Manufacturing system and methods for manufacturing multiple paneinsulated glazing units

Abstract

A manufacturing system for a fenestration glazing unit includes a tripteron system and a control system to selectively actuate at least one pane of the fenestration glazing unit.

Description

MAN UFACTU RI NG SYSTEM AN D METHODS FOR MANU FACTURING MULTI PLE PANE GLAZING UNITSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 514,483, filed July 19, 2023, the entire disclosure of which is incorporated by reference.TECH N ICAL FI ELD

[0002] The present disclosure generally relates to insulated glazing units for fenestration units, and more particularly relates to a manufacturing system and methods for manufacturing multiple pane insulated glazing unit for a fenestration unit.BACKGROU ND

[0003] A fenestration unit, such as a window, sliding window, slider door, etc., may include a frame that supports one or more other components of the unit. For example, the fenestration unit may include a frame that supports a sash, which in turn supports a glazing unit. The glazing unit enables light to pass through the fenestration unit, and may also permit thermal energy to pass through the fenestration unit. As the fenestration unit may be installed in a building or other structure, it is generally undesirable for thermal energy within the building or other structure to pass freely through the glazing unit as it reduces an energy efficiency of the building or other structure.

[0004] Manufacturing the glazing unit may be difficult, time consuming, costly, inefficient, inaccurate, etc. These problems may be exacerbated for glazing units with multiple panes (e.g., three panes).

[0005] Accordingly, it is desirable to provide improved manufacturing methods and improved manufacturing systems for multiple pane glazing units. Furthermore, other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.BRI EF SU MMARY

[0006] In an example embodiment, a manufacturing system for a fenestration glazing unit having a first pane and a second pane is disclosed. The manufacturing system includes a tripteron system having a first elongate support and a second elongate support that are substantially parallel and that extend along an axis. The tripteron system includes a first carriage, a second carriage, and a third carriage. The first carriage is slidably attached to the first elongate support for sliding movement in a first direction and a second direction along the axis. The second carriage is slidably attached to the second elongate support for sliding movement along the axis in the first direction and the second direction. The third carriage is slidably mounted to both the first elongate support and the second elongate support for movement along the axis in the first direction and the second direction. The tripteron system includes a mount. The tripteron system includes a first hinged arm extending between and coupled to the first carriage and the mount, a second hinged arm extending between and coupled to the second carriage and the mount, a third hinged arm extending between and coupled to the third carriage and the mount, and a fourth hinged arm extending between and coupled to the third carriage and the mount. The manufacturing system also includes a control system configured to independently advance the first carriage, the second carriage, and the third carriage in either the first direction or the second direction to selectively actuate the mount to a predetermined position. Moreover, the manufacturing system includes a handling member coupled to the mount and configured for releasable engagement of at least one of the first pane and the second pane.

[0007] In an additional embodiment, a method of manufacturing a fenestration glazing unit having a first pane and a second pane is disclosed. The method includes providing a tripteron system having a first elongate support and a second elongate support that are substantially parallel and that extend along an axis. The tripteron system includes a first carriage, a second carriage, and a third carriage. The first carriage is slidably attached to the first elongate support for sliding movement in a first direction and a second direction along the axis, the second carriage is slidably attached to the second elongate support for sliding movement along the axis in the first direction and the second direction, and the third carriage is slidably mounted to both the first elongate support and the second elongate support for movement along the axis in the first direction and the second direction. The tripteron system also includes a mount. The tripteron system includes a first hinged arm extending between and coupled to the first carriage and the mount, a second hinged arm extending between and coupledto the second carriage and the mount, a third hinged arm extending between and coupled to the third carriage and the mount, and a fourth hinged arm extending between and coupled to the third carriage and the mount, the mount supporting a handling member. The method further includes releasably engaging one of the first pane and the second pane with the handling member. Moreover, the method includes selectively controlling, via a processor of a control system, independent advancement of the first carriage, the second carriage, and the third carriage in either the first direction or the second direction to selectively actuate to a predetermined position the mount, the handling member, and the releasably engaged one of the first pane and the second pane.BRIEF DESCRIPTION OF DRAWI NGS

[0008] The exemplary embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:

[0009] FIG. 1 is a perspective partially cross-sectional illustration of a fenestration unit, such as a vertical sliding window, which includes an exemplary multiple pane insulated glazing unit in accordance with the various teachings of the present disclosure;

[0010] FIG. 2 is a cross-sectional view of the fenestration unit of FIG. 1, taken along line 2-2 of FIG. 1;

[0011] FIG. 3 is perspective view of the multiple pane insulated glazing unit of the fenestration unit ofFIG. 1;

[0012] FIG. 4 is a cross-sectional view of the multiple pane insulated glazing unit, taken along line 4-4 of FIG. 3;

[0013] FIG. 5 is a schematic view of a manufacturing system for manufacturing the glazing unit of FIGS. 1-4, with a handling tool in a first position;

[0014] FIG. 6 is a schematic view of the manufacturing system with the handling tool in a second position;

[0015] FIG. 7 is a schematic view of the manufacturing system with the handling tool in a third position; and

[0016] FIGS. 8-11 are schematic illustrations of a manufacturing process for the glazing unit of FIG. 1-DETAILED DESCRI PTION

[0017] The following detailed description is merely exemplary in nature and is not intended to limit the application and uses. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. In addition, those skilled in the art will appreciate that embodiments of the present disclosure may be practiced in conjunction with any type of fenestration unit that would benefit from a multiple pane insulated glazing unit and the use of the multiple pane insulated glazing unit with a sliding window sash described herein is merely one exemplary embodiment according to the present disclosure. Further, it should be noted that many alternative or additional functional relationships or physical connections may be present in an embodiment of the present disclosure. In addition, while the figures shown herein depict an example with certain arrangements of elements, additional intervening elements, devices, features, or components may be present in an actual embodiment. It should also be understood that the drawings are merely illustrative and may not be drawn to scale.

[0018] Generally, the present disclosure relates to manufacturing systems and methods for manufacturing a multiple pane glazing unit. In some embodiments, the systems and methods of the present disclosure may be utilized to provide a glazing unit with at least three panes. In some embodiments, an intermediate pane may be layered and disposed between a first pane and a second pane, and the intermediate pane may be smaller (e.g., thinner) than the other two panes.

[0019] In some embodiments, the manufacturing system may include a tripteron handling tool system for handling at least one of the panes in the glazing unit (e.g., gripping a pane, vacuum engagement of a pane, actuation of the pane along a direction within an assembly workspace, and / or movement between two different workspaces, etc.). The tripteron system may provide a wide range of motion that may be selectively controlled via relatively simple control mechanisms and computerized control systems. The tripteron system may provide high manufacturing efficiency. The tripteron system may save space, may actuate at high speeds, and may be very accurate in controlled movement / actuation of one or more panes during assembly of the glazing unit. The tripteron system may also be useful for placement of a glazing unit within a frame of a fenestration unit. Other advantages and features are discussed below and are shown in the Figures according to example embodiments.

[0020] With reference to FIGS. 1 and 2, a fenestration unit 10 including a multiple pane insulated glazing unit 200 is shown. The fenestration unit 10 and / or the glazing unit 200 may be configured according to the teachings of co-owned U.S. Patent Application No. 18 / 058,550, filed November 23,2022, published as U.S. Patent Publication 2024 / 0167325 on May 23, 2024, the entire disclosure of which is incorporated by reference herein.

[0021] In this example, the fenestration unit 10 is a sliding window, such as a vertical sliding window, which includes two multiple pane insulated glazing units 200. It should be noted, however, that the present disclosure may be applicable to other types of fenestration units, including, but not limited to horizontal sliding doors, horizontal sliding windows, casement windows, awnings, skylights, etc. In this example, the fenestration unit 10 includes a fenestration frame 12, a fixed, first sash 14 and a movable, second sash 16. The fenestration frame 12 in this example is composed of a polymeric material, such as polyvinyl chloride, which is extruded, however, the fenestration frame 12 may be composed of other materials, including, but not limited to aluminum, wood, cladded wood, wood plastic composite, etc. The fenestration frame 12 supports the first sash 14 and the second sash 16. The first sash 14 is a fixed, non-active sash that is fixedly supported within the fenestration frame 12 and is immovable relative to the fenestration frame 12. The second sash 16 is a sliding sash that is supported within the fenestration frame 12 for sliding movement along a vertical axis 18. The vertical axis 18 is perpendicular to a lateral or horizontal axis 20 (i.e., lateral or horizontal direction), and an interior / exterior axis 22 is perpendicular to the vertical axis 18 and the horizontal axis 20. The first and second sashes 14, 16 are supported within the fenestration frame 12 and are offset along the interior / exterior axis 22 such that the second sash 16 partially overlaps the first sash 14. Generally, the second sash 16 is movable between: 1) a first position, shown in FIG. 2, in which the second sash 16 is closed; 2) a second position, in which the second sash 16 is open to enable ventilation through the fenestration unit 10; and 3) various positions in between the first position and the second position. When the fenestration unit 10 is coupled to a structure, such as a building, an exterior side 26 of the fenestration unit 10 is disposed on and faces outward from an exterior of the building, while an interior side 28 of the fenestration unit 10 is disposed on and faces inward into an interior of the building (FIG. 2).

[0022] In this example, with reference to FIG. 2, a screen 30 is coupled to the fenestration frame 12 so as to be covered by the second sash 16 in the closed, first position. In the second position, the screen 30 is exposed to enable fluids, such as air, to flow through the fenestration unit 10. The second sash 16 may include one or more seals 32, such as brush seals, which assist in inhibiting debris, fluids, etc. from entering through the movement of the second sash 16. The second sash 16 and the fenestration frame 12 may also include interlocking seals 34, which ensures debris, fluids, etc. do not enter through the fenestration frame 12 around the second sash 16. Generally, each of the multiple pane insulatedglazing units 200 is removably retained within the respective sash 14, 16 via one or more glass stops 36. In this example, each of the sashes 14, 16 include two glass stops 36 on opposite sides of the respective sash 14, 16. The glass stops 36 each include a support flange 38 and a flexible leg 40. The support flange 38 is in contact with and adjacent to the respective multiple pane insulated glazing unit 200 when the glass stops 36 are coupled to the respective sash 14, 16. The flexible leg 40 releasably couples the glass stops 36 to the respective sash 14, 16. In one example, each flexible leg 40 is received within a channel 42 defined in the respective sash 14, 16 such that a rotation of the support flange 38 relative to the channel 42 of the respective sash 14, 16 releases the glass stop 36 from the sash 14, 16. This enables the multiple pane insulated glazing unit 200 to be removed for cleaning or replacement, for example.

[0023] With reference to FIG. 3, one of the multiple pane insulated glazing units 200 is shown in greater detail. In some embodiments, each of the multiple pane insulated glazing units 200 is the same. For the sake of brevity, a single multiple pane insulated glazing unit 200 will be described in detail herein. Generally, the multiple pane insulated glazing unit 200 is a multiple pane glazing assembly, which assists in reducing the passage of thermal energy through the fenestration unit 10. In one example, the multiple pane insulated glazing unit 200 includes a first outer pane 202, a second outer pane 204, a third intermediate pane 206, a first spacer 208, and a second spacer 210.

[0024] In this example, the first outer pane 202 is positioned proximate the exterior side 26 of the fenestration unit 10, and the second outer pane 204 is positioned proximate the interior side 28 of the fenestration unit 10. The third intermediate pane 206 may be disposed between the first outer pane 202 and the second outer pane 204 along the interior / exterior axis 22. The first spacer 208 may be disposed between the first outer pane 202 and the third intermediate pane 206 and may support these panes 202, 206 spaced apart along the interior / exterior axis 22. The second spacer 210 may be disposed between the second outer pane 204 and the third intermediate pane 206 and may support these panes 204, 206 spaced apart along the interior / exterior axis 22. The third intermediate pane 206 may be substantially centered between the first and second outer panes 202, 204 along the interior-exterior axis 22. Also, the three panes 202, 204, 206 may be aligned along a common centerline that extends therethrough along the interior-exterior axis 22.

[0025] In one example, the first outer pane 202, the second outer pane 204, and the third intermediate pane 206 are composed of glass, and have about the same glass composition. The first outer pane 202, the second outer pane 204 and the third intermediate pane 206 may be formed using a glass float process.

[0026] In this example, the first outer pane 202, the second outer pane 204 and the third intermediate pane 206 are each composed of boron-free soda lime silicate glass. For example, each of the first outer pane 202 and the second outer pane 204 are composed of about 68 weight percent (wt%) to about 74 weight percent (wt%) of silicon dioxide (SiO2); about 12 weight percent (wt%) to about 16 weight percent (wt%) of sodium oxide (Na2O); about 0 weight percent (wt%) to about 1.1 weight percent (wt%) of potassium oxide (K2O); about 4 weight percent (wt%) to about 13 weight percent (wt%) of Calcium Oxide (CaO); about 0 weight percent (wt%) to about 4.5 weight percent (wt%) of magnesium oxide (MgO); about 0 weight percent (wt%) to about 4.8 weight percent (wt%) of aluminum oxide (AI2O3); less than about 0.3 weight percent (wt%) of sulfur trioxide SO3; and less than about 0.6 weight percent (wt%) of total iron oxide (Fe2O3 and FeO). In certain instances, less than about 0.5 weight percent (wt%) of Cerium oxide (CeO2) and titanium dioxide (TiO2) may be added to allow for a higher iron content. The total iron oxide content assists in filtering infrared and ultraviolet light. Generally, more than 25% of the total iron oxide content is iron oxide (FeO) as a higher concentration of iron oxide (FeO) is beneficial for infrared and ultraviolet light filtering. It should be noted that the weight percent of the total iron in the first outer pane 202, the second outer pane 204 and the third intermediate pane 206 may be reduced if higher visible light transmission is desired. In addition, one or more of the first outer pane 202, the second outer pane 204, and the third intermediate pane 206 may be annealed and / or tempered. In this example, the first outer pane 202 and the second outer pane 204 are annealed.

[0027] Generally, silicon dioxide acts as a glass network former, and alkali (sodium oxides and potassium oxides) and alkaline-earth oxides (calcium and magnesium oxides) act as a glass network modifier. Aluminum oxide acts as an intermediate for the glass network, and the sulfur acts as a refining agent. Generally, the use of this glass composition enables the first outer pane 202, the second outer pane 204 and the third intermediate pane 206 to have good chemical durability, high mechanical performance, and good thermal stability. This glass composition also provides for high throughput rate in the float glass manufacturing process, and the cost of manufacturing this glass composition using the float glass manufacturing process is relatively low compared to a vertical fusion manufacturing process.

[0028] With reference to FIG. 4, the first outer pane 202 includes a first outer surface 220 and a first inner surface 222 that is opposite the first outer surface 220. In this example, the first outer pane 202 is rectangular, and includes a plurality of first edges or sides 224. It should be noted, however, that the first outer pane 202 may have any desired shape, including, but not limited to, circular,trapezoidal, square, or generally any polygonal shape that corresponds with the shape of the second outer pane 204 and the third intermediate pane 206. In one example, the first outer surface 220 is coated, and includes a hard coating or scratch resistant coating, including, but not limited to silica and other oxides or nitrides with high surface hardness. In other embodiments, the first outer surface 220 may be uncoated. The first inner surface 222 is coated, and includes soft coating such as a low emissivity coating, including, but not limited to silver (Ag), copper (Cu), platinum (Pt), rhodium (Rh), nickel (Ni), Chromium (Cr), or combinations thereof in an alloy, etc. The first outer pane 202 has a thickness T1 defined between the first outer surface 220 and the first inner surface 222 or in the interior / exterior axis 22. In some embodiments, the thickness T1 may be about three millimeters (mm). In one example, the first outer pane 202 has a height Hl defined between opposed first sides 224 in the vertical axis 18 of about 800 millimeters (mm) and a width W1 defined between opposed first sides 224 (FIG. 3) in the horizontal axis 20 of about 700 millimeters (mm). It should be noted that the height Hl and the width W1 (FIG. 3) of the first outer pane 202 may vary based on the fenestration frame 12 associated with the multiple pane insulated glazing unit 200, and thus, the values of the height Hl and the width W1 are merely examples.

[0029] With continued reference to FIG. 4, the second outer pane 204 includes a second outer surface 230 and a second inner surface 232 that is opposite the second outer surface 230. In this example, the second outer pane 204 is rectangular, and includes a plurality of second edges or sides 234. It should be noted, however, that the second outer pane 204 may have any desired shape, including, but not limited to, circular, trapezoidal, square, or generally any polygonal shape that corresponds with the shape of the first outer pane 202 and the third intermediate pane 206. In one example, the second outer surface 230 is coated, and includes a hard coating or scratch resistant coating, including, but not limited to silica and other oxides or nitrides with high surface hardness, a tin oxide coating, or a transparent conductive oxide coating. The second inner surface 232 may be coated to include a soft coating such as a low emissivity coating, including, but not limited to silver (Ag), copper (Cu), platinum (Pt), rhodium (Rh), nickel (Ni), Chromium (Cr), or combinations thereof in an alloy, etc.

[0030] In some embodiments, the second outer pane 204 may have the same thickness T1 defined between the second outer surface 230 and the second inner surface 232 (i.e., measured along the interior / exterior axis 22) as the first outer pane 202. Thus, like the first outer pane 202, the second outer pane 204 may have a thickness T1 of about three millimeters (mm). Moreover, in some embodiments, the second outer pane 204 may have the same height defined between opposed second sides 234 in the vertical axis 18 and the same width W1 defined between opposed secondsides 234 (FIG. 3) in the horizontal axis 20 as the first outer pane 202. Thus, the second outer pane 204 may have the same height Hl, the same width Wl, and the same thickness T1 as the first outer pane 202 as indicated in FIG. 4.

[0031] The third intermediate pane 206 may be positioned between the first outer pane 202 and the second outer pane 204. The third intermediate pane 206 includes a third inner surface 240 and a fourth inner surface 242 that is opposite the third inner surface 240. In this example, the third intermediate pane 206 is rectangular, and includes a plurality of third edges or sides 244. In one example, the third inner surface 240 is coated, and includes a hard coating or scratch resistant coating, including, but not limited to silica and other oxides or nitrides with high surface hardness, a tin oxide coating, or a transparent conductive oxide coating. The fourth inner surface 242 may also be coated with a hard coating such as a scratch resistant coating, including, but not limited to silica and other oxides or nitrides with high surface hardness. In certain embodiments, the fourth inner surface 242 may be uncoated. In addition, in certain embodiments, the third inner surface 240 and / or the fourth inner surface 242 may include a soft coating such as a low emissivity coating, including, but not limited to silver (Ag), copper (Cu), platinum (Pt), rhodium (Rh), nickel (Ni), Chromium (Cr), or combinations thereof in an alloy, etc. The low emissivity coating may have an emissivity of about 0.02 to about 0.07, and a solar transmittance of about 0.2 to about 0.7. Generally, the hard coatings, such as the scratch resistant coatings, are coated onto the surfaces of the respective panes 202, 204, 206 during the float glass manufacturing process, using a pyrolytic coating process where the temperature bonds the hard coating onto the respective surface. For the soft coatings, the metallic elements are deposited onto the surface of the respective panes 202, 204, 206 at a relatively lower temperature than that of the pyrolytic coating process using a magnetron sputtering process, for example.

[0032] In one example, the third intermediate pane 206 is a comparatively skinny pane having a thickness T3 that is different and less than the thickness T1 of the first outer pane 202 and the second outer pane 204. In some embodiments, the thickness T3 is about 0.2 millimeters (mm) to about 1.2 millimeters (mm) and in this example, is about 0.7 millimeters (mm). Also, the third intermediate pane 206 has a height H3 defined between opposed third sides 244 in the vertical axis 18 (FIG. 4) and a width W3 defined between opposed third sides 244 (FIG. 3) in the horizontal axis 20. In one example, the height H3 is different and less than the height Hl, and the width W3 is different and less than the width Wl. Stated another way, a perimeter of the third intermediate pane 206 defined by the third sides 244 may be different and less than (i.e., reduced in comparison to) a perimeter of the first outer pane 202 defined by the first sides 224. Similarly, the perimeter of the third intermediate pane 206defined by the third sides 244 may be different and less than (i.e., reduced in comparison to) a perimeter of the second outer pane 204 defined by the second sides 234.

[0033] When assembled, the intermediate pane 206, the first outer pane 202, and the second outer pane 204 may be layered in a stack with the intermediate pane 206 between the outer panes 202, 204, and the panes 202, 204, 206 may share a centerline that extends along the axis 22. The first and second outer panes 202, 204 may be centered on the axis 22 such that the sides 224 substantially have the same, overlapping peripheral profile (when viewed along the axis 22), and the profile of the intermediate pane 206 may be centered within the overlapping profiles of this stack such that the sides 244 are disposed inwardly along the axis 18 and the axis 20 relative to the sides 224, 234. Accordingly, the outer perimeter of the third intermediate pane 206 may be recessed, inset, and disposed inwardly relative to the respective perimeters of the first outer pane 202 and the second outer pane 204. In other words, all sides 244 of the third intermediate pane 206 may be inset and spaced inwardly toward a common centerline relative to the sides 224, 234 when viewed along interior / exterior axis 22. Additionally, it will be appreciated that an area of the third intermediate pane 206 may be different and less than an area of each of the first outer pane 202 and the second outer pane 204.

[0034] The thickness T3 of the third intermediate pane 206 may be smaller than the thickness T1 of the first and second outer panes 202, 204, and as a result, the overall thickness of the glazing unit 200 (measured along the axis 22 between the first outer surface 220 and the second outer surface 230) may be relatively small. Thus, the glazing unit 200 may be advantageously compact. Also, the smaller thickness T3 may provide significant reduction in weight for the glazing unit 200.

[0035] Additionally, a number of advantages may be provided due to the third intermediate pane 206 having a height H3 and width W3 that is different (less than) the height Hl and the width Wl, respectfully, of the first outer pane 202 and the second outer pane 204. The smaller dimensions of the third intermediate pane 206 may provide for ease of assembly of the multiple pane insulated glazing unit 200. In this regard, the third intermediate pane 206 may serve as a visual guide for the coupling of the first spacer 208 or the second spacer 210 to the third intermediate pane 206. In addition, by providing the third intermediate pane 206 with the height H3 and the width W3 that is different and less than the height Hl and the width Wl of the first outer pane 202 and the second outer pane 204, respectively, the third intermediate pane 206 may be less prone to damage during transportation and handling. For example, the sides 244 may be shielded, protected, etc. by the outwardly disposed sides 224 of the first outer pane 202 and the sides 234 of the second outer pane204. Further, by reducing the size of the third intermediate pane 206, the first edges or sides 224 and / or second edges or sides 234 of the thicker outer panes 202, 204 may be the surfaces of the multiple pane insulated glazing unit 200 that are contacted during handling and transportation. Thus, by reducing the peripheral size of the third intermediate pane 206 within the glazing unit 200, the third edges or sides 244 of the third intermediate pane 206 may be protected from contact or experiencing an impact when being handled or transported. Further, the reduced size (height H3 and width W3) of the third intermediate pane 206 may provide shock absorption for the multiple pane insulated glazing unit 200. The recessed sides 244 of the third intermediate pane 206 may eliminate the potential for the third edges or sides 244 of the third intermediate pane 206 to contact the first sides 224 and / or second sides 234 of the respective outer panes 202, 204 during a compression of the multiple pane insulated glazing unit 200 caused by thermal contraction of the fenestration frame 12 and / or the sashes 14, 16.

[0036] With the third intermediate pane 206 positioned between the first outer pane 202 and the second outer pane 204, a first chamber 250 and a second chamber 252 may be defined between the third intermediate pane 206 and the respective one of the first outer pane 202 and the second outer pane 204. In this example, the first chamber 250 may be defined between the first inner surface 222 and the third inner surface 240. The second chamber 252 may be defined by the fourth inner surface 242 and the second inner surface 232. The first spacer 208 may enclose the first chamber 250, and the second spacer 210 may enclose the second chamber 252 such that the first chamber 250 is fluidly isolated from the second chamber 252. In one example, each of the first chamber 250 and the second chamber 252 may have a chamber width WC, and the chamber width WC of the first chamber 250 may be equal to that of the second chamber 252. In this example, the chamber width WC may be approximately 0.7 millimeters (mm). The first chamber 250 and the second chamber 252 may provide insulation between the panes 202, 204, 206, which cooperates in reducing the transmission of thermal energy through the multiple pane insulated glazing unit 200.

[0037] Generally, the first spacer 208 and the second spacer 210 may form a seal about the perimeter of the respective one of the first outer pane 202 and the third intermediate pane 206, and the second outer pane 204 and the third intermediate pane 206.

[0038] The first and second spacers 208, 210 may be substantially similar and may respectively include a spacer base 260, a first spacer leg 262 and a second spacer leg 264 that are arranged to define a C- shaped cross-section (FIG. 4). Each of the first spacer 208 and the second spacer 210 may be hollow. The spacer base 260 may be substantially planar, and may define a spacer outer perimeter 266 ofeach of the first spacer 208 and the second spacer 210. The spacer outer perimeter 266 may be inset, recessed, etc. from the sides 224, 234 of the first and second outer panes 202, 204. The spacer outer perimeter 266 may also be inset, recessed, etc. from the sides 244 of the third intermediate pane 206. The spacers 208, 210 may be attached and sealed to the opposing surfaces of respective panes 202, 204, 206 with a first sealant 300 on the first spacer leg 262 and a second sealant 302 on the second spacer leg 264.

[0039] The spacer base 260 may define a fill opening, which enables a nozzle, tube or other conduit to be inserted to fill the respective one of the first chamber 250 and the second chamber 252 with a fluid F once the multiple pane insulated glazing unit 200 is assembled, if desired. In one example, the fluid F includes, but is not limited to a pressurized gas, air-argon mix, argon-krypton mix, air, etc. In this example, the fluid F is the same between the first chamber 250 and the second chamber 252, but in other embodiments, the fluid F may be different between the first chamber 250 and the second chamber 252.

[0040] Referring back to FIGS. 1 and 2, the assembled glazing unit 200 may be supported in the frame 12 of the fenestration unit 10. The first and second outer panes 202, 204 of the glazing unit 200 may be referred to as "structural panes" since they are directly connected to and in contact with the frame 12 and, therefore, provide substantial support to the overall structural integrity of the glazing unit 200. The intermediate pane 206, on the other hand, may be referred to as a "non-structural pane" since it is indirectly attached to the frame 12 (i.e., attached via the spacers 208, 210, the outer panes 202, 204, etc.) and, therefore, provides less to the overall structural integrity of the glazing unit 200.

[0041] Referring now to FIGS. 5-7, a manufacturing system 1002 of the present disclosure may be provided for manufacturing at least some parts of the glazing unit 200. The manufacturing system 1002 may be used for assembly of the glazing unit 200. The manufacturing system may utilize a manufacturing method of the present disclosure, which is represented in FIGS. 5-11.

[0042] In some embodiments, the manufacturing system 1002 includes a handling tool 1004. The handling tool 1004 may include a three-axis robot or kinematically linear system referred to as a "tripteron" or tripteron system.

[0043] The handling tool 1004 may include two parallel and spaced-apart rails 1006, 1008 or other elongate supports that extend along a rail axis 1001. The handling tool 1004 may also include three input carriages 1011, 1012, 1013. The first carriage 1011 may be slidably attached to the first rail 1006 for sliding movement along the axis 1001, and the second carriage 1012 may be independently and slidably attached to the second rail 1008 for sliding movement along the axis 1001. The third carriage1013 may be slidably mounted to both the first and second rails 1006, 1008 for movement along the axis 1001.

[0044] The tripteron handling tool 1004 may also include belts 1025 (e.g., a first belt 1025A, a second belt 1025B, and a third belt 1025C) respectively disposed in and among the rails 1006, 1008. The belts 1025A, 1025B, 1025C may extend longitudinally along the rails 1006, 1008 and along the axis 1001. The first belt 1025A may be engaged (i.e., operatively coupled) to the first carriage 1011, the second belt 1025B may be engaged and coupled to the second carriage 1012, and the third belt 1025C may be engaged and coupled to the third carriage 1013. The belts 1025 may advance in either direction longitudinally along the ais 1001 within the respective rail 1006, 1008. Accordingly, one belt 1025A, 1025B, 1025C may advance in one direction for advancing the attached ones of the carriages 1011, 1012, 1013. The other belt(s) 1025A, 1025B, 1025C may independently and selectively advance in either direction for advancing the attached ones of the carriages 1011, 1012, 1013. When working in combination, one or more of the belts 1025A, 1025B, 1025C may selectively advance in one or the other direction along the axis 1001, thereby positioning the carriages 1011, 1012, 1013 along the axis 1001.

[0045] The handling tool 1004 may further include a mount 1020 that supports a handling member 1022 (i.e., handling attachment). The handling member 1022 may include a suction cup as well as an attached vacuum source, etc. Pressure in the handling member 1022 may be selectively adjusted for gripping and releasing a pane 1030 of glass (e.g., one of the panes 202, 204, 206 of the glazing unit 200 of FIGS 1-4).

[0046] Also, the mount 1020 may be connected to the carriages 1011, 1012, 1013 collectively by four hinged arms (e.g., a first arm 1040A, a second arm 1040B, a third arm 1040C, and a fourth arm 1040D). The first arm 1040A may extend between and may be coupled to the first carriage 1011 and the mount 1020, the second arm 1040B may extend between and may be coupled to the second carriage 1012 and the mount 1020, the third arm 1040C may extend between and may be coupled to the third carriage 1011 and the mount 1020, and the fourth arm 1040D may extend between and may be coupled to the third carriage 1011 and the mount 1020. Each arm 1040A, 1040B, 1040C, 1040D may have a hinge joint 1042 midway along its longitudinal length. Also, the arms 1040A, 1040B, 1040C, 1040D may be pivotably attached at each end (i.e., pivotally attached to the mount 1020 and to the respective carriage 1011, 1012, 1013).

[0047] The angle of the joints 1042 may be controlled by selectively moving and arranging the belts1025A, 1025B, 1025C within the rails 1006, 1008. The joints 1042 may be free to swing about theirrespective pivot axes according to arrangement of the carriages 1011, 1012, 1013. In other words, the arms 1040A, 1040B, 1040C, 1040D may freely adjust and swing according to the respective positions and movements of the carriages 1011, 1012, 1013. Therefore, moving the belts 1025 changes the arrangement of the carriages 1011, 1012 to, in turn, actuate the mount 1020, the handling member 1022, and the pane 1030.

[0048] FIGS. 5, 6, and 7 show first, second, and third positions, respectively, of the handling tool 1004. It will be appreciated that the handling tool 1004 provides a large degree of freedom of controlled movement. The mount 1020 may move in three axes in a Cartesian coordinate system. Specifically, the mount 1020 may move in either direction along the axis 1001 (along the rails 1006, 1008). The mount 1020 may also move in either direction normal to the axis 1001 along a horizontal transverse axis 1003. Moreover, the mount 1020 may move toward and away from the rails 1006, 1008 along a vertical axis 1005.

[0049] In some embodiments, the mount 1020 may remain substantially level (e.g., within the horizontal plane defined by the axis 1001 and the axis 1003) as the carriages 1011, 1012, 1013 are actuated. In additional embodiments, the mount 1020 may rotate about one or more of the axes 1001, 1003, 1005.

[0050] The rails 1006, 1008 may be mounted along an assembly line of the glazing unit 102. For example, the rails 1006, 1008 may extend from work station where the glazing unit 200 is partly assembled to another work station where further assembly is performed.

[0051] Also, the rails 1006, 1008 may be mounted in a convenient location, such as an overhead support (ceiling, overhead support beams, etc.), or vertical wall mount. In other words, the vertical axis 1005 may be the direction of gravity (downward in FIG. 5), and the arms 1040A, 1040B, 1040C, 1040D may suspend the mount 1020 from the carriages 1011, 1012, 1013 and the rails 1006, 1008. Theus, the tripteron handling tool 1004 may be mounted above a workstation with respect to a direction of gravity, and the pane 1030 may be handled therebelow. That way, the handling tool 1004 may be convenient for use but also unlikely to obstruct the assembly process. In additional embodiments, the tripteron handling tool 1004 may be inverted so that the pane 1030 is supported atop the handling tool 1004. In further embodiments, there may a plurality of tripteron handling tools 1004, which interact for assembly of the glazing unit 200.

[0052] The handling tool 1004 may, therefore, be a parallel axis tripteron system for picking up, handling, and transporting panes, pane-and-spacer-assemblies, and / or other portions of the glazingunit 200. The handling tool 1004 may be highly accurate and may provide repeatable movement. Also, the controls for the handling tool 1004 can be relatively simple.

[0053] The handling tool 1004 may be used in a manual manufacturing process in some embodiments, and the handling tool 1004 may assist the worker in picking up the pane 1030, placing the pane 1030, or otherwise moving the pane 1030.

[0054] Additionally, the handling tool 1004 may be operatively coupled to a control system 1102 that automatically controls actuation of the mount 1020. The control system 1102 may include a processor 1014, at least one sensor 1016, and a memory device 1018. The processor 1014 may generate control commands for actuating the mount 1020 based on stored data in the memory device 1018 and sensed position feedback received from the sensor 1016 (i.e., a position sensor). Control signals from the processor 1014 may actuate the belts 1025A, 1025B, 1025C to selectively actuate the position of the mount 1020 for handling the pane 1030 and / or other parts during the assembly process.

[0055] In some embodiments, the glazing unit 200 may be constructed according to methods shown in FIGS. 8-11. The handling tool 1004 may be used to assist in these methods.

[0056] As shown, the control system 1102 may generate a control signal for the handling member 1022 to grasp the intermediate pane 206. The first spacer 208 may be pressed onto and adhesively attached to one side (e.g., the top side with respect to the vertical axis 1005).

[0057] Then, with the handling member 1022 still engaging the pane 206, the pane 206 may be placed atop the second spacer 210, which is supported atop a first work station support 1026 (e.g., a work table surface, etc.). The second spacer 210 may be is pressed onto and adhesively attached to the opposite surface (e.g., the bottom side) of the intermediate pane 206 (FIG. 9). The handling member 1022 may subsequently release the intermediate pane 206.

[0058] Next, as shown in FIG. 10, the handling member 1022 may be used to grasp and move the first pane 202 and onto a spacer-glass-spacer assembly 1050. The first pane 202 may be pressed onto and adhesively attached to the spacer-glass-spacer assembly 1050. Once placed, the handling member 1022 may release the first pane 202.

[0059] Subsequently, as shown in FIG. 11, the handling member 1022 may grasp the outer side of the first pane 202 and lift the assembled first pane 202, first spacer 208, intermediate pane 206, and second spacer 210 onto the second pane 204, which is supported on a second work station support 1028 (e.g., another work table surface, etc.).

[0060] In additional embodiments, there may be one or more automated features of the method of manufacturing. For example, a laser device 1060 may be used for positioning the spacers 208, 210 onthe intermediate pane 206 (e.g., to be inset at a distance 280 from sides 244 of the pane 206 to the spacer outer perimeter 266 as shown in FIG. 8). The laser device 1060 may also be used to position the first pane 202 and the second pane 204 spaced apart at a distance 282 from the spacer outer perimeter 266 a shown in FIG. 10. In some embodiments, light from the laser device 1060 may be directed to at least two reference points on at least two different parts, reflected light may be detected by the sensor 1016 to detect the relative position of the at least two parts. Then, the processor 1014 may generate control commands for actuating the handling tool 1004 until the sensor 1016 detects that the parts are in a desired position. Then, the parts may be attached. The process flow of FIGS. 8-11 may be the same as described above, except the control system 1102 may control movement of the handling tool 1004 for automated, robotic movement of the parts.

[0061] In some embodiments, the handling tool 1004 may perform the assembly of FIGS. 8-11 with the parts in a horizontal position (i.e., with the direction of gravity extending normal to the panes 202, 204, 206. Thus, gravity may assist in the assembly process for added convenience.

[0062] In some embodiments, the handling tool 1004 may reorient (e.g., flip) the intermediate pane 206 (or the other panes 202, 204) at least ninety-degrees during the assembly process.

[0063] In some embodiments, at least one of the panes 202, 204, 206 may be flipped over (e.g., rotated 180 degrees), for example, when assembling the assembly 1050 of FIGS. 8 and 9.

[0064] The manufacturing system 1002 and the methods of manufacturing discussed herein provide high manufacturing efficiency. Features may be automated for high accuracy, repeatability, and efficiency. The handling tool 1004 may save space, may actuate at high speeds, and may be very accurate. The tool 1004 may also have relatively low operating noise and may be easy to control and maintain.

[0065] Manual assembly steps may be effective. The glazing units 200 may be at least partly manually produces with low risk of damaging the parts, misaligning pats, etc.

[0066] Also, the method may be at least partly automated. As such, manufacturing may be highly efficient. There may be low risk of damage or contamination of the panes, misalignment of the parts, etc. Also, the glazing units 200 may be accurately made with relatively low variation in stack thickness, and other defects can be avoided.

[0067] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way.Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the present disclosure. It is understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the present disclosure as set forth in the appended claims.

Claims

CLAIMSWhat is claimed is:

1. A manufacturing system for a fenestration glazing unit having a first pane and a second pane, the manufacturing system comprising: a tripteron system having a first elongate support and a second elongate support that are substantially parallel and that extend along an axis, the tripteron system including a first carriage, a second carriage, and a third carriage, the first carriage slidably attached to the first elongate support for sliding movement in a first direction and a second direction along the axis, the second carriage slidably attached to the second elongate support for sliding movement along the axis in the first direction and the second direction, the third carriage slidably mounted to both the first elongate support and the second elongate support for movement along the axis in the first direction and the second direction, the tripteron system including a mount, the tripteron system including a first hinged arm extending between and coupled to the first carriage and the mount, a second hinged arm extending between and coupled to the second carriage and the mount, a third hinged arm extending between and coupled to the third carriage and the mount, and a fourth hinged arm extending between and coupled to the third carriage and the mount; a control system configured to independently advance the first carriage, the second carriage, and the third carriage in either the first direction or the second direction to selectively actuate the mount to a predetermined position; and a handling member coupled to the mount and configured for releasable engagement of at least one of the first pane and the second pane.

2. The manufacturing system of claim 1, further comprising a first belt coupled to the first carriage, a second belt coupled to the second carriage, and a third belt coupled to the third carriage; and the control system operatively coupled to the first belt, the second belt, and the third belt for individually actuating the first belt, the second belt, and the third belt to respectively advance the first carriage, the second carriage, and the third carriage in the first direction or the second direction.

3. The manufacturing system of claim 1, wherein the first hinged arm, the second hinged arm, the third hinged arm, and the fourth hinged arm suspend the mount from the first elongate support and the second elongate support, which are mounted above a workstation with respect to a direction of gravity.

4. The manufacturing system of claim 1, wherein the handling member includes a suction device that is supported by the mount, the suction device configured to selectively adjust a suction load for releasably engaging the at least one of the first pane and the second pane.

5. The manufacturing system of claim 1, wherein the control system includes a processor, at least one sensor, and a memory device, the processor configured to generate control commands for actuating the mount based on stored data in the memory device and sensed position feedback received from the at least one sensor.

6. The manufacturing system of claim 5, wherein the axis is a first axis that defines a Cartesian coordinate system in cooperation with a second axis and a third axis, and wherein the processor is configured to generate control commands for selectively actuating the mount along each of the first axis, the second axis, and the third axis.

7. The manufacturing system of claim 1, wherein the fenestration glazing unit includes the first pane, the second pane, and a third pane, wherein one of the first pane, the second pane, and the third pane is layered between the other two of the first pane, the second pane, and the third pane; and the handling member configured for releasable engagement of at least one of the first pane, the second pane, and the third pane.

8. The manufacturing system of claim 1, further comprising a laser system that detects relative position between the at least one of the first pane and the second pane and a spacer; and the control system configured to selectively actuate the mount to the predetermined position according to the detected relative position.

9. A method of manufacturing a fenestration glazing unit having a first pane and a second pane, the method comprising: providing a tripteron system having a first elongate support and a second elongate support that are substantially parallel and that extend along an axis, the tripteron system including a first carriage, a second carriage, and a third carriage, the first carriage slidably attached to the first elongate support for sliding movement in a first direction and a second direction along the axis, the second carriage slidably attached to the second elongate support for sliding movement along the axis in the first direction and thesecond direction, the third carriage slidably mounted to both the first elongate support and the second elongate support for movement along the axis in the first direction and the second direction, the tripteron system including a mount, the tripteron system including a first hinged arm extending between and coupled to the first carriage and the mount, a second hinged arm extending between and coupled to the second carriage and the mount, a third hinged arm extending between and coupled to the third carriage and the mount, and a fourth hinged arm extending between and coupled to the third carriage and the mount, the mount supporting a handling member; releasably engaging one of the first pane and the second pane with the handling member; and selectively controlling, via a processor of a control system, independent advancement of the first carriage, the second carriage, and the third carriage in either the first direction or the second direction to selectively actuate to a predetermined position the mount, the handling member, and the releasably engaged one of the first pane and the second pane.

10. The method of claim 9, wherein the fenestration glazing unit includes the first pane, the second pane, and a third pane, wherein one of the first pane, the second pane, and the third pane is layered between the other two of the first pane, the second pane, and the third pane.

11. The method of claim 10, wherein the first pane is configured to be layered between the second pane and the third pane; and wherein releasably engaging one of the first pane and the second pane includes releasably engaging the first pane.

12. The method of claim 11, wherein the first pane is smaller than the first pane and the second pane.

13. The method of claim 12, wherein the first pane is thinner than the first pane and the second pane.

14. The method of claim 13, further comprising attaching a first spacer and a second spacer to the first pane to define an spacer-pane assembly; and after defining the spacer-pane assembly, attaching the first spacer of the spacer-pane assembly to the second pane and attaching the second spacer of the spacer-pane assembly to the third pane.

Images