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 51, except that the wheel 51e is so constructed
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. The flange 70a
is crimped by the stitch station 52.
'~- The guide station or guide box assembly 53 is seen in
i'~ 20 detail in Fig. 15. The 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 b~ 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 ~f guide wheels 53g and 53h are
30 mounted on the shaft 53e. A key 53i enables the guide wheels to -
be locked in a predetermined position on the shaft 53e. A pair
of spring guide posts or pins 53j and a pair of spring guide
posts or pins 53j' are mounted on the top of side plates 53c and
. -19- .
: ~
079g38 -
~ 3c', respectively. Ilolding bars 53k and 53k' are also positioned
lon side plates 53c and 53c', respectively. Each guide post has a
¦spring 531 thereupon. The guide posts or pins are not connected
Ito the holding bars, but are positioned therein through 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 t.lrougll the machine, the upper block is
Iraised slightly, compressing the springs.
10 ¦ The lower bloc~ 53L) includes side plates 53m and
153m' joined together by cross b~ ce 53n. A shaft 53p is mounted
-~ ¦in bearings 53q and 53q', resl~ec~ively, mounted in the side
plates 53m and 53m', respectively, A pair of lower guide wheels
53r and 53s are mounted on the shaft 53p and spaccd apart
15 ¦therefrom each other and retained in a predetermined position
by means-of key 53t. ~ fixed side guide yolk 53u is mounted on
the inside of side plate 53m' and includes an a~le 53u' on
. ¦ which roller 53u'' is positioned thereon. A movable side guide
yolk 53v is mounted on guide bolt 53'' positioned in a suitable
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
53w' thereon against the shape 71 which in turn urges the shape
71 and shape ? against the wheel 53u''. Snap rings 53y and 53y'
are also positioned on the shaft 53p adjacent bearings 53g and
53q', respectively. The guide blocks are readily removable and
permit 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
. .
- 20 -
'r~,
Il 1079938
!~
. ype as desired Such whecls are preferably made of a material
such as a phenolic resin, vinyl or other suitable material ~ihich ,
does not damage thc metal shapes. The various guide wheels also
have set scre~s therein for fixing the wheels to their respective
' 5 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 ~heels,set in a similar
';' 10 position.
,, The guide statio~s ~)e~'ore each stitchiny station hold
the metal shapes and barrier t:herebetween in proper alignment for
, each successive crimping or stitching operation. Guide stations
,, and stitch stations can be so constructed and assembled that
''' 15 stitching or crimping can be conducted on whichever metal member
. r side of metal member desired. The last guide station guides
the metal shapes ~ith barrier material locked therein or
¦therebetween into the ejector station or unit. The ejector
¦station not only ejects the finished part from th~ stitcher or
,~ 20 ¦stitcher assembly to the ta};e-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-of~ unit 60
' ¦ includes dump arms 61 and 62 mounted on a shaft 63 held by
~' ¦ bearings 64, 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 members 68 and 67. An air rotary actuator 90 is mounted
on a motor base plate 91 mounted on vertical support members 66
.. .
',,
- 21 -
' '
~ 1~ 107993B -
the frame 60', Th~ rotary actuator 90 has a shaft 90a extendiny
¦ therefrom on which is mounted a c3ear 92 which drives a gear 93
¦ ounted on the shaft 63. An air valve 94 is also mounted on the
¦ plate 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
", 10 ¦ raised position so that a ~emb~r T thereon ~ill slide off of the
¦ unit 60 and into a suitable receptacle,
Referring now to l~i(3s. 16 and 16A, a completed thermal
¦ arrier shape T is illustrated in position on the take-off unit
¦ 60 prior to activation of the dump arms and in position after
`- 15 the dump arms have been activated. Dump arm 62 is shot~n in a
raised position in Fig. 16A wherein the finished part T is moved
~, from the position shown in Fig. 16 to the position snown in
ig. 16A and hence into a basket or other suitable container.
ump arm 62, as ~ell 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 90a actuated by the air valve 94.
he air valve 94 is connected to a suitable air supply source by
25 eans of lines 95 and 9$'. It can be appreciated that the frame
f 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
hereon and that a dumping mechanism or some other means be
; 30 rovided for removing the finished part from the take-off unit.
Although a take-off unit of some type is preferred,
he finished parts can be manually handled, if desired. Such a
.,
- 22 -
,~
`; . 11 . 11~7993~
~~nual operation would not be as efficient and would probably
¦ require the services of an additional person to recelve the
¦ finished parts as they are ejected from the stitcher.
¦ Metal shapes are preferably extruded aluminum shapes,
5 ¦ but any other suitable metal or various made metal shapes may he
¦ used. The term aluminum includes all aluminum and aluminum
; I alloys employed or capahle of being employed in the manufacture
of windows, doors, frames therefor, curtain walls, and the like
¦ and in the building or construction industry in qeneral. Such
~'~ 10 ¦ 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 ~terial and have portions thereof which
? can be crir.lped onto the barrier material af~er it has been
inserted.
The insulating material or barrier is preferably made
of plastic. Any other suitable materials ~ay be used which have
the desired characteristic of ~hermal conductivity, strength,
nd rigidity. Although a material of sufficient flexibility that
it can be made into reels or rolls is preferred, material of
reater rigidity can be used. In such case, lengths of barrier
aterial would have to be fed into the feeder by hand or some otner
uitable means.
The foregolng disclosure and description of the
invention is illustrative and explanatory thereof, and various
hanges in the size, shape, and materials, as well as in the
etails of the illustrated construction may be made within the
cope of the appended claims without departing from the spirit
f the invention.
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