AUTOMATIC APPARATUS AND AUTOMATIC METHOD FOR HIGH-PRODUCTIVITY PRODUCTION OF THE INSULATING GLAZING UNIT CONSTITUTED BY AT LEAST TWO GLASS SHEETS AND AT LEAST ONE SPACER FRAME

Abstract

A high-productivity line for the automatic production of panels of an insulating glazing unit composed of at least two glass sheets and at least one spacer frame interposed between the glass sheets in a peripheral position, which delimit a closed internal volume in which the air is usually replaced with a gas and delimit an outer peripheral region or joint, along which one or more sealing/adhesive products applied between the faces of the glass sheets and of the spacer frame give tightness and stability to the joint, of the glass sheets at least one, indicated as of the second type, being subjected to a smaller quantity of processes than the other or others of the glass sheets, indicated as of the first type, the sheet or sheets of the glass sheets of the second type, subjected to the smaller quantity of processes, converging, by means of an oscillating conveyor, from a secondary line for the washing process in a main line for the process of edging, washing, laying of the spacer frame, optional closing of its fourth corner in the case of a flexible profile, placement of a grille only where and when their involvement begins, jointly with the glass sheets of the first type, in the composition of the insulating glazing unit.

Claims

1. A high-productivity line for the automatic production of panels of an insulating glazing unit composed of at least two glass sheets and at least one spacer frame interposed between said glass sheets in a peripheral position, which delimit a closed internal volume in which the air is usually replaced with a gas and delimit an outer peripheral region or joint, along which one or more sealing/adhesive products applied between the faces of said glass sheets and of said spacer frame give tightness and stability to the joint, of said glass sheets at least one, indicated as of the second type, being subjected to a smaller quantity of processes than the other or others of said glass sheets, indicated as of the first type, wherein the sheet or sheets of said glass sheets of the second type, subjected to said smaller quantity of processes, converge, by means of an oscillating conveyor, from a secondary line for the washing process in a main line for the process of edging, washing, laying of said spacer frame, optional closing of its fourth corner in the case of a flexible profile, placement of a grille only where and when their involvement begins, jointly with said glass sheets of the first type, in the composition of said insulating glazing unit.

2. The line according to claim 1, wherein the convergence between said secondary line and said main line is constituted by a Y-shaped coupling.

3. The line according to claim 1, wherein the convergence between said secondary line and said main line is constituted by a T-shaped coupling.

4. The line according to claim 1, wherein said oscillating conveyor constitutes alternately an element for the transit of said glass sheets of the first type in said main line and for the coupling of said glass sheets of the second type that arrive from said secondary line.

5. The line according to claim 4, wherein said oscillating conveyor also performs the function of expulsion, toward a reject line, of said glass sheets of the first type or of the second type that are contaminated by defects that prevent their use and therefore are nonconforming, and are indicated as NC.

6. The line according to claim 4, wherein said oscillating conveyor, by means of a 180 oscillation, also performs the function of reversing the arrangement of said glass sheets of the first type and optionally of the second type, in order to orient the face provided with nanocoating or with other surface treatments or other characteristics based on the orientation of the faces required for the composition of said insulating glazing unit.

7. An automatic method for the composition of an insulating glazing unit, the components of which are at least glass sheets, a spacer frame, one or more sealants/adhesives, and optionally other auxiliary components such as grilles, of said glass sheets at least one, indicated as of the second type, being subjected to a smaller quantity of processes than the other or others of said glass sheets, indicated as of the first type, wherein said glass sheet or sheets of the second type, subjected to said smaller quantity of processes, converge from a secondary line for the washing process in a main line for the process of edging, washing, laying of said spacer frame, optional closure of its fourth corner in the case of a flexible profile, placement of a grille only where and when their involvement begins, jointly with said glass sheets of the first type, in the composition of said insulating glazing unit.

8. The method according to claim 7, wherein the convergence region can also perform the function of unloading said glass sheets that are contaminated by defects that prevent their use and therefore are nonconforming and indicated as NC.

9. The method according to claim 7, wherein the convergence region between said secondary line and said main line can also perform the function of reversing the arrangement of said glass sheets in order to orient the face optionally provided with nanocoating or with other surface treatments or other characteristics according to the orientation of the faces that is required for the composition of said insulating glazing unit.

Description

DESCRIPTION OF THE DRAWINGS

[0058] FIG. 1 is a schematic view of the peripheral portion of the insulating glazing unit 1 in an exemplifying non-exhaustive series of possible combinations (the inside/outside orientation refers to the building): 1A double glazing (single chamber), 1B triple glazing (multiple chamber), 1C layered outer glazing, low-emissivity inner glazing; 1D reflective toughened outer glazing, low-emissivity layered inner glazing; 1E offset layered outer glazing, low-emissivity inner glazing (non-spread protruding portion), both glazings beveled along the entire perimeter; 1F offset and selective layered outer glazing (spread protruding portion), low-emissivity inner glazing; 1G like 1A but with the indication of the containment of gas 7 and both glazings beveled along the entire perimeter; 1H like 1A but with the spacer profile made of expanded synthetic material with the faces coated only with PSA adhesive, moreover comprising an internal grille and moreover with the inner glass sheet of the type with low-emissivity nanotechnology-based coating and with the outer glass sheet of the type with selective nanotechnology-based coating, both glazings beveled along the entire perimeter; 1L like 1A but with a spacer profile made of expanded synthetic material with the faces coated with PSA adhesive and PIB sealant.

[0059] FIGS. 1A-1G show the spacer frame 3 in its hollow transverse cross-section filled with hygroscopic material 4.

[0060] The two types of sealant used are highlighted: in black the butyl sealant 5 (first seal), having the function of initial bonding among the components and of seal both against the entry of humidity and the exit of the gas other than air applied between the lateral surfaces of the spacer frame 3 and the glazings 2, dashes indicating the polysulfide or polyurethane or silicone sealant 6 (second seal) having a mechanical strength function and sometimes, depending on the type of sealant, also acting as a seal both against the entry of humidity and the exit of the gas other than air applied between the outer surface of the spacer frame 3 and the faces of the glass sheets 2 up to the edge of the glass sheets 2 or to the edge of the glass sheet 2m having smaller dimensions.

[0061] In the situation of FIGS. 1H and 1L, the hygroscopic material 4 is embedded in the mass that constitutes the spacer profile 3 at the time of its manufacture.

[0062] The inside/outside orientation is identified visually with icons which represent the sun (outer side) and the radiator (inner side).

[0063] These FIGS. 1A-1L show that the insulating glazing unit 1 can have multiple shapes and that along the production line of the insulating glazing unit glass sheets 2 of the first type and glass sheets of the second type must coexist, since both types are almost always present in the same insulating glazing unit.

[0064] FIGS. 2a, 2b and 2c illustrate the background art, both as a block diagram (the blocks simulating the machine bodies), and as a composition of machines, with an elevation and plan view, related to the traditional insulating glazing unit production line having standard productivity.

[0065] FIGS. 3a, 3b and 3c illustrate the background art, both as a block diagram (the blocks simulating the machine bodies), and as a composition of machines, with an elevation and plan view, related to the traditional insulating glazing unit production line having high productivity.

[0066] FIGS. 4a, 4b and 4c illustrate the most recent background art, both as a block diagram (the blocks simulating the machine bodies), and as a composition of machines, with an elevation and plan view, related to the innovative insulating glazing unit production line having high productivity, shuttle system (Erdman).

[0067] The acronym HT stands for horizontal transfer (actuated by means of shuttles that move transversely, with respect to the plane of the line, the glass sheets 2 of the second type on a rear longitudinal transport conveyor that is coplanar with the main one).

[0068] FIGS. 5a, 5b and 5c illustrate the most recent background art, both as a block diagram (the blocks simulating the machine bodies), and as a composition of machines, with an elevation and plan view, related to the innovative insulating glazing unit production line having high productivity, bridge system (Lisec).

[0069] The acronym VT stands for vertical transfer (actuated by means of lifting feet which move, in the plane of the line and vertically, the glass sheets 2 of the second type on an upper longitudinal transport conveyor that is parallel to the main one).

[0070] FIG. 6 is the block diagram of the solution according to the present invention.

[0071] FIGS. 7a and 7b are elevation and plan views of the distribution of the machines according to the solution of the present invention, a distribution that can be termed Y-shaped, since a merging between the secondary line and the main line is used.

[0072] FIGS. 8, 9 and 10 are views of the oscillating conveyor that provides the Y node for merging the secondary line with the main line, respectively in the following views: front view, front view with some structures shown in dashes in order to make the inner and rear parts visible.

[0073] FIGS. 11a-11e are views of the arrangement of the oscillating conveyor in the respective situations: transit of a glass sheet of the first type; merging of a glass sheet of the second type; routing of said glass sheet of the second type; reversal of the arrangement of a sheet of the first type; expulsion of a glass sheet of the first or second type because it has to be discarded; the glass sheet 2 is shown, in each situation, in dashes and viewed downward from above, i.e., comprising in projection the effect of the inclination by 510 degrees.

[0074] For all the figures, where applicable, the following acronyms (derived from the corresponding terms in English) are used, referring to the process performed by the respective machine:

CR=EDGING

VW=WASHING

TSS=SPACER FRAME PLACEMENT

CT=CLOSING OF 4TH CORNER

GA=GRILLE APPLICATION

APG=FILLING WITH GAS, MATING AND PRESSING

SAHM=SECOND SEALING

HT=HORIZONTAL TRANSFER

VT=VERTICAL TRANSFER

ARC=OSCILLATING CONVEYOR

NC=CONVEYOR FOR NONCONFORMING GLASS SHEETS

P=MAIN LINE

S=SECONDARY LINE

R=REJECT LINE

[0075] The grinding step is not considered because it is required increasingly often in the complete version of full processing of the perimetric edge, i.e., over the entire thickness, and this requires moderate relative speeds between the tool and the glass sheet 2, and with a finishing which also entails tools changing, with the consequence of considerable cycle times; this step, therefore, is performed in machines which are external with respect to those of the production line of the insulating glazing unit 1, in order to avoid compromising the productivity of the apparatus, a productivity which, among the aim and objects of the present invention, is required to be high.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0076] A preferred method of providing the invention is the one of the block diagram of FIG. 6 and of the illustration of the machines of FIGS. 7a and 7b.

[0077] The path of the glass sheets of the first type, for a predominant part of the line, is kept not intersected or alternated by the path of the glass sheets of the second type and therefore the machines that perform the processings thereof (for example: perimetric removal of the nanocoating, application of the spacer frame, optional closing of its fourth corner in the case of a flexible profile, insertion of the grille), which instead do not involve the glass sheets of the second type, are optimized in terms of productivity.

[0078] Only at the merging point, indicated with Y in the mentioned figures, the glass sheets of the second type join the process, and this is optimum because the composition of the insulating glazing unit involves, only from that point onward, all the sheets for the processes of assembly, gas filling, pressing, and second sealing. The glass sheets of the second type merge at the Y merging point, after undergoing only the washing process, through an oscillating conveyor 100 that is aligned alternately either with the conveyors of the main path (main line P) or with the conveyor of the merging branch (secondary line S).

[0079] Apparently, in the line as a whole the washing machines are doubled, but since each one of them is used for a lower productivity, actually it is of a simpler type.

[0080] The use of labor for the feeding of the glass sheets (obviously in the case in which automation or robotics for loading are not used) remains unchanged, because instead of using the two operators at the beginning of the traditional high-productivity line, who moreover in this situation must follows a sometime complex sequence of loadings of the sheets of the first type and of the second type, they are stationed one at the beginning of the main line P and one at the beginning of the secondary line S (for merging) and are considerably facilitated in the loading logic, since the two types of glass sheet are physically separated.

[0081] These are the operating sequences of the line, referred to the type of insulating glazing unit of FIG. 1H, for which substantially all the typical processing stations, as described in the BACKGROUND ART chapter, are involved.

[0082] A premise regarding orientations must be kept in mind: the expression substantially vertical is understood to mean slightly inclined with respect to the vertical; in fact transport of the insulating glazing unit 1 occurs on conveyors the resting plane of which is inclined by approximately 6 degrees (510 degrees) with respect to the vertical plane, and likewise the rollers or other lower supporting/transport elements have their axis inclined by approximately 6 degrees (510 degrees) with respect to the horizontal plane, therefore when mention has been or will be made of substantially horizontal, slightly inclined with respect to the horizontal has been and will be intended.

[0083] With reference to FIG. 7, the glass sheet 2 of the first type is loaded, either manually or by means of a robot, in the inlet conveyor (left portion) of the main line and progressively undergoes the processes of: edging, washing, spacer frame laying, optional closure of its fourth corner in the case of a flexible profile, laying of the grille; while the glass sheet 2 of the second type arrives from the secondary line, along which it undergoes only the washing process, which merges into the main line.

[0084] The merging section is constituted by the oscillating conveyor 100, which is aligned, alternately and with a sequence managed by a programmable logic controller, either with the main line P for the transit of the glass sheets 2 of the first type or with the secondary line S for the merging and subsequent transit of the glass sheets 2 of the second type.

[0085] Moreover, said oscillating conveyor 100, in a configuration with suitable oscillation breadth, performs two further important functions:

[0086] # expulsion of the nonconforming glass sheets of the first type and second type, which otherwise would have to be unloaded manually along the main line or taken to the end of the main line and unloaded there;

[0087] # reversal of the orientation of the glass sheets of the second type (which in this unique case cannot be loaded from the secondary line S since they have to undergo edging and therefore become of the first type), by means of a 180-degree rotation, typically in order to reverse the arrangement of the glass face that bears the nanocoating, which for the process of peripheral removal (first machine of the series shown in FIGS. 7b and 7c) faces the working head, i.e., the operator, while for the subsequent processes, such as coupling with the other glass sheet or sheets in the composition of the insulating glazing unit 1, must face the conveyors (typical cases of FIGS. 1F and 1H, but not only), since this is the only possibility to obtain the necessary combination of the glass sheets 2 in the insulating glazing unit 1.

[0088] While the machines that constitute the main line P are part of the described background art and perform the processes that are also known and described in the BACKGROUND ART paragraph, and the washing machine of the arm of the secondary line S is part of this described background art too, the composition and the characteristics of the oscillating conveyor 100, in view of its function of constituting the Y node according to the inventive concept of the present invention, which modifies the sequence of the flow of the glass sheets 2 of the first type and the glass sheets 2 of the second type, are described hereinafter.

[0089] In FIGS. 7b, 11a-11e, the node Y is shown with an inclined convergence of the secondary line S toward the main line P, hence the Y designation, we might designate this node as T node if this convergence is at 90, although this is irrelevant for the purpose of the inventive concept.

[0090] The oscillating conveyor is divided essentially into a rear plane 101p, with a front plane 101a arranged opposite, both with a substantially vertical arrangement, for the resting and idle sliding of the glass sheets 2, and a conveyor 102, with a substantially horizontal arrangement, for the resting and motorized transport of the glass sheets 2, generally of the type with rollers or a belt, which cooperates with the rear plane 101p, the latter being adjustable while remaining parallel to itself along the direction C.

[0091] The planes 101a and 101p, moreover, can undergo an adjustment with respect to the vertical arrangement (here designated as truly vertical) in both directions, so that the resting and idle sliding planes, as well as the conveyor 102, can align themselves in a coplanar manner with the arrangement of the corresponding elements of the main line P in the alternating situations of the intermediate body 100b in 0 degree and 180 degree phase with respect to the main line P during the oscillation of said intermediate body 100b with respect to the footing 100a about the axis V.

[0092] As a whole, the upper body 100c and the intermediate body 100b constitute the oscillating part of the conveyor 100 on the footing 100a.

[0093] The oscillation of said intermediate body 100b, with respect to the footing 100a, about the axis V, in order to align said intermediate body 100b, in the 0 degree and 180 degree phases with respect to the main line as mentioned earlier and also in order to align said intermediate body 100b with the secondary merging line S and with the module NC for rejecting the defective sheets, is performed by rotating, about the pivot 103, the structure 104 provided with wheels 105 which run on the track 106 by means of the motor 107, which by means of the reduction gear 108 and the toothed pulley 109 (which is not visible and is not designated by numerals in the figures, but can be deduced) makes the entire intermediate body 100b oscillate with respect to the footing 100a by acting on the toothed belt 110, the ends of which and the containment track of which are integral with the footing 100a.

[0094] In the 0 degree and 180 degree phases (the second one being used in order to obtain the orientation of the face bearing the low-emissivity coating that is suitable for the type of insulating glazing unit to be manufactured, by way of non-exhaustive example one of those shown in FIGS. 1A-1L, particularly the ones of Figures IF, 1H), respectively the planes 101p and 101a must be aligned in a coplanar manner with the arrangement of the corresponding planes of the main line P, upstream if the glass sheet is being received at the oscillating conveyor, downstream if the glass sheet is being expelled from the oscillating conveyor (although these two arrangements are typically identical), or with the secondary line S, or with the line R for expelling the nonconforming NC glass sheets 2. For this purpose, the kinematic system constituted by the following is provided: motor 111, reduction gear 112, screw/female thread assembly 113 that actuates the tilting of the rear plane 101p/front plane 101a unit about the longitudinal axis H identified by the pivots 114a, 114b.

[0095] A further kinematic system is necessary in order to adapt the placement of the rear plane 101p, which in the 0 degree phase is at the rear stroke limit which corresponds to the alignment in coplanar mode with the conveyors of the main line P, to the thickness of the glass sheet 2, the need for adaptation deriving from the need to deposit the glass sheet 2 on the front plane 101a when it changes its angular phase by 180, i.e., if said glass sheet 2 must be reversed in its arrangement. During the tilting about the axis H, the distance between the rear plane 101p and the front plane 101a must in fact correspond to the thickness of the glass sheet 2, increased by a small clearance, in order to avoid shocks affecting the same sheet, which would be damaged and would not be coplanar with the downstream conveyor.

[0096] This kinematic system is constituted by the following actuators and components: motor 115, reduction unit 116, mechanical transmission 117, guides 118a, 118b, ball bearing sliders 119a, 119b, torsion bar 120 complete with gears and racks, kinematic system which adjusts the position of the rear plane 101p with respect to the front plane 101a along the transverse axis C.

[0097] To summarize, the essential mechanical components that identify the oscillation axis V (vertical), the tilting axis H (horizontal) and the adjustment axis C (transverse) are respectively; for the axis V, the pivot 103, which is integral with the footing 100a, interacting with the structure 104 of the intermediate body 100b; for the axis H, the pivots 114a, 114b, interacting between the structure 104 of the intermediate body 100b and the upper body 100c; for the axis C, the guides 118a, 118b.

[0098] As regards the conveyor 102, its motor drive belongs to the background art used in all the conveyors of the main line, regardless of whether they are of the roller or belt type, and consists essentially of the gearmotor 121 and the kinematic system 122, for example constituted by a chain and pinions.

[0099] Of course, all the movements connected to the steps of the cycle are mutually interlocked, with the aid of a logic system that is parallel but always active, in order to avoid, during the process, conditions of mutual interference between actuating elements and material being processed, except for those specific for the process.

[0100] Nevertheless, particular attention is given to the safety devices, for preventing injuries; such devices, shown schematically in FIGS. 2c, 3c, 4c, 5c, 7b, consisting of fixed barriers, interlocked movable barriers, optical barriers, electrosensitive mats, etcetera.

[0101] The present invention is susceptible of numerous constructive variations (with respect to what can be deduced from the drawings, the details of which are clear and eloquent), all of which are within the scope of the appended claims; thus, for example, the mechanical solutions for the handling and the adjustments of the oscillating/tilting conveyor, the electronic/mechanical solutions for them, etcetera, the actuation means, which can be electric, electrical-electronic, pneumatic, hydraulic and/or combined, etcetera, the control means that can be electronic or fluidic and/or combined, etcetera.

[0102] The constructive details may be replaced with other technically equivalent ones.

[0103] The materials and the dimensions may be any according to the requirements, particularly arising from the dimensions (base, height and thicknesses) and/or from the shape of the insulating glazing unit 1 to be produced starting from its components: glass sheets 2, spacer profile 3, hygroscopic material 4, sealants 5 (where present), 6, any gas 7, adhesive 8 (where present), grille 9 (where present).

[0104] The description and the figures cited above refer to lines located according to a left-to-right process flow; it is easy to imagine a description and corresponding figures in the case of mirror-symmetrical or otherwise different arrangements, for example that include variations in the direction of the line.

INDUSTRIAL APPLICATION

[0105] The industrial application is of assured interest, since insulating glazing unit production lines are by now configured for the manufacture of the multiple insulating glazing unit configurations, as presented in the first part of the description and partly exemplified in FIG. 1, i.e., they comprise a complete and complex variety of machines that is adapted to obtain all the required processes, but this has caused an implosion of the system, since some of the glass sheets, despite not needing some specific processes, nevertheless travel through the corresponding machines because they are in any case in series with respect to those that are instead necessary for the entirety of the process.

[0106] This implosion consists in the limitation of the cycle time, which, although improved in the past by increasing the process speeds, now is regressing due to the inactivity of some machines caused by the steps of mere transit of the glass sheets defined in the description as of the second type, which cause steps of waiting for the glass sheets of the first type that are intended instead for the corresponding process. On the contrary, since market trends are oriented toward the reduction of final product costs, insulating glazing unit production lines are required to be increasingly high-performing in terms of productivity, flexibility and optimization of the process. As regards productivity, while the typical values of the past were in the range of 500 units for shift, during the last two years the demand has almost tripled, hence the new type of lines described as the most recent background art. The present invention therefore enters, with further advantages, a market situation that is particularly rising, since insulating glazing units are increasingly in demand in relation to the requirements of buildings with high thermal and sound insulation, with safety for accident prevention, intrusion prevention, vandalism prevention, etcetera, but at the same time in a condition of price competitiveness, imposing such mentioned high-performing characteristics. And the solution according to the present invention is certainly at such a level of competitiveness that it is preferred with respect to the solutions, however innovative, proposed by the competition in the described recent background art.

[0107] The disclosures in Italian Patent Application No. 102017000071422 from which this application claims priority are incorporated herein by reference.

[0108] Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly, such reference signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference signs.