INSULATED GLASS UNIT MANUFACTURING STATION AND ASSEMBLY LINE WITH CONTROLLED HEATING OF SPACER

Abstract

A heating station for use with, for example, a high speed parallel manufacturing line for manufacturing insulated glass units, the heating station including at least two opposing infrared heaters that linearly heat spacer material that includes integrated temperature sensitive adhesive. Each of multiple linear infrared heaters includes a respective associated temperature sensor. The infrared heater and temperature sensor are coupled to a spacer heating controller that controls intensity and/or duration of heating of the spacer material and adhesive to provide optimal wetting and adhesive qualities. Individual control of the at least two opposing linear infrared heaters compensates for variable environmental conditions affecting spacer material at different locations around and insulated glass unit.

Claims

1. A method of facilitating adhesion of spacer material having an integrated adhesive to lites of an insulating glass unit (IGU), comprising: individually monitoring a local temperature of portions of the spacer material, portions of an adhesive associated with the single seal spacer material or both at at least one location of the portions where the adhesive is in contact or proximate contact with the lites of the insulated glass unit; identifying the portions of the spacer material where a local temperature of the adhesive is below a desired temperature to facilitate adhesion; selectively applying focused infrared energy to at least the portions of the single seal spacer material where the local temperature of the adhesive is below a desired temperature to facilitate adhesion.

2. The method as claimed in claim 1, further comprising utilizing at least one temperature sensor on a first linear side of the IGU to sense temperature on the first linear side and controlling a focused linear infrared heater to apply the focused infrared energy to the one linear side.

3. The method as claimed in claim 1, further comprising selectively applying focused infrared energy by increasing an intensity of the focused infrared energy.

4. The method as claimed in claim 1, further comprising selectively applying focused infrared energy by increasing a duration of application of the focused infrared energy.

5. The method as claimed in claim 4, further comprising increasing the duration of application of the focused infrared energy by adjusting a speed of movement of a conveyor supporting and moving the insulated glass unit or adjusting movement of a servomotor associated with an infrared heater.

6. The method as claimed in claim 4, further comprising increasing the duration of application of the focused infrared energy by adjusting a speed of movement of a source of the focused infrared energy relative to the insulated glass unit.

7. The method as claimed in claim 1, further comprising individually monitoring the local temperature by use of at least one temperature sensitive camera.

8. The method as claimed in claim 1, further comprising individually monitoring the local temperature by use of a temperature sensor.

9. The method as claimed in claim 1, further comprising individually monitoring a local temperature by utilizing eight temperature sensors located on two opposing sides of four edges of the insulated glass unit and selectively applying focused infrared energy by utilizing eight focused infrared energy sources located on the two opposing sides of the four edges of the insulated glass unit.

10. A heating station for manufacturing insulated glass units, the heating station comprising: a conveyor configured to convey an insulated glass unit; at least two infrared heaters located on opposing sides of the conveyor; at least two temperature sensors located on the opposing sides of the conveyor directed to individually monitor a local temperature of portions of a spacer material of the insulated glass unit, portions of an adhesive associated with the single seal spacer material or both proximate at least one location of the portions where the adhesive is in contact or proximate contact with the lites of the insulated glass unit; a controller in operable communication with the at least two temperature sensors receiving input from the at least two temperature sensors; the controller further being in operable controlling communicating with the conveyor, the at least two infrared heating sources or both; the controller being configured to identify the portions of the single seal spacer material where the local temperature of the adhesive is below a desired temperature to facilitate adhesion; and the controller controlling the at least two infrared heaters to selectively applying focused infrared energy to at least the portions of the single seal spacer material where the local temperature of the adhesive is below a desired temperature to facilitate adhesion.

11. The heating station as claimed in claim 10, further comprising at least two servomotors operably coupled to the at least two infrared heaters.

12. The heating station as claimed in claim 10, wherein the at least two infrared heaters comprise focused linear infrared heaters.

13. The heating station as claimed in claim 10, the controller being further configured to selectively apply focused infrared energy by operating the at least two infrared heaters to increase or decrease an intensity of the focused infrared energy.

14. The heating station as claimed in claim 10, the controller being further configured to selectively apply focused infrared energy by operating the at least two infrared heaters to increase or decrease duration of application of the focused infrared energy.

15. The heating station as claimed in claim 14, the controller being further configured to selectively apply focused infrared energy by operating the at least two infrared heaters to increase or decrease the duration of application of the focused infrared energy by adjusting a speed of movement of the conveyor supporting and moving the insulated glass unit.

16. The heating station as claimed in claim 14, the controller being further configured to selectively apply focused infrared energy by operating the at least two infrared heaters to increase or decrease the duration of application of the focused infrared energy by adjusting a speed of movement of the at least two infrared heaters relative to the insulated glass unit.

17. The heating station as claimed in claim 10, wherein the at least two temperature sensors comprise temperature sensitive cameras.

18. The heating station as claimed in claim 10, wherein the at least two infrared heaters comprise eight linear infrared heaters located on two opposing sides of four edges of the insulated glass unit and the at least two temperature sensors comprise eight temperature sensors located on the two opposing sides of the four edges of the insulated glass unit.

19. The heating station as claimed in claim 18, wherein each of the eight temperature sensors located on the two opposing sides of the four edges of the insulated glass unit senses a local temperature of the adhesive associated with the spacer material on one side of one edge of the insulated glass unit and is communicatively coupled with the spacer heating controller.

20. The heating station as claimed in claim 19, wherein each of the eight linear infrared heaters located on the two opposing sides of the four edges of the insulated glass unit is focused to apply heat proximate the adhesive located on the two opposing sides of the four edges of the insulated glass unit under individual control of the spacer heating controller to thereby maintain the adhesive at or above a desired temperature to facilitate adhesion between the adhesive and lites of the insulated glass unit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0079] 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:

[0080] FIG. 1 is a block diagram depicting a high speed parallel process insulating glass manufacturing line according to an example embodiment of the invention;

[0081] FIG. 2 is an end elevational view of an IGU spacer applicator according to an example embodiment of the invention;

[0082] FIG. 3 is a schematic depiction of an IGU spacer applicator at the beginning of spacer application to a spacer applied lite;

[0083] FIG. 4 is a schematic depiction of an IGU spacer applicator during spacer application to a spacer applied lite bottom edge;

[0084] FIG. 5 is a schematic depiction of an IGU spacer applicator during spacer application to a spacer applied lite trailing edge;

[0085] FIG. 6 is a schematic depiction of an IGU spacer applicator beginning spacer application to a spacer applied lite top edge;

[0086] FIG. 7 is a schematic depiction of an IGU spacer applicator continuing spacer application to a spacer applied lite top edge;

[0087] FIG. 8 is a schematic depiction of an IGU spacer applicator during spacer application to a spacer applied lite leading edge;

[0088] FIG. 9 is a schematic depiction of a dual head IGU secondary sealer at the initiation of an IGU sealing sequence;

[0089] FIG. 10 is a schematic depiction of a dual head IGU secondary sealer as a first sealing head applies secondary sealant to a leading edge of an insulated glass unit and a second sealing head engages the bottom edge of the insulated glass unit;

[0090] FIG. 11 is a schematic depiction of a dual head IGU secondary sealer as a first sealing head applies secondary sealant to a top edge of an insulated glass unit and a second sealing head applies sealant to the bottom edge of the insulated glass unit;

[0091] FIG. 12 is a schematic depiction of a dual head IGU secondary sealer as the first sealing head completes application of secondary sealant to a top edge of an insulated glass unit and the second sealing head completes application of sealant to the bottom edge of the insulated glass unit;

[0092] FIG. 13 is a schematic depiction of a dual head IGU secondary sealer as the first sealing head applies secondary sealant to a trailing edge of an insulated glass unit and a second sealing head disengages from the bottom edge of the insulated glass unit;

[0093] FIG. 14 is an elevational view of a double gas press according to an embodiment of the invention;

[0094] FIG. 15 is an elevational view of a single gas press according to an embodiment of the invention;

[0095] FIG. 16 is a block diagram depicting a high speed parallel process insulating glass manufacturing line with gas filling according to another example embodiment of the invention;

[0096] FIG. 17 is a front elevational view of a heating station according to an example embodiment;

[0097] FIG. 18 is a side elevational view of the heating station of claim 17;

[0098] FIG. 19 is perspective view of a vertical sealing roller press according to an example embodiment of the invention;

[0099] FIG. 20A is a perspective view of a vertical sealing platen press according to an example embodiment of the invention;

[0100] FIG. 20B is a perspective view of a gas fill manifold assembly according to an example embodiment of the invention;

[0101] FIG. 21A is a perspective view of a fourth corner sealer incorporating a roller according to an example embodiment of the invention;

[0102] FIG. 21B is a detail perspective view of a fourth corner sealer roller according to an example embodiment of the invention;

[0103] FIG. 22 is a perspective view of a fourth corner sealer incorporating an angled rocking structure according to an example embodiment of the invention;

[0104] FIG. 23 is a perspective view of a two part angled fourth corner sealer according to an example embodiment of the invention;

[0105] FIG. 24 is a perspective view of a fourth corner infrared heater according to an example embodiment of the invention;

[0106] FIG. 25 is a perspective view of an auto-topping press according to an example embodiment of the invention;

[0107] FIG. 26 is a schematic block diagram of temperature sensors, infrared heaters and a closed loop feedback arrangement including a controller and heating station conveyor according to an example embodiment of the invention;

[0108] FIG. 27 is a schematic horizontal cross-sectional view of an insulated glass unit and four linear infrared heaters oriented vertically as well as four temperature sensors according to an example embodiment of the invention;

[0109] FIG. 28 is a schematic vertical cross-sectional view of the insulated glass unit of FIG. 27 and four linear infrared heaters oriented horizontally as well as four temperature sensors according to an example embodiment of the invention; and

[0110] FIG. 29 is a schematic partial depiction of an insulated glass unit and single seal spacer according to an example embodiment of the invention.

[0111] 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 OF THE DRAWINGS

[0112] Referring to FIG. 1 according to an example embodiment of the invention, high speed parallel process insulating glass manufacturing line 50 generally includes infeed station 52, washer 54, inspection station 56, shuttle 58, driven parallel infeed conveyor 60, IGU spacer applicator 62, following queue station 64, driven grid station 66, second queue station 68, gas press and fill station 70, secondary edge sealer 72, and non-driven outfeed queue station 74. This example embodiment may include elements that are optional as will be discussed herein. However, the elements of the invention are to be defined by the claims appended hereto.

[0113] Infeed station 52 is generally conventional in design and known to those skilled in the art and need not be further described.

[0114] Washer 54 is general conventional in design and need not be described further herein. Washers 54 are known to those skilled in the art and are available from a number of manufacturers. Washer 54 however, is a glass lite or pane washer that operates with the lite in a generally vertical orientation.

[0115] Inspection station 56 is generally conventional in design and need not be further described herein.

[0116] Shuttle 58 according to an example embodiment of the invention includes double shuttle mechanism 76. Double shuttle mechanism 76 travels back and forth and divides incoming lites from infeed station 52, washer 54 and inspection station 56 into spacer applied lites 78 and topping lites 80. According to an example embodiment of the invention, spacer applied lites 78 are directed to front conveyor line 82 while topping lites 80 are directed to rear conveyor line 84. For the purposes of discussion of the invention, while spacer applied lite 78 and topping lite 80 may be identical or similar pieces of glass, spacer applied lite 78 refers to lites to which a perimeter spacer has been or will be applied during the manufacturing process while topping lite 80 refers to lites that will be applied on top of the spacer applied lite and perimeter spacer to create a partially assembled insulated glass unit.

[0117] Front conveyor line 82 generally transports spacer applied lites 78. Front conveyor line 82 extends generally from shuttle 58 to gas press and fill station 74. This should not be considered limiting as depending upon the exact design of high speed parallel manufacturing line 50 according to example embodiments of the invention, this extent may vary. Rear conveyor line 84 generally transports topping lites 80 and, similar to front conveyor line 82, in an example embodiment, extends generally from shuttle 58 to gas press and fill station 74.

[0118] Driven parallel infeed conveyor 60 is generally conventional in design and known to those skilled in the art and need not be further described here. Driven parallel infeed conveyor 60 includes front conveyor line 82 and rear conveyor line 84 upon which spacer applied lite 78 and topping lite 80 are conveyed.

[0119] Referring to FIGS. 2-8, IGU spacer applicator 62 generally includes applicator head 86, applicator gantry 88 and servo driven cup 90. Front conveyor line 82 upon which spacer applied lite 78 is transported is accessible to applicator head 86. Rear conveyor line 84 transports topping lites through IGU spacer applicator 62 to the rear.

[0120] Applicator head 86 is supported by applicator gantry 88 and applicator head 86, in combination with applicator gantry 88, is capable of translation in x, y and z axes. Applicator head 86 is generally also capable of rotational movement about the z axis to facilitate application of spacers to spacer applied lite 78.

[0121] Servo driven cup 90 supports suction cups configured to selectively grip spacer applied lite 78. Such suction cups are generally conventional and need not be further described here to those of ordinary skill in the art. As best seen in FIG. 4, servo driven cup 90 is configured to grip spacer applied lite 78 and advance it slightly prior to the beginning of application to permit the staging of a following spacer applied lite 78 while a perimeter spacer is applied to the leading spacer applied lite 78.

[0122] IGU spacer applicator 62 generally also includes vertical support 104 in addition to front conveyor 100 and rear conveyor 102.

[0123] Referring particularly to FIGS. 3-8, according to an example embodiment of the invention, spacer is applied while spacer applied lite 78 is moving forward. Thus, applicator head 86 and applicator gantry 88 are configured to follow spacer applied lite 78 as it is conveyed forward and to apply spacer while spacer applied lite 78 is being conveyed forward.

[0124] According to an example embodiment of the invention, movement of applicator head 86, applicator gantry 88 and servo driven cup 90 are coordinated with each other so that spacer is applied first to bottom edge 92 of spacer applied lite 78 followed by trailing edge 94 of spacer applied lite 78 then top edge 96 and leading edge 98 in sequence while spacer applied lite 78 travels forward. Accordingly, applicator head 86 first travels backward relative to the motion of spacer applied lite 78 to apply spacer bottom edge 92 of spacer then upward to apply spacer to trailing edge 94 then forward relative to spacer applied lite 78 to apply spacer to top edge 96. Applicator head 86 then travels downward along leading edge 96 to complete spacer application around the perimeter of spacer applied lite 78. All the while spacer applied lite 78 travels forward on the assembly line.

[0125] According to an example embodiment of the invention, applicator head 86 then rotates in a clockwise direction while returning to apply spacer to a following spacer applied lite 78.

[0126] Driven grid station 66 is generally conventional in design and includes grid applicator 106. Driven grid station 66 is generally conventional in design and need not be further described here.

[0127] Gas press and fill station 70 according to example embodiments of the invention may include double gas press 108 or single gas press 110.

[0128] According to an example embodiment, depicted in FIG. 14, double gas press 108 includes two gas press compartments 112 including front gas press compartment 114 and rear gas press compartment 116. Each of front gas press compartment 114 and rear gas press compartment 116 include gas ducts 118 and internal conveyor 120.

[0129] Double gas press 108 generally includes three platens 122. Platens 122 include front platen 124, central platen 126 and back platen 128. Each of the three platens 122 includes suction grippers (not depicted) on at least one surface thereof. According to an example embodiment of the invention, front platen 124 includes suction grippers (not depicted) on one surface thereof while central platen 126 includes suction grippers on two surfaces thereof and back platen 128 includes suction grippers on one surface thereof.

[0130] Double gas press 108 includes gas supply 130 as well. Front gas press compartment 114 and rear gas press compartment 116 are configured to open and close to accept spacer applied lites 78 and topping lites 80. Double gas press 108 is configured so that front gas press compartment 114 and rear gas press compartment 116 shuttle back and forth to align with front conveyor 100 and rear conveyor 102.

[0131] Front platen 124 is configured to be movable back and forth relative to central platen 126 to open and close front gas compartment 114 while also bringing spacer applied lite 78 into close proximity to topping lite 80 for mating. Rear gas press compartment 116 is configured so that back platen 128 and central platen 126 may be moved relative to each other in a similar fashion.

[0132] According to another example embodiment depicted in FIG. 15, single gas press 110 generally includes housing 132 enclosing front platen 134 and back platen 136. Housing 132 further includes side doors 138, internal conveyor 140 and gas ducts 142. Single gas press 110 is structured to travel or shuttle forward and back between front conveyor 100 and rear conveyor 102. Front platen 134 is movable relative to back platen 136. Gas ducts 142 may be located below, at the leading edge or at the trailing edge of single gas press 110. Side doors 138 are configured to open and close to contain gas therein and exclude atmospheric gas during the gas filling process.

[0133] If gas ducts 142 are located below the location at which spacer applied lites 78 are received, gas ducts may be configured to withdraw and advance while internal conveyor 140 is withdrawn and advanced to permit gas filling. For example, gas ducts 142 and internal conveyor 140 can be mutually coupled and movable perpendicular to their long axis.

[0134] Referring to FIGS. 9-13, according to an example embodiment, secondary edge sealer 72 generally includes first edge sealing head 144, second edge sealing head 146, servo driven cup 148, and gantry 150.

[0135] According to an example embodiment of the invention, first edge sealing head 144 is supported by gantry 150. Second edge sealing head 146 is separately located at a lower edge of where insulated gas units that have been gas filled and pressed pass through secondary edge sealer 72. According to an example embodiment of the invention, first edge sealing head 144 travels on gantry 140 to apply secondary edge sealant to leading edge 98, top edge 96 and trailing edge 94 of insulated glass units. Second edge sealing head 146 applies secondary edge sealant to bottom edge 92 of insulated glass units. According to an example embodiment of the invention, servo driven cups 148 grip and transport the insulated glass unit forward. It is notable that according to the present invention, insulated glass units never travel backwards on the conveyor line but always move forward. This is also true of spacer applied lites 78 as spacers are applied to them. Servo driven cups 148 are configured to displace the insulated glass unit forward to permit staging of a following insulated glass unit 78 while the first unit is being edge sealed.

[0136] According to an example embodiment of the invention, each of the first edge sealing heads 144 and lower second edge sealing heads 146 includes first corner wiper 152 and second corner wiper 154 that eliminate or minimize the need for operator touch-up of insulated glass units. First corner wiper 152 is coupled to first edge sealing head 144 while second corner wiper 154 is coupled to second edge sealing head 146.

[0137] Having been secondary edge sealed the insulated glass unit is conveyed from secondary edge sealer 72 to non-driven outfeed queue station 74.

[0138] Non-driven outfeed queue station 74 is generally conventional in design and need not be further described here.

[0139] According to another embodiment of the invention, the invention includes a method of manufacturing insulated glass units. According to an embodiment of the invention, the method includes receiving glass lites at infeed station 52; conveying the glass lites to washer 54; washing and drying the glass lites in washer 54; conveying the glass lites to an inspection station 56 and further conveying the glass lites to shuttle 58. The method may include shuttling alternate lites to front conveyor line 82 and rear conveyor line 84 and shuttle 58 and distributing spacer applied lites 78 to front conveyor line 82 and distributing topping lites 80 to rear conveyor line 84. The method may then include conveying spacer applied lites 78 and topping lite 80 through infeed conveyor 60 to IGU spacer applicator 62.

[0140] The method may further include applying IGU spacer to spacer applied lite 78 while spacer applied lite 78 is constantly moving forward or at least never being moved backward. The method may further include applying spacer to spacer applied lite 78 first, along bottom edge 92, second, along trailing edge 94, third, along top edge 96 and fourth, along leading edge 98. The method further includes conveying spacer applied lite 78 from IGU spacer applicator 62 to following queue station 64.

[0141] The method also includes optionally applying grids at driven grid station 66.

[0142] According to another embodiment, the method includes conveying spacer applied lite 78 and topping lite 80 via second queue station 68 to gas press and fill station 70.

[0143] According to one embodiment of the invention, the method further includes gas filling and applying topping lite 80 to spacer applied lite 78 in double gas press 108.

[0144] The method further includes in another embodiment applying topping lite 80 to spacer applied lite 78 and gas filling in single gas press 110.

[0145] A method according to an embodiment of the invention includes mating topping lite 80 with spacer applied lite 78 in a double gas press. In this embodiment of the invention, alternate insulated glass units are assembled in a front gas compartment 114 and a rear gas compartment 116 of double gas press 108.

[0146] According to another embodiment of the invention, the method further includes mating topping lite 80 with spacer applied lite 78 and gas filling in single gas press 110.

[0147] According to another embodiment of the invention, the method further includes conveying an insulated glass unit from double gas press 108 or single gas press 110 to secondary edge sealer 72. The method further includes secondary edge sealing of the insulated glass unit by first edge sealing head 144 and second edge sealing head 146. The method further includes sealing in sequence leading edge 98, top edge 96, and trailing edge 94 of the insulated glass unit with first edge sealing head 144 while simultaneously sealing bottom edge 92 with second edge sealing head 146. The method according to the invention further includes conveying the insulated glass unit with servo driven cup 148 during the edge sealing process. The method may further include secondary edge sealing the insulated glass unit while continuously moving the insulated glass unit forward in the conveying process.

[0148] Referring to FIGS. 16-24, another embodiment of high speed parallel manufacturing line 50 is depicted.

[0149] Referring to FIG. 16, the depicted embodiment generally includes infeed station 156, vertical washer 158, inspection station 160, shuttle 162, driven parallel infeed conveyor 164, single seal IGU spacer applicator 166, following queue station 168, driven grid station 170, second queue station 172, press and seal unit 174, heating station 176, vertical press 178, and fourth corner sealer 180.

[0150] Infeed station 156 is generally conventional in design and similar to that described above.

[0151] Vertical washer 158 is generally conventional in design and similar to that described above.

[0152] Inspection station 160 is generally conventional in design and similar to that described above.

[0153] Shuttle 162 is similar to that described above.

[0154] Driven parallel infeed conveyor 164 is similar to that described above.

[0155] Single seal IGU spacer applicator 166 is adapted to apply single seal spacer products. Single seal spacer products are utilized without the need to apply a secondary seal and without a need for corner notching as the single seal spacer products are flexible enough to be applied at corners of the IGU by bending the single seal spacer product. Referring to FIG. 2, single seal IGU spacer applicator 166 includes heated spacer drum 182 for storage of spacer material. The motion and structure of single seal IGU spacer applicator 166 is similar to that described above with relation to applicator head 86, applicator gantry 88 and servo driven cup 90. Single seal IGU spacer applicator 166 is constructed and adapted so that when spacer material is applied, a fourth corner of the insulated glass unit is left slightly open to ambient air.

[0156] Following queue station 168 is generally conventional and similar to that described above.

[0157] Driven grid station 170 is generally conventional and similar to that described above.

[0158] Second queue station 172 is generally conventional and similar to that described above.

[0159] Referring to FIGS. 20B and 25, press and seal unit 174 may include auto topping press with gas fill 184 and infeed shuttle 186. Auto topping press may also include gas fill manifold assembly 187.

[0160] Referring to FIGS. 17 and 18, heating station 176 follows press and seal unit 174 and generally includes: heating station frame 188, conveyor 190 and infrared heating units 192. In the depicted embodiment, infrared heating units 192 are configured to heat eight edges of an insulated glass unit being processed. That is both sided of each edge of a rectangular IGU. Infrared heating units 192 heating units may also be adapted to heat the edges of IGUs that are not rectangular in shape, such as polygonal IGUs, circular IGUs or arch topped IGUs.

[0161] In the depicted embodiment, infrared heating units 192 include focused infrared lamps 194 that are linear in nature. This should not be considered limiting. Infrared heating units 192 may be of any desired shape. Focused infrared lamps 194 may be fixed or movable. If they are movable, focused infrared lamps 194 may be movable along with the IGU as it is conveyed. Infrared heating units 192 may include vertical heater 196 and horizontal heater 198. If movable, both vertical heater 196 and horizontal heater 198 may be moved to align with the respective vertical and horizontal edges of an insulated glass unit as it is conveyed.

[0162] If fixed, vertical heater 196 and horizontal heater 198 are of sufficient length to heat the height and width of the largest insulated glass unit capable of being processed. If vertical heater 196 is fixed, the insulated glass unit may be paused as it is being conveyed twice to heat vertical edges. Horizontal heater 198 may be used to apply heat to horizontal edges of an insulated glass unit while the insulated glass unit is being conveyed. In this case, horizontal heater 198 is positionable and adjustable as to vertical separation to heat the upper and lower edges of insulated glass units passing through heating station 176 of a variety of heights of IGUs.

[0163] Referring to FIGS. 19 and 20, vertical press 178 in various embodiments of the invention may include platen press 200 or roller press 202.

[0164] Referring to FIGS. 20A and 20B, application of platen press 200 is expected to minimize rebound and the consequent displacement of filler gas contained within an insulated glass unit which still has an open corner. Platen press 200 generally includes: base frame 204, front platen assembly 206, back platen assembly 208, conveyor assembly 212 and platen shifter assembly 214. Base frame 204 supports front platen assembly 206 and back platen assembly 208. At least one of front platen assembly 206 and back platen assembly 208 is movable relative to the other by the operation of platen shifter assembly 214. Conveyor assembly 212 is located slightly below and between front platen assembly 206 and back platen assembly 208 and allows conveying of an insulated glass unit into and out of the space between front platen assembly 206 and back platen assembly 208.

[0165] Referring now to FIG. 19, roller press 202 generally includes roller base frame 216, front roller set 218 and back roller set 220. In the depicted embodiment, front roller set 218 includes seven rollers 222 and back roller set 220 includes seven rollers 222. Rollers 222 may be heated. Roller press 202 generally also includes drive motor 224 and serpentine belt or chain 226. Serpentine belt or chain 226 is coupled to drive motor 224 and to idler rollers as depicted in FIG. 19. Use of roller press 202 has the advantage that it allows continuous forward movement of an IGU being processed.

[0166] Referring now to FIGS. 21A-24, fourth corner sealer 180 generally includes base frame 228 supporting fourth corner sealing device 230. Fourth corner sealing device 230 may include angled rocking fourth corner sealer 232, roller fourth corner sealer 234 or two-part angled fourth corner sealer 236.

[0167] Referring to FIG. 22, angled rocking fourth corner sealer 232 generally includes angled portion 238 and rocking mechanism 240. Angled portion 238 generally represents an inside corner 242. Rocking mechanism 240 may include linear actuator 244. Angled portion 238 acts about pivot of inside corner 246.

[0168] Roller fourth corner sealer 234, in an embodiment depicted in FIG. 21B, generally includes linear actuators 248 and corner roller 250. Linear actuators 248 act orthogonally relative to each other and are configured to move corner roller 250 around a corner to be sealed. Corner roller 250 is typically of a diameter much greater than the depth of set back of the spacer of the insulated glass unit and may present multiple rollers of different widths as depicted to accommodate different thickness spacers.

[0169] Two part angled fourth corner sealer 236, in an embodiment depicted in FIG. 23, generally includes first angled sealer 252 for vertical edge and second angled sealer 254 for horizontal edge, vertical edge linear actuator 253 and horizontal edge linear actuator 255.

[0170] Referring now to FIG. 24, according to an example embodiment, fourth corner sealer 180 includes fourth corner infrared heater 256. In the depicted embodiment fourth corner infrared heater 256 includes two heat lamps 258 inside protective shrouds 260.

[0171] According to another embodiment of the invention, with reference to FIGS. 26, 27, 28 and 29, infrared heating units 192 may be individually controlled in a coordinated fashion to heat spacer material 262 along each of eight or more edges of IGU 264 to a desired controlled temperature to facilitate adhesion of spacer adhesive 266 associated with or integral to spacer material 262. Infrared heating units 192 can be individually servo controlled by individual servomotors 265 to control the speed and motion of infrared heating units 192 relative to motion of IGU 264 on each of two sides and four edges of IGU 266.

[0172] In an example embodiment depicted in FIGS. 27 and 28 in horizontal and vertical cross section respectively, infrared heating units 192 include first IR heater 268, second IR heater 270, third IR heater 272, fourth IR heater 274, fifth IR heater 276, sixth IR heater 278, seventh IR heater 280 and eighth IR heater 282. Each of the above infrared heating units 192 includes or is accompanied by individual temperature sensor 284. Temperature sensors 284 are each directed to monitor temperature of spacer material 262 and associated adhesive 266 on each side of spacer material 262. Temperature sensors 284 may include, for example, temperature sensing cameras or other sensors such as thermocouples, RTDs (resistance temperature detectors), thermistors and semiconductor based integrated circuits.

[0173] Temperature sensors 284 may include first temperature sensor 286, second temperature sensor 288, third temperature sensor 290, fourth temperature sensor 292, fifth temperature sensor 294, sixth temperature sensor 296, seventh temperature sensor 298 and eighth temperature sensor 300. Each infrared heating unit 192 and each individual temperature sensor 284 is coupled to spacer heating controller 302. Referring again to FIG. 26, spacer heating controller 302 monitors the temperature of spacer material 262 along each of eight or more edges of IGU 264 via temperature sensors 284. Spacer heating controller 302 is operably coupled to each of infrared heating units 192, servomotors 265 and/or to heating station conveyor 304 to modify the temperature of spacer material 262 by a change in speed of heating station conveyor 304 or speed of infrared heating units 192 if they are movable and/or duration or intensity of heating operation each infrared heating unit 192.

[0174] First IR heater 268, second IR heater 270, third IR heater 272 and fourth IR heater 274 are, for example, located on a first side of IGU 264 while fifth IR heater 276, sixth IR heater 278, seventh IR heater 280 and eighth IR heater 282 are located on an opposing side of IGU 264.

[0175] Similarly, first temperature sensor 286, second temperature sensor 288, third temperature sensor 290 and fourth temperature sensor 292 are located on a first side of IGU 264 while fifth temperature sensor 294, sixth temperature sensor 296, seventh temperature sensor 298 and eighth temperature sensor 300 are located on second opposing side of IGU 264.

[0176] First temperature sensor 286 is coupled to spacer heating controller 302 and signals from first temperature sensor 286 are received by spacer heating controller 302 indicating a temperature of spacer adhesive 266 of spacer material 262 in a vicinity of first IR heater 268. If a temperature of spacer adhesive 266 is below a desired temperature for adhesion, spacer heating controller 302 for example, controls first IR heater 268 to increase the intensity of heating of spacer adhesive 266. In another example, if a temperature of spacer adhesive 266 is below a desired temperature to facilitate adhesion, spacer heating controller 302 adjusts heating station conveyor 304 or servomotor 265 to stop or slow to increase the duration of heating of spacer adhesive 266. Alternately, motion of first IR heater 268 can be adjusted to increase duration of heating.

[0177] The interconnection and interaction of second temperature sensor 288, third temperature sensor 290, fourth temperature sensor 292, fifth temperature sensor 294, sixth temperature sensor 296, seventh temperature sensor 298 and eighth temperature sensor 300 and respectively second IR heater 270, third IR heater 272, fourth IR heater 274, fifth IR heater 276, sixth IR heater 278, seventh IR heater 280 and eighth IR heater 282 with spacer heating controller 302 and heating station conveyor 304 are similar to those of first temperature sensor 286 and first IR heater 268 and, therefore, will not be further described here.

[0178] In operation, glass lites are fed into high speed parallel manufacturing line 50 at infeed station 52. Glass lites are conveyed to washer 54 where they are washed and dried. Glass lites are then conveyed to inspection station 56 for inspection. Then glass lites are conveyed to shuttle 58 which places alternate glass lites on front conveyor 100 or rear conveyor 102. Spacer applied lites 78 are transported on front conveyor 100 while topping lites 80 are transported on rear conveyor 102. Spacer applied lites 78 are then transported to IGU spacer applicator 62 where spacer is applied first to bottom edge 92, then to trailing edge 94, then to top edge 96 and finally to leading edge 98. Spacer is applied while the spacer applied lite 78 is moving forward on the conveyor line. Spacer applied lite 78 and topping lite 80 are then transported via following queue station 64 optionally to driven grid station 66 and then to second queue station 68. Spacer applied lites 78 and topping lites 80 are then conveyed to gas press and fill station 70 which according to alternate embodiments of the invention may include double gas press 108 or single gas press 110. In either case, topping lites 80 are transferred to the front of the gas press and fill station 70 and are mated with spacer applied lite 78 while gas filling takes place. This creates an insulated glass unit that has been primarily sealed. The insulated glass unit is then transported to secondary edge sealer 72 which applies secondary edge sealant via two edge sealing heads including first edge sealing head 144 and second edge sealing head 146. First edge sealing head 144 applies secondary sealant to leading edge 98, top edge 96 and trailing edge 94 of the insulated glass unit in that sequence. Simultaneously, second edge sealing head 146 applies secondary edge sealant to bottom edge 92. During the secondary edge sealing process, edge sealant is wiped at the corners by first corner wiper 152 and second corner wiper 154. Completed insulated glass units having been secondarily edge sealed are then conveyed to non-driven outfeed queue station 74.

[0179] According to the embodiment depicted in FIGS. 16-24 when spacer applied lite 78 arrives at single seal IGU spacer applicator 166 single seal spacer material is applied to spacer applied lite 78 along bottom edge 92 followed by trailing edge 94 followed by top edge 96 and leading edge 98 in sequence. The fourth corner of spacer applied light where leading edge 98 and bottom edge 92 meet is left slightly open.

[0180] Spacer applied lite 78 is conveyed to press and seal unit 174 where topping lite 80 is mated to spacer applied lite 78 to create an IGU. The IGU is conveyed to heating station 176 where eight edges of the IGU are heated to increase wettability of the single seal IGU spacer adhesive. If infrared heating units 192 are moveable they are moved to heat areas of the IGU as required. The IGU is then conveyed to vertical press 178 where the IGU is pressed to enhance the seal between the lites and the single seal spacer material. The fourth corner of the IGU remains open after application of vertical press 178.

[0181] The IGU is then conveyed to fourth corner sealer 180 where the fourth corner is sealed trapping a non-air filling gas within the IGU. If present, fourth corner heater 256 may be applied to raise the temperature of the fourth corner to facilitate sealing.

[0182] Referring to FIGS. 26, 27 and 28, first temperature sensor 286 is coupled to spacer heating controller 302 and sends signals from first temperature sensor 286 that are received by spacer heating controller 302 indicating a temperature of spacer adhesive 266 of spacer material 262 in a vicinity of first IR heater 268. Spacer heating controller 302 receives and processes signals from each of temperature sensors 284. If a temperature of spacer adhesive 266 is below a desired temperature for facilitating adhesion, spacer heating controller 302 for example, controls first IR heater 268 to increase the intensity or duration of heating of spacer adhesive 266. In another example, if a temperature of spacer adhesive 266 is below a desired temperature for adhesion, spacer heating controller 302 adjusts heating station conveyor 304 to stop or slow to increase the duration of heating of spacer adhesive 266. Spacer heating controller 302 can alter several of the above factors in combination to achieve desired temperature of space adhesive 266.

[0183] The present invention may be embodied in other specific forms without departing from the spirit of the essential attributes thereof; therefore, the illustrated embodiments should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than to the foregoing description to indicate the scope of the invention.

[0184] 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.

[0185] 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.

[0186] 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.

[0187] 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.

[0188] 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.