Note: Descriptions are shown in the official language in which they were submitted.
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INSULATING GLASS UNIT FINAL SEALING ASSEMBLY AND METHOD
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The following application claims priority under 35 U.S.C. 119(e)
to co-
pending U.S. Provisional Patent Application Serial No. 62/500,704 filed May
03, 2017
entitled INSULATING GLASS UNIT FINAL SEALING ASSEMBLY AND METHOD, U.S.
Provisional Patent Application Serial No. 62/629,785 filed February 13, 2018
entitled
INSULATING GLASS UNIT PLUG AND INSTALLATION METHOD, AND U.S.
Provisional Patent Application Serial No. 62/539,779 filed August 01, 2017
entitled
INSULATING GLASS UNIT FLUID EXCHANGE ASSEMBLY AND METHOD. The
above-identified provisional applications are incorporated herein by reference
in their
entireties for all purposes.
TECHNICAL FIELD
[0002] 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.
BACKGROUND
[0003] 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.
[0004] Typically, sealant is manually applied around a majority of the
spacer
frame periphery, while leaving a small opening formed through the spacer frame
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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.
[0005] 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
SUMMARY
[0006] 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.
[0007] 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
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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.
[0008] 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.
[0009] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] 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
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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:
[0011] FIG. 1 is an overview schematic block diagram of a sealant
processing
system;
[0012] FIG. 2 is a right side elevation view of a sealing station in
accordance
with one example embodiment of the present disclosure;
[0013] FIG. 3 is a left side elevation view of the sealing station of
FIG. 2;
[0014] FIG. 4 is a perspective view of the sealing station of FIG. 2;
[0015] FIG. 5 is a rear perspective view of a sealant dispensing
apparatus and
vision system;
[0016] FIG. 6 is a front perspective view of a sealant dispensing
apparatus and
vision system coupled to the sealing station of FIG. 2;
[0017] FIG. 6A is a is a section view of FIG. 6 taken along section lines
6A-6A;
[0018] FIG. 7 is a rear perspective view of FIG. 6;
[0019] FIG. 8 is a right side perspective view of FIG. 6;
[0020] FIG. 8A is a right side perspective view of a sealant dispensing
apparatus
including a smoothing apparatus and vision system coupled to the sealing
station of FIG.
2;
[0021] FIG. 9 is a perspective view of a dispensing head of FIG. 7
[0022] FIG. 10A is a section view of FIG. 7 taken along section lines 10-
10;
[0023] FIG. 10B is a top plan view of FIG. 10A in a first pivoted
position;
[0024] FIG. 10B is a top plan view of FIG. 10A in a second pivoted
position;
[0025] FIG. 11A is a side elevation view of FIG. 10A;
[0026] FIG. 11B is a side elevation view of FIG. 11A in a first pivoted
position;
[0027] FIG. 11C is a side elevation view of FIG. 11A in a second pivoted
position;
[0028] FIG. 12 is a side elevation view of FIG. 11A in a third pivoted
position;
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[0029] FIG. 13 is a front elevation view of a partially constructed
insulating glass
unit (IGU);
[0030] FIG. 14 is a perspective view of a sealant dispensing apparatus
dispensing
sealant on an IGU wherein a vision system monitors the dispensing;
[0031] FIG. 14A is a section view of FIG. 14 taken along section lines
14A-14A;
[0032] FIG. 15 is a flow diagram of a method of sealant application; and
[0033] FIG. 16 is a flow diagram of a second method of sealant
application.
[0034] 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.
[0035] 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.
DETAILED DESCRIPTION
[0036] 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.
[0037] FIG. 1 schematically depicts a window sealing system 10 for
sealing
window frames or insulating glass units (hereinafter IGUs 100). The IGUs 100
comprise
one or more glass lites 210, 212, spaced by a spacer frame 201 (see FIGS. 13
and 14). In
FIG. 14, a portion of the spacer frame 201 on a front face 206 of the IGU 100
was
omitted for clarity. The IGU 100 referred herein throughout is a selected one
of a
plurality of IGUs in an assembly line or being presented in a cart or fixtures
to the sealing
system 10. The select one IGU 100 may have the same or differing size, number
of
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panes or lites, etc. from the plurality of IGUs. The sealing system 10 as
described herein
is capable of discriminating between IGUs differences, such as the sizes and
types to
perform the same operation as described on the IGU 100.
[0038] 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 FIG.
14). Atmospheric air is evacuated from the opening 203, after which an inert
gas is then
inserted the opening into the space 207 within the IGU 100 (e.g., bounded by
the spacer
frame 201 and the glass lites 210, 212). A rivet, screw, cover, or other
fastener 205 is
inserted into the opening 203, and sealant 40 is automatically applied over
the uncovered
area 209 and bonded with the applied sealant 200 by the window sealing system
10.
[0039] 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. hi another example embodiment, the vision
system 12 is a
laser scanner.
[0040] 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 FIG. 4)
presented as one of many different size and types of IGUs to be processed
within a
fixture, rack, or mobile cart 64. In the illustrated embodiment, the optical
sensor 16
identifies a portion of the IGU that has a different optical property than the
rest of the
IGU (e.g., the uncovered area 209 that lacks sealant 40) (see, for example,
FIG. 13) and
records the coordinates of the portion (e.g., the coordinate are stored by the
controller
35). The coordinates identify a location in three-dimensional space that the
controller 35
can find repeatedly when the IGU 100 is stationarily positioned in the fixture
64.
Once the coordinates are identified, the sealant dispensing apparatus 14 is
actuated (e.g.,
via the articulating arm 62) to the coordinates (e.g., responsive to
instruction by the
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controller 35). The sealant dispensing apparatus 14 dispenses sealant 40 over
an area
designated by the coordinates (see FIG. 14A). Concurrently, the vision system
12
monitors physical properties of the sealant 40, such as the temperature of the
sealant,
and/or an amount of sealant overflowing from the designated area and the
sealant
dispensing apparatus 14. The vision system 12 generates a feedback loop 35a
with the
controller 35, wherein the controller instructs the sealant dispensing
apparatus 14 to
adjust an application speed of the sealant 40, a flow rate of the sealant, a
temperature of
the sealant, or the like to account for changes in the observed physical
properties of the
sealant and maintain optimal sealant application conditions.
[0041] Views of the sealant station 60 constructed in accordance with one
example embodiment of the present disclosure are illustrated in FIGS. 2-4 The
sealant
station 60 comprises the articulating arm 62, a support stand 66, and a tool
support
assembly 68. The tool support assembly 68 includes a tool support arrangement
70 for
selectable coupling to selectable components comprising the optical sensor 16,
the sealant
dispensing apparatus 14, and/or the vision system 12. The selectable couplable
components are enabled and actuated by instructions from the controller 35 to
translate
and rotate into a position relative to selected portions of an IGU 100. The
controller 35
instructs or directs the operation of the optical sensor 16, the sealant
dispensing apparatus
14, and the vision system 12, and various functions associated therewith.
[0042] 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 FIG. 4. The sealant station 62 includes a base 102, a
first member
104, a first arm 106, a second member 107, a second arm 108, and a third
member 112.
The base 102 rotates about the Y axis, thus rotating the first member 104,
first arm 106,
second member 107, second arm 108, third member 112, and tool support assembly
68.
The first member 104 rotates about the X axis, thus rotating the first arm
106, second
member 107, second arm 108, third member 112, and tool support assembly 68.
The
second member 107 rotates about the X axis, thus rotating the second arm 108,
third
member 112, and tool support assembly 68. The third member 112 rotates about
the X
axis, thus rotating the tool support assembly 68.
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[0043] 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.
[0044] 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 FIG. 4) or a camera based visual sensor that images
an entire
region of the spacer frame 201. Other alternate embodiments utilize tactile or
touch
sensors for determining the spacer frame profile. In the illustrated example
embodiment,
the visual sensor 16 identifies areas of the IGU 100 comprising a different
profile. The
profiling of the IGU 100 by the visual sensor 16 in one example embodiment
occurs
when the IGU is supported in a frame securing assembly 64.
[0045] Referring to FIG. 4, the frame securing assembly 64 includes a
number of
clamps and corresponding pins for fixing an IGU 100 in place. For example, the
frame
securing assembly 64 has fixed clamps or fencing 82 and 84 that contact an
outer surface
of the IGU 100 in a region of one or more corners of the IGU. The IGU 100 has
top and
bottom surfaces 202, 204, respectively that are oriented within the frame
securing
assembly 64 in a generally vertical plane with respect to a shop floor. In an
example
embodiment, the IGUs 100 will be positioned such that the face of the IGU
comprising
the opening 203, and thus, the uncovered area 209 lacking sealant 40, faces
the
articulating arm 62. Further details of the fixed clamps 82 and 84 and their
operation is
found in U.S. Patent Nos. 8,250,023 and 7,921,064, which are assigned to the
assignee of
the present disclosure and both patents are incorporated herein by reference
for all
purposes in their entireties.
[0046] Referring to FIGS. 5-13, the sealant dispensing apparatus 14
comprises a
tool connector 18, a dispensing head 21 for depositing sealant 40 on the IGU
100, a
sealant valve 28 fluidly connected to the dispensing head, a cylinder 23 for
opening and
closing the sealant valve, and a sealant input 20 connected to a sealant
reservoir (not
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shown). Referring to FIGS. 5 and 6, the tool connector 18 of the sealant
dispensing
apparatus 14 is configured to be releasably coupled to the articulating arm 62
via the tool
support arrangement 70. The tool connector 18 comprises a cone shaped portion
18b
abutting a nose portion 18a. The tool support arrangement 70 interacts with at
least one
of the nose portion 18a and the cone shaped portion 18b to secure the sealant
dispensing
apparatus 14, such that the sealant dispensing apparatus is controlled in
three dimensional
space by the articulating arm 62 until the sealant dispensing apparatus is
uncoupled. The
sealant dispensing apparatus 14 has a home location having coordinates known
by the
controller 35. The home location comprises a rack or holder on which the
sealant
dispensing apparatus 14 rests. The articulating arm 62 couples to the sealant
dispensing
apparatus 14 when it is located at the home location for movement to a
dispensing
position in relation to the IGU 100. The articulating arm 62 then places the
sealant
dispensing apparatus at the home location after the sealant 40 has been
dispensed.
[0047] 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.
[0048] Referring
again to FIGS. 5-13, the dispensing head 21 comprises heating
elements 31, 32, 33, a flexible attachment hose 30 fluidly coupled to the
sealant valve 28,
and thus the sealant input 20, the flexible attachment hose runs through the
heating
elements, a dispensing element 22 comprising a nozzle 26 coupled to the
flexible
attachment hose for dispensing sealant 40. The flexible attachment hose 30 is
adjacent
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the heating elements 31, 32, 33 to maintain a fluid state of the sealant 40
during
application of the sealant to the IGU 100 and maintains a sufficient
temperature of the
sealant to ensure bonding between the newly applied sealant and the previously
manually
applied solidified sealant 200. In one example embodiment, the heating
elements 31, 32,
33 maintain a temperature between about 275 F to about 475 F, and the sealant
40, when
leaving the nozzle 26, has a temperature above 350 F. In another example
embodiment,
a front face heating element 51 is present above the nozzle 26 on a front face
24 of the
dispensing head 21, wherein the front face heating element further interacts
with the
sealant 40 during application to maintain the temperature of the sealant
between about
275 F to about 475 F. It would be appreciated by one having ordinary skill in
the art that
though first and second heating elements are nearer the dispensing element 22,
and the
hose 30 is between the third heating element 33 and the first and second
heating
elements, multiple heating element configurations are contemplated. For
example,
having less than or more than three heating elements, having the heating
elements
together on one or the other side of the hose 30, etc.
[0049] As in the illustrated example embodiment of FIGS. 9-12, the
flexible
attachment 30 is buttressed by one or more springs 30A, 30B (e.g., a coil
spring wrapped
around the attachment, tensions springs, extension springs, etc.). The one or
more
springs 30A, 30B support the dispensing element 22, and thus the nozzle 26,
while
allowing the dispensing element 22, the one or more heating elements 31, 32,
and/or the
front face heating element 41 to pivot, compress, expand, translate and/or
rotate relative
to the x-axis, the y-axis, the z-axis and the IGU 100. Thus, the dispensing
element 22
remains flush with front side edges 214 of both the first and second glass
lites 210, 212,
which prevents the sealant 40 from escaping sideways along the x-axis and past
the front
side edges. As shown in the illustrated example embodiment of FIG. 10A, where
the first
glass lite 210 and the second glass lite 212 of the IGU 100 have front side
214 edges that
are coplanar along a z, x coordinate plane, the dispensing element 22 does not
pivot when
coming into contact with the front side edges. As shown in the example
embodiments of
FIGS. 10B-10C, the dispensing element 22 pivots toward a first direction
(arrow A) or a
second direction (arrow B), responsive to the first and second lites 210, 212
being uneven
along the z, x coordinate plane. In FIG. 10B, responsive to the front edge of
the second
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glass lite 212 extending further from the spacer frame 201 than the first
glass lite 210, the
dispensing element 22 pivots in the first direction (arrow A) to evenly
distribute the
sealant 40. Conversely in FIG. 10C, responsive to the front edge of the first
glass lite 210
extending further from the spacer frame 201 than the second glass lite 212,
the dispensing
element 22 pivots in the second direction (arrow B) to evenly distribute the
sealant 40.
[0050] Similarly as shown in the illustrated example embodiment of FIG.
11A,
where the first glass lite 210 and the second glass lite 212 of the IGU 100
have front side
214 edges that run parallel to the y-axis, the dispensing element 22 does not
pivot when
coming into contact with the front side edges. When the front side 214 edges
are not
parallel to the y-axis, the dispensing element 22 pivots as illustrated in
FIGS. 11B-11C
toward a forward (arrow C) or backward (arrow D) direction to be flush with
the front
side edges. Additionally, as in the illustrated embodiment of FIG. 12, the
dispensing
element 22, responsive to encountering the glass lites 210, 212 can move along
the z-axis
(arrow E) to partially shorten the hose 30, to prevent hitting the glass lites
with significant
force, or to mitigate a force applied to the lites during contact. It would be
appreciated by
one having ordinary skill in the art that the dispensing element 22 can
concurrently pivot
along the y, z coordinate plane, the x, z coordinate plane, and x, y
coordinate plane to
adjust to various positions of the glass lites 210, 212. Thus, the quality of
the seal created
by the sealant 40 is uniform even when the glass lites 210, 212 are uneven,
tilted, or the
like.
[0051] The dispensing element 22 comprises the front face 24 in which the
nozzle
opening 26 is defined. In the illustrated example embodiments of FIGS. 5-13,
the front
face 24 terminates in a top face 25 of the dispensing element 22 that extends
along a
plane at a 90 angle relative to the front face. In another example
embodiment, the top
face 25 extends along a plane that is transverse to the front face 24. The
angle of the top
face 25 relative to the front face 24 is configured to capture excess sealant
40 in a bead
38, and to help evenly spread the sealant by acting as a sealant
spreader/scraper.
[0052] In the illustrated example embodiment of FIG. 8A, a smoothing
apparatus
41 is coupled to the sealant dispensing apparatus 14 via an arm 43. The
smoothing
apparatus 41 comprises a smoothing element 45 coupled to a front face 47 of
the
smoothing element. In one example embodiment, the front face 24 of the nozzle
26 is
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coplanar with the front face 47, the smoothing element 45, or extends in front
of the front
face of the nozzle in a direction away from the tool connector 18. In one
example
embodiment, the smoothing element reaches a temperature between about 275 F to
about
475 F. In another example embodiment, the arm 43 comprises a flexible
attachment that
functions in a same or similar manner as the flexible attachment 30 that
supports the
dispensing element. The arm 43 supports the smoothing apparatus 41 as it
pivots,
compresses, expands, translates and/or rotates relative to the x-axis, the y-
axis, the z-axis
and the IGU 100, responsive to the alignment of the first side edges 214 of
both the first
and second glass lites 210, 212.
[0053] In the illustrated example embodiment of FIGS. 14 and 14A, the
vision
system 12 is coupled to the sealant dispensing apparatus 14, such that a beam
34 emitted
from the vision system interacts with the top face 25 of the nozzle 26, and/or
the bead 38.
The vision system 12 comprises a laser vision system and/or an infrared vision
system,
wherein the vision system emits a laser or an infrared beam and determines a
physical
property of the bead 38 by capturing refracted/reflected light after the light
had interacted
with the bead. In one example embodiment, the size of the bead 38 and/or the
temperature of the bead is determined and communicated to the controller 35
during use
to control the speed or movement of the arm 62 and/or dispensing of the
sealant 40 to
apply a controlled amount of sealant along the uncovered area 209.
[0054] During use, and as illustrated in the example method 300 of FIG.
15, at
302, the coordinates of the uncovered area 209 are determined by the optical
sensor 16,
the articulating arm 62 will couple to the tool connector 18, to couple the
sealant
dispensing apparatus 14 to the arm. In one example embodiment, a first sealant
dispensing apparatus 14 or a second sealant dispensing apparatus will be
selected based
upon a width of the IGU, wherein the first and second sealant dispensing
apparatuses
have different nozzles 26, having different widths and/or dimensions
configured to
interact with a given IGU 100 of a plurality of IGUs, the IGU having a
particular width.
At 304a, the articulating arm 62 will move the sealant dispensing apparatus 14
such that
the smoothing apparatus 41 abuts the IGU 100 over the uncovered area 209. The
articulating arm 62 will move the smoothing apparatus 41 over the solidified
sealant 200
and the uncovered area 209 to smooth any uneven areas (e.g., bumps or lumps)
in the
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solidified sealant by heating the sealant to a liquefying or viscous
temperature and
smoothing the heated sealant to remove the bumps or lumps. In one example
embodiment, method step 304a is optional, and performed when the optical
sensor 16
detects the lump or bump. In another example embodiment, method step 304a is
performed whether the optical sensor 16 detects the lump or bump or does not
detect such
an imperfection.
[0055] 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 FIGS.
13, and 14A). The nozzle 26 is aligned at a first or second end 209a, 209b,
respectively,
of the uncovered area 209, where the sealant 200 is present but not of
sufficient
thickness, or not present (see FIG. 13). It would be appreciated by one having
ordinary
skill in the art, that though IGUs 100 having double pane glass is shown,
multi-pane
IGUs (e.g., such as triple pane windows having two spacer frames and three
glass lites)
are contemplated and would be sealed in a same manner as the double pane IGUs.
[0056] The nozzle 26 is aligned to dispense sealant 40 beginning at the
second
end 209b (see FIG. 13). At 306, the nozzle 26, once aligned, starts dispensing
sealant 40
while moving along the edges of the first and second lites 210, 212, in a
first dispensing
direction (arrow F) along the y-axis. As the sealant dispensing apparatus 14
is moved
along the first dispensing direction (arrow F) excess sealant 40 forms the
bead 38. At
308, the vision system 12 detects physical properties of the bead 38. At 309,
the
application of the sealant 40 is altered based upon the physical properties of
the bead 38,
for example, if the bead is too big, the controller 35 will determine that too
much sealant
40 is being dispensed or the sealant dispensing apparatus 14 is moving too
slowly. In
such instances, the controller 35 will adjust one of the flow speed of the
sealant, or
increase the speed at which the sealant dispensing apparatus 14 is moving. In
another
example, if the bead 38 is too small, the controller 35 will determine that
too little sealant
40 is being dispensed or the sealant dispensing apparatus 14 is moving too
quickly for
optimal sealant deposition. In such instances, the controller 35 will increase
one of the
flow speed of the sealant, or decrease the speed at which the sealant
dispensing apparatus
14 is moving.
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[0057] 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.
[0058] At 312, the sealant dispensing apparatus is removed from the IOU
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 IOU 100. The
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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.
[0059] During use, and as illustrated in a second example method 400 of
FIG. 16,
at 402, the coordinates of the uncovered area 209 are determined by the
optical sensor 16,
the articulating arm 62 will couple to the tool connector 18, to couple the
sealant
dispensing apparatus 14 to the arm. At 404, the articulating arm 62 will move
the sealant
dispensing apparatus 14 to abut the IGU 100 as described above with regard to
step 304
of the example method 300 illustrated in FIG. 15. The nozzle 26 is aligned at
an initial
position to dispense sealant 40 beginning at the second end 209b (see FIG.
13).
[0060] 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.
[0061] 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
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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.
[0062] 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.
[0063] 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.
[0064] 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
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amendments made during the pendency of this application and all equivalents of
those
claims as issued.
[0065] 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.
[0066] 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.
[0067] 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
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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.
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