INDEPENDENTLY OPERATING INSULATED GLASS UNIT ASSEMBLY LINE AND METHOD

Abstract

An insulated glass assembly line generally includes a first and second automated lite picker, a washer, a vertical gas filling and wetting station, a robot, and an applicator station.

Claims

1. (canceled)

2. A manufacturing line for manufacturing insulated glass units, the manufacturing line comprising: a spacer applicator station, which receives a lite from a first conveyor and includes a first robot that grips a front surface of the lite and separates a back surface of the lite from the first conveyor by a distance sufficient to enable a spacer applicator to be positioned between the lite and the first conveyor, wherein the spacer applicator applies spacer material around perimeter edges of the back surface of the lite, thus forming a spacer applied lite; a vertical gas filling and wetting station that receives a wetting lite positioned on the first conveyor, wherein the first robot aligns the spacer applied lite with the wetting lite and brings the spacer material into contact with the wetting lite, and a gas source fills a cavity between the spacer applied lite and the wetting lite at least partially with a non-air gas into and the first robot presses the spacer applied lite and the wetting lite together, thus forming a primary sealed insulated glass unit; and a secondary sealing station.

3. The manufacturing line of claim 2, further comprising an infeed station that includes a lite picker and a lite storage rack.

4. The manufacturing line of claim 3, wherein the lite picker comprises an articulated robotic arm.

5. The manufacturing line of claim 2, wherein the vertical gas filling and wetting station further includes a gas fill enclosure comprising a moveable door shiftable between at least a gas filling position and a resting position, and a terminal door opposing the moveable door at a distance sufficient to accommodate the presence of the spacer applied lite and the wetting lite interposed between the terminal door and the moveable door.

6. The manufacturing line of claim 2, further comprising a roll press intermediate between the vertical gas filling and wetting station and the secondary sealing station.

7. The manufacturing line of claim 2, wherein the secondary sealing station includes a secondary sealant conveyor, a second robot adjacent the secondary sealant conveyor, and a secondary sealant applicator.

8. The manufacturing line of claim 7, wherein the second robot grips a front surface of the primary sealed insulated glass unit and separates a back surface of the primary sealed insulated glass unit from the secondary sealant conveyor.

9. The manufacturing line of claim 8, wherein the second robot moves the primary sealed insulated glass unit into alignment with the secondary sealant applicator, the secondary sealant applicator being positioned at least partially between the primary sealed insulated glass unit and the secondary sealant conveyor.

10. The manufacturing line of claim 9, wherein the secondary sealant applicator applies secondary sealant material around peripheral edges of the primary sealed insulated glass unit.

11. A method of manufacturing insulated glass units, the method comprising: interposing a spacer applicator between a lite separated from a first conveyor in a vertical orientation and the first conveyor; applying spacer material with the spacer applicator around perimeter edges of a back surface of the lite, thereby forming a spacer applied lite; aligning the spacer applied lite with a wetting lite positioned on the first conveyor, wherein the spacer material is between the spacer applied lite and the wetting lite; contacting the spacer material of the spacer applied lite to the wetting lite; filling a cavity between the spacer applied lite and the wetting lite at least partially with a non-air gas from a gas source; pressing the spacer applied lite and the wetting lite together, thereby forming a primary sealed insulated glass unit; and applying secondary sealant material around peripheral edges of the primary sealed insulated glass unit.

12. The method of claim 11, further including washing the lite before applying the spacer material.

13. The method of claim 11, further including conveying the lite from an infeed station to a spacer applicator station.

14. The method of claim 11, further including gripping a front surface of the lite and separating the back surface of the lite from the first conveyor before applying the spacer material.

15. The method of claim 11, further including the steps of: positioning a moveable door proximate an infeed side of a vertical support; shifting the moveable door between at least a gas-filling position and a resting position; and positioning a terminal door opposing the moveable door a distance away from the moveable door sufficient to accommodate the spacer applied lite and the wetting lite between the terminal door and the moveable door.

16. The method of claim 11, further including pressing the primary sealed insulated glass unit before applying the secondary sealant material.

17. The method of claim 11, further including transferring the primary sealed insulated glass unit to a secondary sealing station.

18. The method of claim 11, further including interposing a secondary sealant applicator between the primary sealed insulated glass unit separated from a secondary sealant conveyor in a vertical orientation and the secondary sealant conveyor.

19. The method of claim 11, further including gripping a front surface of the primary sealed insulated glass unit and separating a back surface of the primary sealed insulated glass unit from a secondary sealant conveyor before applying the secondary sealant material.

20. The method of claim 11, further including applying a corking material to at least one of a front surface of the primary sealed insulated glass unit and a back surface of the primary sealed insulated glass unit after applying the secondary sealant material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0072] Subject matter hereof may be more completely understood in consideration of the following detailed description of various embodiments in connection with the accompanying figures, in which:

[0073] FIG. 1 is a block diagram of an example insulated glass unit assembly sequence according to the prior art;

[0074] FIG. 2 is a perspective view of an insulated glass unit assembly line according to an example embodiment of the invention;

[0075] FIG. 3 is a perspective view of an insulated glass unit assembly line according to another example embodiment of the invention;

[0076] FIG. 4 is a perspective view of an insulated glass unit assembly line including a robotic glass picker and a first and second following robots according to an example embodiment of the invention;

[0077] FIG. 5 is a plan view comparing the floor plan and space requirements of a conventional insulated glass unit assembly line in comparison with an example embodiment of the invention;

[0078] FIG. 6 is a perspective view of a robotic automated lite picker according to an example embodiment of the invention;

[0079] FIG. 7 is a perspective view of the robotic automated lite picker of FIG. 6 in a different orientation;

[0080] FIG. 8 is a perspective view of the robotic automated lite picker of FIG. 6 in an orientation in which a light is placed on a vertical conveyor;

[0081] FIG. 9 is a perspective view of a glass gripper assembly with suction cups in an extended position;

[0082] FIG. 10 is a perspective view of the glass gripper assembly with the doctrine cups in a retracted position;

[0083] FIG. 11 is a perspective view of a gas filling and wetting station including a robot in a first orientation;

[0084] FIG. 12 is a perspective view of the gas filling and wetting station robot and a second orientation;

[0085] FIG. 13 is a perspective view of the gas filling and wetting station robot in a third orientation;

[0086] FIG. 14 is a perspective view of a gas filling enclosure;

[0087] FIG. 15 is a perspective view of a spacer applicator robot and a spacer applicator station according to an example embodiment of the invention;

[0088] FIG. 16 is another perspective view of the spacer applicator robot and the spacer applicator station according to an example embodiment of the invention;

[0089] FIG. 17 is another perspective view of the spacer applicator robot and spacer application station according to an example embodiment of the invention;

[0090] FIG. 18 is another perspective view of the spacer applicator robot and spacer application station;

[0091] FIG. 19 is a perspective view of a spacer applicator head according to an example embodiment of the invention; and

[0092] FIG. 20 is a perspective view of a secondary sealant applicator head according to an example embodiment of the invention.

[0093] While various embodiments are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the claimed inventions to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.

DETAILED DESCRIPTION

[0094] Referring to FIG. 1, an example prior art assembly line 100 and method is depicted in a block diagram. According to the example prior art, in-feed station 102 is followed by washer station 104. Washer station 104 is followed by inspection station 106. Inspection station 106 transfers insulated glass lites to the spacer application station 108 at which spacer material is applied to an insulated glass lite. The spacer applied light is then conveyed to outfeed station 110 and further conveyed to topping and gas filling station 112. At topping and gas filling station 112 a second light is applied on an opposing side of the spacer material from the first lite to create an insulated glass unit which is primary sealed. In addition, a non-air gas, such as argon, is optionally placed within the space between the lites formed by the spacer material to increase the energy efficiency of the insulated glass unit. The insulated glass unit is next conveyed to out-feed station 114 and then to secondary sealant station 116. At secondary sealant station 116, secondary sealant is applied around a periphery of the insulated glass unit. The completed insulated glass unit is then transferred to out-feed station 118, from which it is removed for storage and/or delivery. As can be seen, the prior art manufacturing approach includes many steps and results in an assembly line of considerable length, requiring a substantial amount of physical space in a manufacturing facility. In the conventional facility depicted in FIG. 5, the length is approximately 157′9″ with the capability of processing insulated glass units up to ten feet in length.

[0095] Referring now to FIG. 2, an example insulated glass assembly line 120 according to an example embodiment of the invention is depicted. Insulated glass assembly line 120 generally includes first automated lite picker 122, second automated lite picker 124, lite washer 126, vertical gas filling and wetting station 128, robot 130, applicator station 132 and IGU storage racks 134.

[0096] First automated lite picker 122 generally includes ground engaging support 136, vertical conveyor 138, picker arm 140 and lite storage rack 142.

[0097] Ground engaging support 136 supports vertical conveyor 138. Vertical conveyor 138 generally includes support platform 144, conveyor 146 and support frames 148. Support platform 144 and conveyor 146 present a horizontal surface upon which lites 150 rest as lites 150 are conveyed along IGU assembly line 120 by movement of conveyor 146.

[0098] Conveyor 146 may conveniently be made as a belt conveyor or a roller conveyor. Other conveyors known to those skilled in the art may be utilized as well.

[0099] Support frames 148 generally include pre-picker arm support frame 152 and post picker arm support frame 154. Each of support frames 148 present roller beams 156. Roller beams 156 may include roller wheels, roller bearings or other roller structures.

[0100] Picker arm 140 is supported by picker arm vertical support column 158. Picker arm 140 generally includes extension arm track 162 coupled to and supported by picker arm vertical support column 158 and extension arm slide 164 which is slidably supported within extension arm track 162. Extension arm slide 164 and extension arm track 162 cooperate in much the same fashion as a drawer slide and track. Extension arm slide is coupled to and supports glass gripper 166, which is configured to grip and support lites 150 typically by the application of vacuum or suction. Substantially vertical, in this context, means that the lites are held at an orientation that is less than about 25 degrees of true vertical. More typically, the lites are held within 6 to 10 degrees of true vertical, for example, at 6 degrees of true vertical.

[0101] First lite storage rack 142 is located substantially opposite from first automated lite picker and is structured to support lites 150 and is tilted slightly backwards from vertical so that lites 150 are held in place by gravity.

[0102] Second automated lite picker 124 is substantially similar to first automated lite picker 122 and includes similar structures to first automated lite picker 122. Therefore, second automated lite picker 124 will not be further described here.

[0103] Lite washer 126 is generally conventional in design and known to those of skill in the art. Lite washer 126 is structured to wash lites 150 and need not further be described here.

[0104] Vertical gas filling and wetting station 128 generally includes vertical conveyor 168 and gas fill enclosure 170.

[0105] Vertical conveyor 168 generally includes vertical support 172. Vertical support 172 includes in feed 174, outfeed 176, rear wall 178 and conveyor 180. In feed 174 is located proximate lite washer 126.

[0106] Gas fill enclosure 170 includes in feed side movable door 182 and terminal door 184. Movable door 182 may be located at an in-feed side of gas fill enclosure 170, for example proximate to in-feed side 174, and is shiftable between a gas filling position and a resting position. Terminal side door 184 may be located at a terminal side of gas fill enclosure 170, for example proximate to out-feed side 176, and is optionally shiftable between a gas filling position and a resting position. Gas fill enclosure 170 also includes gas source 186. At least one of movable door 182 and terminal door 184 may include nozzles or ports (not shown) in fluid communication with gas source 186. Alternatively, gas source 186 may be in fluid communication with conveyor 180 so that the gas is injected from the bottom of gas fill enclosure 170. Additional embodiments may include other structures or positions for gas source 186. Robot 130 generally includes robot support track 188, robot base support platform 190 and articulated robot arm assembly 192. Robot base support platform 190 is supported by robot support track 188. Robot base support platform 190 in turn, supports articulated robot arm assembly 192.

[0107] Robot support track 188 generally includes support rails 194 and perpendicular applicator track coupling 196. Support rails 194 stabilize robot support track 188.

[0108] Robot base support platform 190 includes movable robot dolly 198. Movable robot dolly 198 is movably supported on robot support track 188 to facilitate travel of robot 130 along robot support track 188.

[0109] Articulated robot arm assembly 192 generally includes movable robot arm 198 and glass gripper head 200. Articulated robot arm assembly 192 and glass gripper head 200 are of sufficient strength and mobility to support the largest size of insulated glass units expected to be processed.

[0110] Spacer application station 108 generally includes applicator track 202, spacer applicator 204 and secondary sealant applicator 206. In the depicted example embodiment, applicator track 202 is coupled to robot support track 188 at perpendicular applicator track coupling 196. Spacer applicator 204 and secondary sealant applicator 206 are movable along applicator track 202. Applicator track 202 is oriented generally parallel to insulated glass assembly line 120. Applicator track has first end 208 and second end 210. In the depicted embodiment, spacer applicator 204 has a resting position proximate first end 208 and secondary sealant applicator 206 has a resting position proximate second end 210. In the depicted embodiment, applicator track 202 includes parallel horizontal rails 212, but other configurations are also possible.

[0111] Spacer applicator 204 generally includes spacer applicator base 214, spacer applicator support column 216, spacer applicator vertical traveler support 218, spacer applicator head 220, and spacer storage unit 222. Spacer applicator base 214 rests movably on horizontal rails 212 of applicator track 202 and supports spacer applicator support column 216. Spacer applicator vertical traveler support 218 is coupled to spacer applicator support column 216, along which spacer applicator vertical traveler 218 can move vertically. Spacer applicator head 220 is movably coupled to spacer applicator vertical traveler support 218 on which spacer applicator head 220 can move rotationally and vertically. Spacer applicator head 220 is operably coupled to spacer storage unit 222 to receive a supply of spacer material.

[0112] Spacer storage unit 222 in the depicted embodiment generally includes flexible spacer applicator head coupling 224, spacer supply conduit 226 and stored spacer material 228.

[0113] Secondary sealant applicator 206 generally includes secondary sealant applicator base 230, secondary sealant support column 232, secondary sealant vertical traveler support 234 and secondary sealant applicator head 236. Secondary sealant applicator base 230 is movably supported by applicator track 202. Secondary sealant applicator base 230 supports secondary sealant support column 232, which in turn supports secondary sealant vertical traveler support 234. Secondary sealant vertical traveler 234 can move vertically along secondary sealant support column 232. Secondary sealant applicator head 236 is movably coupled to secondary sealant vertical traveler support 234, on which secondary sealant applicator head 236 can move rotationally and vertically. Secondary sealant applicator head 236 is coupled in fluid communication with a supply of secondary sealant (not shown).

[0114] IGU storage racks 134 are adapted to receive and store completed insulated glass units. IGU storage racks 134 are conventional in design and need not be further described here. They are, however, very similar in structure to the lite storage racks 142.

[0115] Referring to FIG. 3, an alternate embodiment of the invention is depicted. According to the embodiment depicted in FIG. 3 first robot 130 and second robot 238 are utilized. First robot 130 and second robot 238 are similar or identical in structure and need not be further described here. The depicted embodiment also includes topping and gas filling station 112 as well as a following station 240. Following station 240 is similar to topping and gas filling station 112 but need not include any gas filling structures.

[0116] Referring to FIG. 4, another alternative embodiment of the invention is depicted. This embodiment includes robotic lite picker 242 and robotic vertical conveyor 244. It is notable that this embodiment, like the other embodiments the invention disclosed by this specification, is substantially shorter in length than a conventional insulated glass processing facility. As can be seen by reference to FIG. 5, the depicted embodiment has an approximate length of 62′6″ for a facility that is adapted to process insulated glass units up to ten feet in length. This example represents a space savings of approximately 60% over the example conventional insulated glass processing facility.

[0117] Robotic glass lite picker 242 generally includes robot base support platform 246, articulated robot arm assembly 248, glass gripper head 250 and roller beams 252. Robot base support platform 246 supports articulated robot arm assembly 248 which in turn supports glass gripper head 250 and roller beams 252. Glass gripper head 250 is arranged relative to roller beams 252 to grip glass lites 150 while glass lights 150 are in contact with or proximate to roller beams 252.

[0118] Robotic vertical conveyor 244 generally includes roller beams portion 254 and robot pass-through portion 256. The roller beams portion 254 is generally similar to roller beams 156. However, robot pass-through portion 256 is sized and shaped to accommodate roller beams 252 when articulated robot arm assembly 248 is aligned in generally coplanar alignment with roller beams portion 254.

[0119] Robotic glass lite picker 242 may be located in front of robotic vertical conveyor 244 or, as depicted in FIG. 4, behind robotic vertical conveyor 244. The embodiment of the invention depicted in FIG. 4 has an even smaller footprint and shorter length than the embodiments depicted in FIG. 2 and FIG. 3.

[0120] In contrast to the embodiment depicted in FIG. 3, in the embodiment of FIG. 4, second robot 238 is located behind secondary sealing station 258. In the depicted embodiment, the second robot 238 includes glass gripper head 260 coupled to roller beams 262. Secondary sealant conveyor 264 located at secondary sealing station 258 is similar to robotic vertical conveyor 244 in that it includes roller beams portion 254 and robot pass-through portion 266. This structure enables glass gripper head 260 with roller beams 262 to receive a primary sealed IGU, and to support and present the primary sealed IGU for secondary sealant application.

[0121] FIGS. 6, 7 and 8 to depict various positions of robotic lite picker 242 as articulated during a manufacturing process.

[0122] Referring to FIG. 6, robotic lite picker 242 is depicted along with robotic vertical conveyor 244 and lite washer 126. Lite storage racks 142 are depicted as well. Glass gripper head 250, in this depiction, is located proximate to first lite storage rack 142.

[0123] Referring to FIG. 7, robotic lite picker 242 is depicted with glass gripper head 250 located proximate to second lite storage rack 142.

[0124] Referring to FIG. 8, robotic lite picker 242 is depicted with glass gripper head 250 located proximate robotic vertical conveyor 244. Here, glass gripper head 250 is generally aligned with roller beams 252 by motion of articulated robot arm assembly 248 so that glass lite 150 can be transferred to robotic vertical conveyor 244. Glass gripper head 250 can pass through robot pass-through portion 256 and align glass lite 150 with roller beams portion 254 so that the glass lite 150 can be conveyed by robotic vertical conveyor 244. Two lite storage racks 142 are present to accommodate the use of two different types of glass lites 150 in the manufacturing process. As discussed elsewhere in this application, one glass lite 150 may have a low E coating that facilitates improved energy efficiency. Another, glass lite 150 may lack such a coating. The 2 lite storage racks 142 each accommodate one of the types of glass lites 150.

[0125] Referring to FIGS. 9 and 10, an example embodiment of glass gripper head 250 is depicted.

[0126] In FIG. 9, glass gripper head 250 is depicted with glass grippers 166 spread apart which is useful when gripping and supporting larger glass lites 150.

[0127] In FIG. 10, glass gripper head 250 is depicted with glass grippers 166 moved closer together which is useful when gripping and supporting smaller glass lites 150. FIGS. 9 and 10 also depict an alternative embodiment of roller beams 252 as compared to for example, FIG. 4.

[0128] Referring now to FIGS. 11, 12 and 13, robotic glass filling and wetting station 128 is depicted.

[0129] In FIG. 11, third robot 238 is depicted supporting glass lite 150 proximate glass filling and wetting station 128 such that glass lite 150 with spacer material applied can be mated with a further glass lite 150 for gas filling and to create an insulated glass unit.

[0130] Referring to FIG. 12 a completed insulated glass unit is supported by third robot 238 proximate lite storage rack 142 in which completed insulated glass units may be stored.

[0131] Referring to FIG. 13, second robot 238 is depicted mating a spacer applied lite 150 to a further glass lite 150 during the gas filling and wetting process.

[0132] Referring now to FIG. 14, vertical gas filling and wetting station 128 is depicted including vertical conveyor 168. Vertical conveyor 168 includes vertical support 172 and in feed side movable door 182, terminal side door 184 and gas source 186. In the depicted embodiment both in feed side movable door 182 terminal side door 184 are movable to accommodate various sized insulated glass units.

[0133] Referring now to FIGS. 15, 16, 17, and 18, applicator station 132 is depicted along with third robot 238. In each of these FIGS., third robot 238 is depicted supporting glass lite 150 proximate spacer applicator 204 at which spacer material is applied to a back side of the glass lite 150.

[0134] In FIG. 15, spacer applicator head 220 is depicted at the beginning of spacer application proximate an upper right corner of the glass lite 150.

[0135] In FIG. 16, spacer applicator head 220 is depicted at a lower right corner of glass lite 150 having applied spacer material to the right edge glass lite 150.

[0136] In FIG. 17, spacer applicator head 220 is depicted at a lower left corner of glass lite 150 having applied spacer material to the right edge of glass lite 150 and the bottom edge of glass lite 150.

[0137] In FIG. 18, spacer applicator head 220 is depicted at an upper left corner of glass lite 150 having applied spacer material to the right edge of glass lite 150, the bottom edge of glass lite 150 and the left edge of the glass lite 150. Spacer applicator head 220 that applies spacer to a top edge of the glass lite 150 returning to the position depicted in FIG. 15.

[0138] Referring now to FIG. 19, spacer applicator head 220 is depicted in isolation. Features of spacer applicator head 220 are known to those skilled in the art and need not be further described here.

[0139] Referring now to FIG. 20 secondary sealant applicator head 236 in isolation. Features of secondary sealant applicator head 236 are known to those skilled in the art need not be further described here.

[0140] In operation, referring to FIGS. 2, 6, 7 8 and 6-18, glass lites 150 are transferred from lite storage racks 142 to vertical conveyor 138 by first automated lite picker 122 and second automated lite picker 124 or by robotic lite picker 242. The use of first automated lite picker 122 and second automated lite picker 124 accommodates the use of lites 150 that are coated on one side. Lites 150 with a coating on the side facing first automated lite picker 122 are placed in one lite storage rack 142 while lites 150 with a coating on the side facing away from second automated lite picker 124 are provided in second lite storage rack 142.

[0141] Extension arm slide 164 extends outwardly from extension arm track 162 until glass gripper 166 makes contact with lites 150. Glass gripper 166 is activated to grip lite 150. Extension arm slide 164 then retracts into extension arm track 162 and lite 150 is released on vertical conveyor 168. Lites 150 are then conveyed through washer station 104 where they are cleaned.

[0142] After cleaning, lites 150 are conveyed to vertical gas filling and wetting station 128 where robot 130 or 238 engages lite 150 with glass gripper head 200. Robot 130 4 to 38 then lifts lites 150 into a position parallel to spacer application station 108.

[0143] Spacer applicator head 220 applies spacer around the perimeter of lites 150. It is notable that spacer applicator head 220 applies spacer on the back side of lites 150, that is, the side of lites 150 facing the insulated glass assembly line 120. This is contrary to known prior art.

[0144] While spacer is being applied to lite 150, a further lite 150 passes through washer station 104 into position at topping and gas filling station 112. Robot 130 or 238 then places lite 150, fitted with the spacer, against lite 150 that is at topping and gas filling station 112 and presses the two lites 150 together to create a primary seal.

[0145] The insulated glass unit thus formed is then lifted from topping and gas filling station 112 and brought into alignment with secondary sealant station 116 so that secondary sealant applicator 206 can apply secondary sealant to the peripheral edges of the insulated glass unit. When the insulated glass unit is complete, robot 130 places the insulated glass unit onto one of IGU storage racks 134.

[0146] Referring to FIG. 3, operation of this alternative embodiment is similar to the embodiment depicted in FIG. 2 until the insulated glass unit is assembled with the primary seal. In this alternative embodiment, the first robot 130 returns the insulated glass unit to topping and gas filling station 112. The insulated glass unit is then conveyed to following station 240 where second robot 238 lifts the insulated glass unit and presents the insulated glass unit to secondary sealant applicator head 236 for application of the secondary seal. After secondary sealant applicator head 236 applies the secondary sealant to the insulated glass unit, second robot 238 places the completed insulated glass unit on IGU storage racks 134. The manufacturing cycle then repeats. Of course, earlier stations of insulated glass assembly line 120 may be in operation when materials are passed to later stations so that insulated glass units may be manufactured continuously.

[0147] Referring to FIG. 4, in the depicted embodiment lites 150 are removed from lite storage racks 142 by robotic lite picker 242. Lites 150 are then transferred by robotic lite picker 242 to robotic vertical conveyor 244. In doing so, roller beams 252 associated with glass gripper head 250 are aligned to be coplanar with roller beams portion 254 of robotic vertical conveyor 244. Glass gripper head 250 releases lite 150, and lite 150 is conveyed into and through lite washer 126 where lite 150 is cleaned.

[0148] Lites 150 are then conveyed out of lite washer 126 to vertical gas filling and wetting station 128. A first lite 150 is then lifted from the vertical gas filling and wetting station 128 by first robot 130. First robot 130 then positions lite 150 in alignment with the applicator station 132 where spacer applicator 204 applies spacer material to four edges of lite 150. Meanwhile a second lite 150 has been picked and sent through lite washer 126 to vertical gas filling and wetting station 128. After spacer material is applied to first lite 150 supported by the first robot 130, first robot 130 then brings first lite 150, including spacer material that has been applied, into contact with second lite 150 that is positioned at vertical gas filling and wetting station 128. Gas filling is accomplished prior to the complete mating of first lite 150 and second lite 150. Once the gas filling is completed at vertical gas filling and wetting station 128, first robot 130 presses the two lites 150 together with spacer material in between. First robot 130 then releases primary sealed insulated glass unit, which is then conveyed from vertical gas filling and wetting station 128 to secondary sealing station 258 in the vicinity of second robot 238. Optionally, the primary sealed insulated glass unit may pass through roll press 266 which then presses the insulated glass unit which has been primary sealed to assure good contact between the applied spacer and lites 150.

[0149] The insulated glass unit is then received by secondary sealing station 258, roller beams 252 of second robot 238 and roller beams portion 254 of secondary sealing station 258. While the insulated glass unit is conveyed, roller beams 252 adjacent to glass gripper head 250 are positioned coplanar with roller beams portion 254 of secondary sealing station 258. Once the insulated glass unit is in position, glass gripper head 250 of second robot 238 is actuated to grip the lite 150 of the insulated glass unit. Second robot 238 then lifts the insulated glass unit and positions it in alignment with secondary sealant applicator 206.

[0150] Secondary sealant applicator head 236 then travels about the perimeter of the insulated glass unit to apply secondary sealant to the peripheral edges of the IGU. Once the secondary sealant is completely applied, second robot 238 transfers the completed insulated glass unit to IGU storage racks 134. Optionally, corking applicator station 270 may be utilized to apply corking material to one or both external surfaces of the insulated glass unit. Corking is utilized to provide a separation between adjacent insulated glass units on IGU storage racks 134 by application of cork spacers or spacers of other material. The manufacturing cycle then repeats. Of course, earlier stations of insulated glass assembly line 120 may be in operation when materials are passed to later stations so that insulated glass units may be manufactured continuously.

[0151] Various embodiments of systems, devices, and methods have been described herein. These embodiments are given only by way of example and are not intended to limit the scope of the claimed inventions. It should be appreciated, moreover, that the various features of the embodiments that have been described may be combined in various ways to produce numerous additional embodiments. Moreover, while various materials, dimensions, shapes, configurations and locations, etc. have been described for use with disclosed embodiments, others besides those disclosed may be utilized without exceeding the scope of the claimed inventions.

[0152] Persons of ordinary skill in the relevant arts will recognize that the subject matter hereof may comprise fewer features than illustrated in any individual embodiment described above. The embodiments described herein are not meant to be an exhaustive presentation of the ways in which the various features of the subject matter hereof may be combined. Accordingly, the embodiments are not mutually exclusive combinations of features; rather, the various embodiments can comprise a combination of different individual features selected from different individual embodiments, as understood by persons of ordinary skill in the art. Moreover, elements described with respect to one embodiment can be implemented in other embodiments even when not described in such embodiments unless otherwise noted.

[0153] Although a dependent claim may refer in the claims to a specific combination with one or more other claims, other embodiments can also include a combination of the dependent claim with the subject matter of each other dependent claim or a combination of one or more features with other dependent or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.

[0154] Any incorporation by reference of documents above is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of documents above is further limited such that no claims included in the documents are incorporated by reference herein. Any incorporation by reference of documents above is yet further limited such that any definitions provided in the documents are not incorporated by reference herein unless expressly included herein.

[0155] For purposes of interpreting the claims, it is expressly intended that the provisions of 35 U.S.C. § 112(f) are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim.