Apparatus for dispensing sealant material and method of use thereof

Abstract

An apparatus (10) for delivering sealant material includes a first nozzle (12) having a first spray head (14) and a second nozzle (16) having a second spray head (18). The first and second spray heads each independently have an outlet, an inlet opposite the outlet, and an open passageway extending from the inlet through the spray head body to the outlet. The first nozzle is spaced apart from the second nozzle to form a space between the spray heads to allow a part to enter from a first side of the apparatus and exit from a second side of the apparatus while passing by the first and second nozzle heads. A notch (60) is formed through the respective bodies of the first and second spray heads at the side of the part where it exits the apparatus to distribute sealant material onto respective sides of the part.

Description

[0001] Cross Reference to Related Applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 084,122, filed September 28, 2020, the entirety of which is incorporated by reference herein. BACKGROUND TECHNICAL FIELD

[0004] The present invention relates to devices for dispensing sealant material, such as devices for dispensing sealant material onto the sides of a spacer for an insulating glass unit, as well as methods of using the devices, spacers formed therefrom, and insulating glass units formed from the spacers.

[0005] BACKGROUND

[0006] Insulating glass units (IGUs) are formed from two or more glass plies that are separated by one or more spacers to form an air gap between the glass plies. A sealant material is applied to the spacer to bond the glass plies to the spacer while providing a barrier to gas, such as air, and liquid, such as water, from flowing into and out of the air gap. The amount, location, size, and shape of the sealant material applied to the spacer contribute to the effectiveness of the sealant material and the resulting IGU.

[0007] Significant effort has been expended to develop methods and devices for forming IGUs, including devices and methods for preparing spacers. While current devices and methods can provide a sealant material to a spacer for an IGU, there remains a need for improved systems for applying a sealant to provide better performance in the final IGU, faster overall application processes, improved weathering performance, and the like.

[0008] Accordingly, it would be desirable to provide an improved device and method for applying a sealant material that can be used to prepare a spacer for an IGU. SUMMARY

[0009] The present invention includes a device for delivering a sealant material. The device includes a first nozzle comprising a first nozzle tip and a second nozzle comprising a second nozzle tip. The first nozzle tip and the second nozzle tip each independently have an outlet, an inlet opposite the outlet, and an open passageway extending from the inlet through the nozzle body to the outlet. The first nozzle is spaced apart from the second nozzle such that the outlet of the first nozzle tip faces the outlet of the second nozzle tip, forming a space between the two nozzle tips to allow a component to enter a first side of the device and exit a second side of the device while passing through the first nozzle tip and the second nozzle tip. At the side of the device where the component exits, the first nozzle tip and the second nozzle tip are formed with notches through the respective bodies for dispensing the sealant material onto respective sides of the component.

[0010] The present invention also relates to a method of applying sealant material to a spacer of an insulating glass unit. The method includes passing an elongate spacer through a space formed between a first nozzle and a second nozzle of the above-described apparatus; and applying sealant material to a first side of the spacer by the first nozzle and to a second, opposite side of the spacer by the second nozzle as the spacer passes through the apparatus.

[0011] The present invention also includes a spacer comprising sealant material formed by the above-described method, and an insulating glass unit comprising such a spacer formed between opposing glass plies.

[0012] The present invention also relates to the following clauses:

[0013] A first aspect relates to an apparatus for delivering sealant material, the apparatus comprising: a first nozzle comprising a first nozzle head and a second nozzle comprising a second nozzle head, the first and second nozzle heads each independently comprising an outlet, an inlet opposite the outlet, and an open passageway extending from the inlet through the body of the nozzle head to the outlet, wherein the first nozzle is spaced apart from the second nozzle such that the outlet of the first nozzle faces the outlet of the second nozzle, forming a space between the two nozzle heads to allow a component to enter a first side of the apparatus and exit a second side of the apparatus while passing through the first and second nozzle heads, and wherein at the side of the component exiting the apparatus, the first nozzle head and the second nozzle head are formed with a recess through the respective body for dispensing sealant material onto respective sides of the component.

[0014] A second aspect relates to the apparatus of the first aspect, wherein the recess extends through a portion of the body of the respective nozzle head in a longitudinal direction from the outlet toward the inlet.

[0015] A third aspect relates to the apparatus of the first or second aspect, wherein the height of the recess at the outlet of the nozzle head is greater than the recess height at which the recess terminates within the body of the nozzle head.

[0016] A fourth aspect relates to the apparatus of any of the preceding aspects, wherein the thickness of the recess extends laterally through the body of the nozzle head in a direction from the second side of the nozzle head to the first side of the nozzle head, and wherein the thickness of the recess extends through the open passageway to a point before the first side of the nozzle head.

[0017] A fifth aspect relates to the apparatus of any of the preceding aspects, wherein the recess extends longitudinally a distance that is no more than half the length of the body of the nozzle head.

[0018] A sixth aspect relates to the apparatus of any of the preceding aspects, wherein the first nozzle and the second nozzle each independently comprise a single nozzle.

[0019] A seventh aspect relates to the apparatus of any of the preceding aspects, wherein the notch is triangular.

[0020] An eighth aspect relates to the apparatus of the seventh aspect, wherein the triangular notch has three points, and wherein a first point of the triangular notch extends through a body of the respective nozzle in a longitudinal direction, and a second point and a third point of the triangular notch extend through the respective nozzle body in opposite perpendicular directions.

[0021] A ninth aspect relates to the apparatus of any of the preceding aspects, further comprising at least one pump that dispenses the sealant material through the first nozzle and the second nozzle.

[0022] A tenth aspect relates to the apparatus of any of the preceding aspects, further comprising a controller in operable communication with the at least one pump, and one or more computer-readable storage media in operable communication with the controller and containing programmed instructions that, when executed, cause the controller to dispense the sealant material through the first nozzle and the second nozzle.

[0023] An eleventh aspect relates to the apparatus of any of the preceding aspects, wherein the outlets of the nozzles are spaced apart by a distance to apply the sealant material to opposite sides of a long, narrow spacer for an insulated glass unit.

[0024] A twelfth aspect relates to a method of applying a sealant material to a spacer of an insulated glass unit, the method comprising: passing a long, narrow spacer through a space formed between a first nozzle and a second nozzle of an apparatus according to any of the first through eleventh aspects; and applying the sealant material to a first side of the spacer by the first nozzle and to a second, opposite side of the spacer by the second nozzle as the spacer passes through the apparatus.

[0025] A thirteenth aspect relates to the method of the twelfth aspect, wherein the first nozzle and the second nozzle are spaced apart by a distance such that the outlets of the first nozzle and the second nozzle are substantially flush with the first side and the second side of the spacer.

[0026] A fourteenth aspect relates to the method of the twelfth or thirteenth aspect, wherein the notch extends through a portion of a body of the respective nozzle in a longitudinal direction from the outlet toward the inlet.

[0027] A fifteenth aspect relates to the method of the fourteenth aspect, wherein the notch extends longitudinally by a distance that is no more than half a length of the nozzle body.

[0028] The sixteenth aspect relates to the method of either the fourteenth or fifteenth aspect, wherein the thickness of the notch extends laterally through the nozzle body in a direction from the second side of the nozzle to the first side of the nozzle, and wherein the thickness of the notch extends through the open channel to a position prior to the first side of the nozzle.

[0029] The seventeenth aspect relates to the method described in any one of the twelfth to sixteenth aspects, wherein the apparatus includes at least one pump that dispenses sealant material through a first nozzle and a second nozzle.

[0030] The eighteenth aspect relates to the method of the seventeenth aspect, wherein the pump moves the sealant material to generate an upstream pipeline pressure in the range of 400 ps i to 1200 ps i.

[0031] The nineteenth aspect relates to the method of the seventeenth or eighteenth aspect, wherein the apparatus further includes a controller operatively communicative to the at least one pump, and one or more computer-readable storage media operatively communicative to the controller and containing programming instructions, which, upon execution of the programming instructions, cause the controller to dispense sealant material through a first nozzle and a second nozzle, and wherein the method includes automatically applying sealant material to a first side of the spacer by the first nozzle and to a second side of the spacer by the second nozzle as the spacer passes through the apparatus.

[0032] The twentieth aspect relates to a spacer comprising a sealant material formed by the method described in any one of the twelfth to nineteenth aspects.

[0033] The twenty-first aspect relates to an insulating glass unit comprising the spacer described in the twenty-first aspect formed between opposing glass sheets. Attached Figure Description

[0034] FIG. 1 This is a front view of the sealant dispensing device according to the present invention;

[0035] FIG. 2 yes FIG. 1 A perspective view of the sealant dispensing device shown;

[0036] FIG. 3 This is a side perspective view of the nozzle of the sealant dispensing device according to the present invention;

[0037] FIG. 4 This is a front perspective view of the sealant dispensing device according to the present invention;

[0038] FIG. 5 yes FIG. 1 A front view of the sealant dispensing device, showing the spacer passing between the nozzles;

[0039] FIG. 6 is FIG. 2 is a perspective view of a sealant dispensing device in

[0040] FIG. 7 is a front view of a sealant dispensing device according to the present invention, the device including additional nozzles;

[0041] FIG. 8 is a perspective view of a sealant dispensing device in FIG. 1 is a front view of a sealant dispensing device in

[0042] FIG. 9A is a perspective view of a sealant dispensing device in FIG. 2 is a perspective view of a sealant dispensing device in

[0043] FIG. 9B is a perspective view of a sealant dispensing device in FIG. 2 is a perspective view of a sealant dispensing device in

[0044] FIG. 9C is a perspective view of a sealant dispensing device in FIG. 2 is a perspective view of a sealant dispensing device in

[0045] FIG. 9D is a perspective view of a sealant dispensing device in FIG. 2 is a perspective view of a sealant dispensing device in SUMMARY

[0046] For purposes of the description hereinafter, the terms "upper", "lower", "right", "left", "vertical", "horizontal", "top", "bottom", "lateral", "longitudinal", and derivatives thereof shall relate to the application as oriented in the drawing figures. However, it is to be understood that the application can assume alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the specification, are simply exemplary embodiments of the application. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.

[0047] Further, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of "1 to 10" is intended to include all sub-ranges, for example, from the minimum value of 1 and the maximum value of 10, that are between and including the minimum value of 1 and the maximum value of 10.

[0048] In this application, the use of singular includes plural and the use of plural includes singular, unless specifically stated otherwise. Also, in this application, the use of "or" means "and / or" unless specifically stated otherwise, even though "and / or" can be explicitly used in certain instances.

[0049] As shown in FIG. 1 , the present disclosure is directed to a device 10 for dispensing a sealant material. The sealant material dispensed through the device 10 is selected to provide desired gas and liquid barrier properties. The sealant material can also be selected to provide good adhesion properties. Non-limiting examples of suitable sealant materials include hot melt butyl, reactive hot melt butyl, polyurethane, polyisobutylene, reactive polyisobutylene, silane-terminated polymer, silicone, silicone-modified polyurethane, and combinations thereof.

[0050] Referring again to FIG. 1 , the device 10 includes a first nozzle 12 having a first spray head 14 and a second nozzle 16 having a second spray head 18. The first spray head 14 and the second spray head 18 can extend from a body 20 of the nozzle 12 and the nozzle 16 to deliver the sealant material onto a component. The nozzles 12 and 16 and their respective spray heads 14 and 18 can each independently have various sizes and shapes for different systems and various applications. For example, the spray heads 14 and 18 can have a rectangular, square, or circular shape to dispense a particular amount of sealant material. As further shown in FIG. 1 , the nozzles 12 and 16 can each have a single spray head 14 and 18. Alternatively, the nozzles 12 and 16 can each have two or more spray heads 14 and 18.

[0051] As shown in FIG. 2As shown, the tips 14 and 18 are in fluid communication with a fluid passageway 21 formed through the body 20 of the nozzles 12 and 16, where the sealant material is dispensed into and through the nozzles 12 and 16. The fluid passageway 21 can be formed through any portion of the body 20 of the nozzles 12 and 16 so long as the sealant material can enter and pass through the tips 14 and 18. For example, the fluid passageway 21 can be formed through the side or top of the body 20 of the nozzles 12 and 16 such that the passageway 21 extends to the tips 14 and 18. It should be understood that the fluid passageway 21 can extend through the body 20 of the nozzles 12 and 16 in any direction so long as the fluid passageway 21 is in fluid communication with the tips 14 and 18.

[0052] As FIG. 2 Further shown, the first nozzle 12 and the second nozzle 16 are in fluid communication with a conduit 22, such as by the use of an eductor located in the fluid passageway 21, which in turn is in fluid communication with a containment device 24 containing the sealant material. The conduit 22 can include a tube made of a material including, for example, plastic, rubber, metal, or combinations thereof. The containment device 24 containing the sealant material can include a can, a bucket, and other types of containers sufficient to contain and store the sealant material.

[0053] As FIG. 3 And FIG. 4 shown, various features of the first nozzle 12 are shown. However, it should be understood that FIG. 3 And FIG. 4 the features shown are representative of features found in both the first nozzle 12 and the second nozzle 16 of the device 10. Accordingly, features described herein with respect to FIG. 3 And FIG. 4 the first nozzle 12 will be referred to as features found in both the first nozzle 12 and the second nozzle 16.

[0054] Referring to FIG. 3 And FIG. 4 , the tips 14 and 18 each independently include an outlet 30 from which the sealant material exits the nozzles 12 and 16, an inlet 32 opposite the outlet 30, and an open channel 34 extending from the inlet 32 through a body 36 of the tips 14 and 18 to the outlet 30, where the sealant material flows in through the fluid passageway 21. As FIG. 3 And FIG. 4 further shown in

[0055] The open passageway 34 extending through the bodies 36 of the nozzles 14 and 18 can have various shapes and sizes, so long as the open passageway 34 is capable of receiving and delivering sealant material away from the nozzles 12 and 16 onto a component, such as a spacer for an insulating glass unit (IGU). It should be understood that the size of the open passageway 34 should be capable of dispensing a sufficient amount of sealant material to provide the desired sealant performance between the component and one or more surfaces to which the component is connected.

[0056] Referring to FIG. 1 , the first nozzle 12 is spaced apart from the second nozzle 16 such that the outlet 30 of the first nozzle 14 faces the outlet 30 of the second nozzle 18, forming a space 40 between the nozzles 14 and 18. Referring to FIG. 5 and FIG. 6 , the distance between the nozzles 14 and 18 is selected to form a space 40 that allows a component 42 having opposing sides 44 to pass between the nozzles 14 and 18 while delivering sealant material 46 from the nozzles 14 and 18 onto the surfaces of the opposing sides 44 of the component 42. For example, as shown in FIG. 5 and FIG. 6 , the component 42 can include a channel-like, elongated spacer, and the nozzles 14 and 18 are spaced apart at a distance to dispense and apply the sealant material 46 onto the surfaces of the opposing sides 44 of the channel-like, elongated spacer of the component 42.

[0057] As shown in FIG. 3 and FIG. 6 , it should be understood that during application of the sealant material 46, the component 42 enters between the nozzles 12 and 16 at a first side 50 of the nozzles 14 and 18, which also represents an entrance of the component 42 into the space 40 between the nozzles 14 and 18. The component 42 moves through the space 40 with the opposing sides 44 of the component 42 passing the outlets 30 of the nozzles 14 and 18 while the sealant material is applied on the opposing sides 44. Then, the component 42 exits the device 10 at a second side 52 of the nozzles 14 and 18, which also represents an exit of the space 40 between the nozzles 14 and 18, with the component 42 exiting the device with the sealant material formed on the opposing sides 44.

[0058] Referring to FIG. 4 , the nozzles 12 and 16 each independently have a notch 60 formed through the body 36 of the nozzles 14 and 18. The notch 60 is formed through at least the second side 52 of the nozzles 14 and 18. The notch 60 extends through a portion of the body 36 of each nozzle 14 and 18 in a longitudinal direction (as indicated by reference character "A") from the nozzle outlet 30 toward the nozzle inlet 32. As FIG. 3 and FIG. 4As shown, the notch 60 extends at least through the outer surface 38 of the second side 52 of the nozzle 14 and nozzle 18 and into a portion of the body 36.

[0059] like FIG. 3 and FIG. 4 As shown, the thickness of the notch 60 can extend laterally (as indicated by reference numeral "C") through the body 36 of the nozzles 14 and 18 in a direction from the second side 52 toward the first side 50. For example, refer to FIG. 3 The thickness of the notch 60 can extend laterally from the second side 52 through the open channel 34 toward the first side 50 (as indicated by reference numeral "C") through the body 36 of the nozzle 14 and nozzle 18. In such an example, the thickness of the notch 60 can extend laterally (as indicated by reference numeral "C") through the open channel 34 to a position before the first side 50. That is, the thickness of the notch 60 does not extend through the first side 50 of the body 36 of the nozzle 14 and nozzle 18.

[0060] Reference FIG. 3 and FIG. 4 The open channel 34 is set back from the outer surface 38 of the outlet 30 of the nozzles 14 and 18. Thus, the notch 60 forms a cavity within the body 36 of the nozzles 14 and 18, with the open channel 34 located at the rear of the cavity, allowing the sealant material 46 to exit through the open channel 34 and enter the cavity formed by the notch 60. It should be understood that when the notch 60 is formed, the outer surface 38 and a portion of the body 36 at the second side 52 of the nozzles 14 and 18 are removed, leaving an open area in a portion of the second side 52.

[0061] The notch 60 can have various shapes and sizes formed through the nozzles 14 and 18 to provide a desired shape and amount of sealant material 46 on the surfaces of opposite sides 44 of the component 42 (e.g., a channel-like spacer), such as FIG. 5 and 6 As shown. For example, the notch 60 may extend longitudinally from the outlet 30 to the inlet 32 ​​by a certain distance (as indicated by the reference letter "A"), the distance being no more than half the length of the body 36 of the nozzle 14 and nozzle 18 (i.e., 50% or less), or no more than 1 / 4 the length of the body 36 of the nozzle 14 and nozzle 18 (i.e., 25% or less), or no more than 1 / 10 the length of the body 36 of the nozzle 14 and nozzle 18 (i.e., 10% or less).

[0062] The notches 60 can also be sized to provide a desired volume of sealant on the selected areas of the part 42. For example, the notches 60 can be sized to provide an amount of sealant of 0.006 to 0.010 cubic inches per linear inch of each side 44 of the part 42, such as about 0.008 cubic inches per linear inch of each side 44 of the part 42.

[0063] Referring to FIG. 3 and FIG. 4 The notches 60 can also be shaped and sized such that the notches 60 are wider in a vertical direction (as shown by reference letter "B") measured at the outlets 30 of the nozzles 14 and 18 than the height of the notches 60 where the notches 60 terminate within the bodies 36 of the nozzles 14 and 18. Thus, in these examples, the notches 60 taper in a longitudinal direction (as shown by reference letter "A") from the outlets 30 of the nozzles 14 and 18 toward the inlets 32.

[0064] The notches 60 can also be shaped in a desired shape, including but not limited to a triangle, a trapezoid, and the like. For example, as shown in FIG. 3 and FIG. 4 The notches 60 are triangular and have three points 62, 64, and 66, with the first point 62 extending longitudinally (as shown by reference letter "A") through the bodies 36 of the nozzles 14 and 18. That is, the first point 62 of each triangular notch 60 extends through the bodies 36 of the nozzles 14 and 18 in a longitudinal direction (as shown by reference letter "A") toward the inlets 32 of the nozzles 14 and 18. The second point 64 and the third point 66 of the triangular notches 60 extend through the bodies 36 in opposite vertical directions (as shown by reference letter "B"), such as along the outer faces 38 of the second sides 52 of each of the nozzles 14 and 18.

[0065] As previously described, the opposing sides 44 of the part 42 pass the outlets 30 of the first nozzle 14 and the second nozzle 18 at a selected distance to receive the sealant material 46 exiting the open channel 34. For example, the opposing sides 44 of the part 42 can be spaced a distance from the outer surfaces 38 of the outlets 30 such that the opposing sides 44 are flush or substantially flush with the outer surfaces 38 of the outlets 30 to form a closed cavity. As the sealant material 46 is dispensed through the open channel 34, the sealant material 46 fills the cavity of the notches 60. Since the outer surfaces 38 and a portion of the bodies 36 at the second sides 52 of the nozzles 14 and 18 are removed by the notches 60, the sealant material 46 forms on the sides 44 of the part 42 as the part 42 exits the space 40 formed between the nozzles 14 and 18. It will be appreciated that the sealant material 46 formed on the sides 44 of the part 42 will take the shape of the notches 60.

[0066] The apparatus 10 can also have additional components. For example, as shown in FIG. 7 the apparatus 10 can include an additional nozzle 80 positioned below the space 40 to apply the sealant material 46 to the bottom of the part 42. The additional nozzle 80 can include all or only some of the features of the previously described nozzles 12 and 16. Alternatively, the additional nozzle 80 can be different from the previously described nozzles 12 and 16.

[0067] Referring to FIG. 2 the apparatus 10 can also include at least one pump 90 for controlling the dispensing of the sealant material 46 into the nozzles 12 and 16. The apparatus 10 can include one pump 90 that controls the dispensing of the sealant material 46 into both the first nozzle 12 and the second nozzle 16. Alternatively, the apparatus 10 can include two or more pumps 90 that control the dispensing of the sealant material 46 into the first nozzle 12 and the second nozzle 16, respectively. The one or more pumps 90 can be used to control the amount and speed of the dispensing of the sealant material 46 into the first nozzle 12 and the second nozzle 16.

[0068] Non-limiting examples of other components that can be used with the apparatus 10 include sensors (not shown) that detect various parameters and conditions within the nozzles 12 and 16, the shrouds 14 and 18, and / or the space 40 formed between the shrouds 14 and 18. For example, the sensors can be used to detect the following parameters and conditions, including temperature, pressure, sealant flow rate, and / or the presence of the sealant material 46 within the shroud body 36, the open channel 34, and / or the space 40 formed between the shrouds 14 and 18. For example, the shrouds 14 and 18 can have thermocouples for measuring the temperature of the sealant and pressure sensors for maintaining a consistent dispensing pressure.

[0069] In addition, the apparatus 10 can also include temperature control components to heat or cool the temperature within the open channel 34, the fluid channel 21, and / or the conduit 22 in fluid communication with the containment device 24. For example, the nozzles 12 and 16 can be heated by conduction, such as by using a manifold with heating elements (e.g., heating rods) and thermocouples.

[0070] Additionally, referring to FIG. 2 the apparatus 10 can include a controller 110 in operable communication with one or more computer readable storage media that cause the controller to utilize the one or more pumps 90 to dispense the sealant material 46 into and through the nozzles 12 and 16. The controller 110 also has the ability to acquire information from or access other components, such as sensors. It should be understood that the controller 110 can include one or more microprocessors, CPUs, and / or other computing devices.

[0071] The controller 110 and one or more computer-readable storage media can be used to automatically control the apparatus 10. As used herein, the term "automatically control" refers to control of the apparatus 10 without substantial involvement of a human operator during normal operation of the apparatus 10, without the need for manual control of controllable components. As such, during normal operation, the apparatus 10 can be controlled without an operator monitoring or adjusting various parameters of the apparatus 10.

[0072] As shown, the component 42 receiving the sealant material 46 can include a spacer for an insulating glass unit (IGU). Accordingly, the present disclosure includes a method of applying a sealant material to a spacer (e.g., a channel-like elongated spacer) for an IGU. The method includes passing the component 42 including the spacer through the space 40 formed between the first nozzle 14 and the second nozzle 18 of the apparatus 10. The spacer enters the space 40 at the first side 50 of the nozzles 14 and 18. The spacer of the component 42 moves through the space 40 with the opposing side faces 44 of the spacer of the component 42 passing the outlets 30 of the nozzles 14 and 18 while the sealant material 46 is dispensed through the nozzles 14 and 18.

[0073] Each of the side faces 44 of the spacer of the component 42 is spaced a distance from the respective first nozzle 14 and second nozzle 18 to receive the sealant material 46. For example, the distance between the nozzles 14 and 16 can be selected to form the space 40 in which the opposing side faces 44 of the spacer of the component 42 are flush or substantially flush with the outer surface 38 of the outlets 30 (e.g., providing a gap distance of 0.005 to 0.010 inches between the side faces 44 of the spacer of the component 42 and the inner surface 38 of the outlets 30). The sealant material 46 (e.g., triangular sealant material 46) is formed on the side faces 44 of the spacer of the component 42 as the spacer of the component 42 moves past the second side 52 of the nozzles 14 and 18 and exits the space 40.

[0074] The method can be automatically controlled using the controller 110 in operable communication with one or more computer-readable storage media containing programmed instructions that, when executed, cause the controller 110 to dispense the sealant material 46 through the first nozzle 14 and the second nozzle 18. The controller 110 can automatically operate the pump 90 to control the flow rate and pressure of the sealant material 46 being delivered. For example, the controller 110 can automatically operate the pump 90 to move the sealant material at an upstream line pressure in the range of 400 psi to 1200 psi. The controller 110 can also operate the temperature within the nozzles 12 and 16, for example, in the range of 140°F to 360°F.

[0075] As previously mentioned, the method can be used to form a spacer of the component 42 having a sealant material 46 (e.g., a triangular sealant material 46) on opposite sides 44 of the spacer of the component 42. Referring to FIG. 8 , the resulting spacer of the component 42 can be used to form an IGU by being placed between two or more glass plies 200 and 202.

[0076] It should be appreciated that the spacer of the component 42 can have various shapes, designs, and configurations that can have the sealant material 46 (e.g., a triangular sealant material 46) applied thereto using the apparatus 10. For example, as shown in FIG. 8 , the spacer of the component 42 can be a channel-like, elongated spacer, such as the spacer available from GED under the trade designation Super Spacer®. Alternatively, the spacer of the component 42 can have other shape designs and configurations, including the following shapes: FIG. 9A , where the spacer 200 has a wavy wall 202 extending between two sides 204, available from GED under the trade designation Quantum®; ; FIG. 9B , where the spacer 210 contains an enclosed assembly 212 (e.g., at least one polycarbonate or aluminum gasket for additional performance) and has two sides 214, available from Quanex under the trade designation and ; FIG. 9C , where the spacer 230 is a non-metallic, polymer spacer having two sides 234, available from Quantex under the trade designation Super Spacer®; ; and FIG. 9D FIG. 9D , where the spacer 240 includes a channel-like portion 242 having two sides 244 that forms a primary seal for the IGU and a desiccant-filled area 244 under the channel-like portion 242 that forms a secondary seal, available from Quanex under the trade designation Endur TM XL ; and

[0077] It was discovered that the previously described apparatus 10 provides additional benefits downstream in the manufacturing process. In particular, the apparatus 10 enables better accelerated weathering test results and enables operation of the post-heater / roll press equipment at lower temperatures and higher speeds, e.g., 14% lower sealant temperature and 30% to 50% faster line speed for triple IGUs, as compared to currently known apparatus and methods for applying sealant material. The resulting sealant material 46 also provides improved bonding, particularly when applied to the sides of the spacers of the components 42 used to form IGUs. It was also discovered that the aforementioned spacers of the components 42 provide a good barrier to liquids and gases, e.g., air, from flowing into and out of the air gap formed in the IGUs.

[0078] It should be understood that the aforementioned apparatus 10 and methods can be used in various systems for forming spacers and / or forming IGUs. Non-limiting examples of such systems are described in the following U.S. patents, the entire contents of which are incorporated herein by reference: 7,275,570; 7,445,682; 7,448,246; 7,610,681; 7,802,365; 7,866,033; 7,901,526; 8,056,234; 8,474,400; 8,720,026; 8,904,611; 9,212,515; 9,279,283; 9,428,953; 9,765,564; 10,156,515; 10,184,290; 10,267,083; 10,316,578; 10,352,090; 10,352,091; 10,369,617; 10,533,367; and 10,577,856. The apparatus 10 can be incorporated into various portions of such systems.

[0079] While particular embodiments of the present application have been described herein for purposes of illustration, many modifications and variations that can be made therein without departing from the scope of the application defined in the appended claims.

Claims

1. An apparatus for delivering sealant material, comprising: a first nozzle comprising a first nozzle tip, and a second nozzle comprising a second nozzle tip, the first and second nozzle tips each independently comprising an outlet, an inlet opposite the outlet, and an open channel extending from the inlet through the nozzle body to the outlet, wherein each outlet includes an outer surface forming a perimeter around at least a portion of the open channel, wherein the first nozzle is spaced apart from the second nozzle such that the outlet of the first nozzle faces the outlet of the second nozzle, forming a space between the nozzle tips to allow a component to pass from a first side or each nozzle tip of the apparatus and exit from a second side or each nozzle tip of the apparatus, while passing through the first and second nozzle tips, and wherein a recess is formed through each of the first and second nozzle tips at the second side of the component as it exits the apparatus to distribute sealant material onto each side of the component, wherein the recess extends in a longitudinal direction from the outlet toward the inlet through a portion of the body of each first and second nozzle tip, and the recess extends at least through the outer surface at the second side of the nozzle tip and into a portion of the body.

2. The apparatus of claim 1, wherein a height of the recess at the outlet of the nozzle tip is greater than a height of the recess where the recess terminates within the body of the nozzle portion.

3. The apparatus of claim 1 or 2, wherein a thickness of the recess extends laterally through the body of the nozzle tip in a direction from the second side of the nozzle tip toward the first side of the nozzle tip, and wherein the thickness of the recess extends through the open channel to a location before the first side of the nozzle tip.

4. The apparatus of any of claims 1-3, wherein the recess extends longitudinally no more than a distance of one-half the length of the body of the nozzle tip.

5. The apparatus of any of claims 1-4, wherein the recess is triangular.

6. The apparatus of any of claims 1-5, further comprising at least one pump that distributes sealant material through the first and second nozzle tips.

7. The apparatus of claim 6, further comprising a controller in operable communication with the at least one pump, and one or more computer readable storage media in operable communication with the controller and containing programmed instructions that, when executed, cause the controller to distribute the sealant material through the first and second nozzle tips.

8. The apparatus of any of claims 1-7, wherein the outlets of the nozzle tips are spaced apart a distance to apply the sealant material to opposite sides of a long, narrow spacer for an insulated glass unit.

9. A method of applying sealant material to a spacer of an insulated glass unit, the method comprising: passing a spacer through a space formed between a first nozzle tip and a second nozzle tip of an apparatus according to any of claims 1-8; and a sealant material is applied to a first side of the spacer by the first nozzle and a second opposite side of the spacer by the second nozzle as the spacer passes through the apparatus.

10. The method of claim 9, wherein the first and second nozzles are spaced apart a distance such that the outlets of the first and second nozzle portions are substantially flush with the first and second sides of the spacer.

11. The method of claim 9 or 10, wherein the apparatus includes at least one pump that dispenses the sealant material through the first and second nozzles, and wherein the pump moves the sealant material to create an upstream line pressure in the range of 400 psi to 1200 psi.

12. The method of any of claims 9-11, wherein the apparatus includes the controller in operable communication with the at least one pump, and one or more computer readable storage media in operable communication with the controller and containing programmed instructions that, when executed, cause the controller to dispense the sealant material through the first and second nozzles, and wherein the method comprises: a sealant material is applied to a first side of the spacer by the first nozzle and a second side of the spacer by the second nozzle as the spacer passes through the apparatus.

13. A spacer comprising a sealant material formed by the method of any of claims 9-12.

14. An insulating glass unit comprising the spacer of claim 13 formed between opposing glass plies.

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