Method and apparatus for attaching slit spacers to pane edges

Abstract

A method for attaching a slit spacer to the edge of a pane includes opening a slit in the spacer to define a channel before the spacer contacts the edge of the pane, placing the edge of the pane within the channel, and allowing the spacer to elastically close the edge of the pane. This avoids forcing the slit in the spacer open primarily using the edge of the pane. If the pane is made of thin glass, using the edge of the panel to open the spacer channel could damage the panel, especially if the spacer is installed relatively quickly. Opening the slit in the spacer into a channel wide enough to avoid or minimize contact between the edge of the panel and the inner surface of the spacer reduces the force the panel experiences during installation.

Description

[Technical Field]

[0001] This disclosure relates to methods and apparatus for attaching spacers to the edges of panes, and more particularly to methods and apparatus for attaching flexible slit spacers to the edges of central panes used in triple glazing units.

[0002] Background information Multi-pane insulation units are used to improve the energy efficiency of homes and other buildings. A multi-pane insulation unit includes a pair of outer glass panes, spaced apart by spacers positioned around or just inside the panes. The two panes cooperate with the spacers to form an insulated, sealed cavity filled with air or an inert gas. One or more inner panes are held approximately parallel to the outer pane by a spacer assembly. The inner pane can be a separate pane of the same thickness as the outer pane, a thinner pane, or a thin, flexible plastic inner film, usually made of polyethylene terephthalate (PET). In a three-pane unit, the inner pane divides a cavity into two, adding an additional layer of insulation between the outside and inside air. One way to form a three-pane insulation unit is to use two spacers between the three panes to create adjacent, individually sealed, insulated cavities. An example of this configuration is shown in Figures 4-7 of U.S. Patent No. 4,831,799. Another method for forming a triple-pane insulation unit is disclosed in WO 2021 / 055447, which uses a slit spacer 10, as shown in Figures 1 and 2 of the present application. In Figure 1, the triple-pane insulation unit 2 includes a first outer pane 4, a second outer pane 6, and an inner third inner pane 8 supported by a perimeter spacer assembly 10. Panes 4, 6, and 8 can be glass or other materials, such as transparent or translucent polymer panes. The combination of the outer panes 4 and 6 and the spacer assembly 10 defines an inner insulation chamber that can be filled with air or an inert gas. The inner third pane 8 can be substantially thinner (0.5 mm-2.0 mm, e.g., 0.7 mm) than panes 4 and 6, so that the thickness and weight of the unit 2 are comparable to or not significantly greater than conventional double-pane units. The thicknesses of the first and second panes 4 and 6 can be provided in the range of 2 mm-10 mm, e.g., 3 mm-4 mm and 9 mm-10 mm.

[0003] The spacer assembly 10 includes a spacer body 20 made from a solid or foamed resilient material, such as rubber, silicone, or EPDM. This material may be water vapor permeable or impermeable. If the material is permeable, a desiccant may be disposed throughout the spacer body 20. Depending on the moisture and gas permeability of the material used on the backside of the spacer assembly 10, the spacer assembly 10 may include a vapor and gas barrier 22 applied to the outer surface 24 of the spacer body 20. This barrier 22 may be a coating applied directly to the spacer body 20 or a separate sheet 22 adhered to the spacer body 20. The vapor barrier 22 may be a metal foil, a plastic sheet, or a metalized plastic film.

[0004] The flexible or semi-rigid foam spacer body 20 can be manufactured from a thermoplastic or thermoset plastic. Suitable thermoset plastics include silicone and polyurethane. Suitable thermoplastic materials include thermoplastic elastomers such as Santoprene. Silicone foam can also be used. Advantages of silicone foam include excellent durability, minimal outgassing, low compression set, excellent resilience, high temperature stability, and low temperature flexibility. An additional advantage of silicone foam is that the material is breathable, allowing water vapor to easily reach the desiccant within the foam.

[0005] Desiccants are added as fillers during the foam manufacturing process. The types of desiccants used are typically 3A molecular sieve zeolite to remove water vapor, plus a small amount of 13X molecular sieve. Silica gel or activated carbon is used to remove organic vapors. In general, the amount of desiccants used should match the amount typically incorporated into conventional sealed glazing units.

[0006] The interior surface 34 of the spacer body 20 must be UV resistant to prevent dusting or peeling during prolonged exposure to sunlight. Depending on the material used, various special measures can be taken to ensure the required long-term durability, such as adding UV stabilizers to the material or covering or coating the interior surface 34 of the spacer body 20. Durable plastic materials, such as silicone, have excellent UV resistance and do not require special coating or covering of the interior surface.

[0007] Adhesive 26 bonds spacer body 20 to the inner surfaces of panes 4 and 6. This adhesive can be a pressure-sensitive acrylic adhesive. Pressure-sensitive adhesive 26 is pre-applied to both sides of spacer body 20. Five key criteria must be considered when selecting an appropriate adhesive: high adhesion, shear strength, heat resistance, UV resistance, and non-outgassing. While a variety of adhesives are available for use with silicone foam spacer bodies, a UV-resistant pressure-sensitive acrylic adhesive can be used.

[0008] The spacer assembly 10 is lined with a sealant 28. The sealant 28 can be a polyisobutane-based sealant. The sealant 28 is disposed on the exterior of the spacer assembly 10 within a channel formed between the first pane 4 and the second pane 6.

[0009] The spacer body 20 defines a channel that resiliently retains the outer edge of the inner third pane 8. The channel includes an open channel base 30 and a channel neck 32 that connects the channel base 30 to an inner surface 34 of the spacer body 20. The center of the channel base 30 is offset inwardly within the spacer body 20 from the centerline of the spacer body 20 (reference dimension 40 in FIG. 2 ). Before the inner third pane 8 is placed within the channel base 30, the width of the channel neck 32 is less than the thickness of the inner pane 8, and a shoulder portion 36 of the spacer body 20 that defines the channel neck 32 resiliently engages the inner third pane 8 to apply a compressive force. The shoulder portion 36 is bounded by the channel base 30, the channel neck 32, and the inner surface 34. Summary of the Invention [Problem to be solved by the invention]

[0010] When the inner third pane 8 is closed, the shoulder portions 36 provide a closed, smooth appearance to the inner surface 34. Because the inner surface 34 is visible, providing a closed, smooth appearance is a desirable feature for the spacer body 20.

[0011] There is a need in the art for a method and apparatus for attaching a spacer similar to spacer 10 to the end of pane 8 while minimizing the possibility of pane 8 breaking. [Means for solving the problem]

[0012] Disclosure Overview The present disclosure provides methods and devices for attaching slit spacers to the edges of panes. These methods include opening slits in the spacer to define open channels, contacting the spacer to the edges of the panes, and then sealing the edges of the panes with the spacer. This avoids forcing the slits in the spacer open primarily using the edges of the panes. When panes are thin glass, opening the spacer channels using the edges of the panels can damage the panels, especially when the spacer is installed at a relatively high speed. The slits in the spacer are opened to form open channels wide enough to avoid or minimize contact between the edges of the panels and the inner surface of the spacer, thereby reducing the forces the panels experience when installed.

[0013] The present disclosure involves deforming a portion of a slit spacer attached to the edge of a pane, thereby forming an open channel into which the edge of the pane is inserted, and which then seals the pane.

[0014] In one configuration, the present disclosure provides a method and apparatus for bending a slit spacer to form an open channel. The outer surface of the spacer is engaged with a bending device, such as a roller or curved surface, which bends the spacer away from the inner surface of the slit, opening the slit into an open channel. The spacer is bent about an axis perpendicular to the longitudinal or length dimension of the spacer. With the slit open to form the open channel, the spacer is placed over the edge of the pane. As the spacer moves away from the bending device, it resiliently conforms to the edge of the pane.

[0015] In another aspect, the present disclosure provides a method and apparatus for deforming a spacer to open a slit spacer and form an open channel. As the spacer moves through an applicator head, the central portion of the outer surface contacts a bending device, such as a wheel, bearing, or knob, which pushes the center of the spacer toward the inner surface (or slit face) while holding the ends of the spacer in place. This opens the slit and forms the open channel. The spacer is bent around an axis parallel to the longitudinal or length dimension of the spacer. With the slit open and the open channel defined, the spacer is placed over the edge of the pane. The spacer then elastically seals the edge of the pane as it moves away from the bending device.

[0016] The present disclosure provides for a method that can be performed manually, by semi-automatic, or by an automatic device. The present disclosure provides for a device that can be incorporated into a manual spacer installation tool or a semi-automatic or automatic installation head.

[0017] Individual features described herein can be combined in different combinations than those specifically described below to form different configurations of the devices of the present disclosure. The foregoing non-limiting features, as well as other features of the present disclosure, are more specifically described below. A more complete understanding of the devices, assemblies, and methods can be obtained by reference to the accompanying drawings. The accompanying drawings are not intended to illustrate the relative size and dimensions of assemblies. In these drawings and the following description, like numerical designations refer to components having similar functions. Specific terminology used in the description is intended to refer only to the specific structure of the embodiments selected for illustration in the drawings, and is not intended to define or limit the scope of the present disclosure. [Brief explanation of the drawings]

[0018] [Figure 1] FIG. 1 is a cross-sectional view of the center portion of a conventional triple pane insulating glass unit. [Figure 2]FIG. 2 is a cross-sectional view of an exemplary conventional spacer body. [Figure 3] FIG. 3 is an end view of a first configuration of the spacer applicator device showing the slit spacer bent to form an open channel that receives the edge of the pane. [Figure 4] FIG. 4 is a side view of the spacer applicator device of FIG. 3, with the pane and a portion of the spacer removed to show the open channel closing. [Figure 5] FIG. 5 is a side view of a second configuration of the spacer applicator device. [Figure 6] FIG. 6 is an end view of the spacer applicator device of FIG. [Figure 7] FIG. 7 is an enlarged end view showing the portion of the spacer of FIG. 3 where it engages the edge of the pane. [Figure 8] FIG. 8 is a plan view of FIG. [Figure 9] FIG. 9 is an enlarged end view showing the portion of the spacer of FIG. 6 where it engages the edge of the pane. [Figure 10] FIG. 10 is a plan view of FIG. [Figure 11] FIG. 11 shows a cross section of an exemplary slit spacer. DETAILED DESCRIPTION OF THE INVENTION

[0019] Detailed Description of Disclosure A first embodiment of the disclosed method and apparatus is shown in Figures 3, 4, 7, and 8. A second embodiment of the disclosed method and apparatus is shown in Figures 5, 6, 9, and 10. These embodiments provide a method and apparatus for attaching a slit spacer 100 to the edge of a pane 102, such as thin glass, as shown in the drawings. The spacer 100 can have the structure of the spacer 10 described in the Background section or a spacer structure with a slit in the inner surface 104 of the spacer 100 for receiving the edge of the pane 102. Figure 11 shows an exemplary spacer configuration having a slit 106 that can be opened by the methods and apparatus described herein. The spacer body shown in Figure 11 is flexible and resilient, as described in the Background section above.

[0020] In a first embodiment, the spacer 100 is bent around an axis perpendicular to the length of the spacer 100, opening a slit to form an open channel that receives the edge of the pane 102. As shown in FIG. 8 , the spacer 100 is inserted into an applicator device 110 in a direction perpendicular to the edge of the pane 102. The applicator device 110 has guides that align the spacer 100 and hold it at a right angle as it moves relative to the device 110. The spacer 100 is engaged with a bending device 112 and rotated to a position that opens the spacer slit. In one example configuration, the spacer 100 is rotated at least 90 degrees so that it is parallel to the edge of the pane 102. In other configurations, the spacer is bent at an angle less than perpendicular to the edge of the pane 102, and can be turned less than 90 degrees, as long as the bend is sufficient to open the shape of the slit defined by the spacer. The thickness of the spacer and the shape of the slit determine the amount of bending required to open the slit. The bending device 112 can be either a roller or a fixed curved surface. The height of the bending device 112 is greater than the width of the spacer 100. The bending device 112 is smooth and has a large enough radius to prevent damage to the moisture barrier 114 on the outer surface of the spacer 100 when the bending device 112 engages the spacer. The radius must also be small enough to bend the spacer 100 to open the slit 106 and accommodate the edge of the pane 102. We have found that a bending device with a 4.76 mm (3 / 16 inch) radius can bend spacer bodies with thicknesses (between the inner and outer surfaces) of about 6 mm (about 0.25 inch) to about 13 mm (about 0.50 inch) sharply enough to open the slit without damaging the moisture barrier 114. The motion of moving the spacer around the device 112 opens the center of the spacer, allowing it to be positioned over the edge of the pane. This motion continues as the applicator placement head moves around the pane. Just before engaging the edge of the pane 102, the slits in the spacer open to receive the edge of the pane without forcing the edge of the pane 102 into the spacer.The slits in the spacer are large enough to prevent the end walls of the pane 102 from engaging the inner surface 104 of the spacer 100. This movement is relative. The pane can be stationary and the applicator can move, or the applicator can be stationary and the pane can move, or a combination of both can be used.

[0021] The portion of the spacer 100 that engages the bending device 112 and the portions before and after the bending device 112 open the slits to form an open channel (see FIG. 4). The portion of the spacer 100 that formed the open channel moves over the edge of the pane 102. As the bending device 112 moves away from the open channel, the spacer material relaxes and fits tightly against the pane 102, attaching the spacer 100 to the pane 102.

[0022] In a second embodiment, the spacer 100 is bent around an axis parallel to the length of the spacer. In these embodiments, a bending device 212 engages the center of the outer surface of the spacer opposite the slit location in the rectangular cross section of the spacer, and the top and bottom inner corners 216 are held by guide supports 214, causing the bending device 212 to bend the spacer into a gentle "C" shape. In the illustrated exemplary configuration, two guide supports 214 are shown. The guide supports 214 can be aligned along the bending device 212 or can be located upstream and downstream of the bending device 212 location. As previously mentioned, the bending device 212 can be a rotating roller or bearing, or a fixed curved surface. As the spacer 100 passes through the bending device 212, the center portion of the spacer 100 is pushed outward toward the pane 102, opening the slit and forming an open channel. The edge of the pane 102 is inserted into the open channel, after which the spacer closes, sealing the edge of the pane 102. As mentioned above, the movements are relative: the pane can be fixed and the applicator can move, or the applicator can be fixed and the pane can move, or a combination of both.

[0023] The applicator devices 110 and 210 include a cutting device for cutting the entire spacer 100 after the spacer 100 has been applied around the entire periphery of the pane 102. The applicator devices 110 and 210 also include a scoring device for scoring the inner surface of the spacer 100 to form corners. The devices 110 and 210 can be manually operated, semi-automated, or fully automated. When using a manually operated applicator, the pane 102 rests on a selectively rotating platform 120 (e.g., a vacuum table) that holds the pane 102 in place during application. An automated applicator moves around the pane 102. Alternatively, a "cartwheel" can be used as a means of automation. In a cartwheel approach, the applicator is stationary and the pane is moved to the head for application. Such a cartwheel approach can also be used in conjunction with manual application methods. Multiple applicators 110 and 210 can be used along different sides of the pane 102. In either embodiment, the spacer 100 can be quickly attached to the pane 102 while reducing the risk of damaging the thin pane 102 .

[0024] In the above description, specific terms have been used for brevity, clarity, and ease of understanding. These terms have been used for descriptive purposes and should be broadly interpreted, without implying unnecessary limitations beyond the requirements of the prior art. Furthermore, the above description and accompanying drawings are illustrative, and the invention is not limited to the details shown or described.

[0025] Throughout the description and claims of this specification, the words "comprise" and "comprising," and variations of these words such as "comprise" and "comprising," are not intended to exclude additives, components, integers, or steps.

Claims

1. 1. A method for attaching a flexible, resilient slit spacer to an edge of a thin pane, the method comprising the steps of: applying a bending force to a first portion of the elastic slit spacer to change the slit from a closed state to an open state; moving the spacer and the thin pane relative to one another to position a portion of the thin pane within the open slit; and Removing the bending force from the first portion of the slit spacer to cause the slit spacer to resiliently close from the open state to a closed state and engage the thin pane.

2. 10. The method of claim 1, further comprising the step of changing the slit to an open state before the thin pane contacts the resilient slit spacer to minimize contact between the thin pane and the spacer during attachment of the thin pane to the spacer.

3. The method of claim 1 , wherein the step of applying a bending force is performed by a bending device that is not part of the thin pane.

4. The method of claim 1 , further comprising bending the first portion of the slit spacer about an axis perpendicular to the length of the slit spacer.

5. The method of claim 4 , wherein the slit spacer has an outer surface, and further comprising the step of orienting the spacer on the bending device with the outer surface of the slit spacer engaging the bending device.

6. The method of claim 5 further comprising bending the first portion of the slit spacer at least 90 degrees.

7. The method of claim 5 further comprising rotating the bending device.

8. The method of claim 5 , wherein the slit spacer has a water vapor barrier on an outer surface thereof, and further comprising contacting the water vapor barrier with the bending device.

9. The method of claim 1 , further comprising bending the first portion of the slit spacer about an axis parallel to the length of the slit spacer.

10. 10. The method of claim 9, further comprising applying a bending force with a bending device engaging the center of the outer surface of the slit spacer while supporting both inner corners of the slit spacer.

11. The method of claim 10 further comprising rotating the bending device while engaging the outer surface of the slit spacer.

12. The method of claim 11 , wherein the slit spacer has a water vapor barrier on an outer surface thereof, and further comprising contacting the water vapor barrier with the bending device.

13. 1. A method for attaching a slit spacer to an edge of a thin pane, the slit spacer having an outer surface and an opposing inner surface and a side having an inner corner defined as a location where the slit spacer joins the inner surface, the slit spacer defining a slit extending through the inner surface, the method comprising: bending the slit spacer to open the slit to receive the edge of the thin pane; moving the edge of the thin pane and the opening slit relative to one another until the edge of the pane is inside the opening slit; and Elastically closing the slit at the edge of the thin pane to connect the slit spacer to the pane.

14. 14. The method of claim 13, wherein the step of bending the slit spacer to open the slit occurs before the thin pane contacts the slit spacer, minimizing contact between the thin pane and the slit spacer while the spacer is attached to the thin pane.

15. The method of claim 13 further comprising bending the first portion of the slit spacer about an axis perpendicular to the length of the slit spacer.

16. 1. A method for attaching a resilient slit spacer to an edge of a thin pane, the method comprising the steps of: applying a bending force to the slit spacer to open the slit before the spacer engages the thin pane; After the slit is opened, placing an edge of the thin pane within the opened slit; and Removing the bending force to cause the slit to resiliently close at the edge of the panel and connect the slit spacer to the panel.

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