System for making safety panes for architectural products

Abstract

Various aspects for a securely conveying, processing, and / or laminating a dimensionally large, cross-sectionally thin glass sheet to configure a safety pane and / or a coated thin glass sheet for use in the manufacture of architectural products incorporating thin glass therein.

Description

Attorney Docket No. SP24-313PCTSYSTEM FOR MAKING SAFETY PANES FOR ARCHITECTURAL PRODUCTSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S. C. §119 of U.S. Provisional Application No. 63 / 725,746 filed November 27, 2024, the content of which is incorporated herein by reference in its entirety.FIELD OF THE DISCLOSURE

[0002] Generally, the present disclosure is directed towards embodiments of systems and methods for making thin glass safety glazings, which can be incorporated into architectural products to achieve tailored designs with improved, advantaged performance over incumbent IGU designs. Also, the present disclosure is directed towards embodiments of an automated IGU manufacturing line that incorporates an in-line shuttling and lamination device to manufacture safety film - thin glass laminates for incorporation into specialty IGU and architectural products, including methods for making the same.BACKGROUND

[0003] To address increasing concerns over energy use and sustainability while improving people comfort, home builders are looking for better higher thermal performance and government organizations incentivize the use of higher thermal performance windows (E.g. Energy Star in the US). Triple pane windows provide an efficient solution to decrease the U-factor of windows (where lower the U-factors denote higher window insulation). A thin triple pane IGU, with a central pane having a cross-sectional thickness below 3.0 mm, are advantaged because there is increased cavity space for the insulating gas and a lower weight (as compared to a thick center pane). However, certain safety regulations require that all panes meet certain standards, even with an enclosed center pane in the inner cavity of the IGU. There are significant challenges in manufacturing thin glass that meets safety requirements.SUMMARY OF THE DISCLOSURE

[0004] The present disclosure provides solutions to manufacture thin glass that meets safety requirements, where the thin glass is architecturally dimensioned (e.g. large areal dimension, small cross-sectional thickness). Pursuant to the disclosure, when thin center pane laminated with a film is required for functional (e.g safety, anti-theft, among other applications)Attorney Docket No. SP24-313PCT or decorative benefit, the equipment and systems set forth herein are configured to provide thin safety panes, which include thin glass and a safety film. Also, the equipment and systems set forth herein are configured to enable improved yield processing of thin glass (e.g. with coatings or the like).

[0005] In some embodiments, the tilting conveyor shuttle is configured to handle and convey thin glass (which can flex as compared to thick glass) in a controlled manner, so that the thin glass has lower frequencies of breakage, defects and / or flaws associated with the conveyance and processing (including lamination). In some embodiments, the system is configured to laminate this thin sheet of glass without creating optical defects or scratches / flaws in the processed or laminated thin glass.

[0006] In some embodiments, the equipment is configured to off-load the thin glass and transfer it to the next station / conveyor for downstream processing and / or storage. In some embodiments, the equipment is configured in a compact layout that minimizes the footprint of the equipment in installation.

[0007] Generally, the present disclosure is directed towards embodiments of systems and methods for making a safety glazing that is an architecturally sized (i.e. large areal dimension) thin layer of glass in combination with a safety film, where the safety glazing is utilizable in architectural applications to provide improved performance attributes while meeting or exceeding regulatory requirements and safety standards. Also, the present disclosure is directed towards equipment for handling and processing architecturally sized, cross-sectionally thin glass into safety laminates. Further, the present disclosure is directed towards lamination systems for handling and processing architecturally sized, thin glass into a safety glazing in an automated manner. One or more of the embodiments of safety glazings, IGUs having safety glazings and windows incorporating such IGUs are configured to comply with In one aspect, a system for processing thin glass for architectural products, the system comprising: a thin glass processing device; and a glass transfer device, configured to securely retain a cross-sectionally thin, dimensionally large piece of thin glass and convey the thin glass sheet at least one of to, from, or through the thin glass processing device.

[0008] In some embodiments, the thin glass processing device is selected from: a laminator device and a glass surface treatment device.

[0009] In some embodiments, thin glass processing device is a laminator device, wherein the laminator device, is configured to receive the thin glass sheet from glass transferAttorney Docket No. SP24-313PCT device and apply a film onto a major surface of the thin glass sheet, to yield a safety pane (laminated thin glass sheet).

[0010] In some embodiments, the glass transfer device is configured as a glass conveyance device, in which glass is air floated onto the laminator device via a shuttle plate.

[0011] In some embodiments, the thin glass sheet is retained in place on a back plate of the glass conveyance device thru the use of vacuum force.

[0012] In some embodiments, the thin glass sheet and the back plate of the glass conveyance device is configured to be movable to adjust to a vertical, horizontal, or angled position, where such positioning is configured for lamination via the laminator device.

[0013] In some embodiments, the back plate of the glass conveyance device is configured to receive the safety pane (after lamination) and transfer the safety pane out of the laminator device.

[0014] In some embodiments, the laminator device is configured to apply a film to a thin glass sheet during glass conveyance, while the thin glass sheet is retained on the back of the glass conveyance device.

[0015] In some embodiments, the conveyor device is configured to move glass from a first position to a second position, while enabling the thin glass sheet to be positioned at different angles to retain and / or process the thin glass sheet, while configured to convey the lower-most edge of the thin glass sheet via frictional engagement and while configured to convey the major surface of the thin glass sheet via vacuum and / or positive pressure (push-pull floating the thin glass sheet to avoid sliding engagement with the maj or surface of the thin glass sheet).

[0016] In some embodiments, a conveyance device is configured with a table configured with a plurality of holes (or orifices / through holes).

[0017] In some embodiments, the table of the conveyance device is configured with a plurality of first holes having an average size configured to enable vacuum / negative pressure applying a pulling force on the major surface of the thin glass sheet.

[0018] In some embodiments, the table of the conveyance device is configured with a the plurality of second holes have an average size configured to enable positive pressure / air blowing out of the holes towards the surface of the thin glass sheet.

[0019] In some embodiments, the table is configured to be supplied with air (positive pressure) through a plurality of holes configured in a first pattern (density and spacing) in theAttorney Docket No. SP24-313PCT table surface) and vacuum (negative pressure) through a plurality of holes configured in a second pattern (density and spacing) in the table surface.

[0020] In some embodiments, the table is configured to be adjustable in tilt angle from a first position (pl), to a second position (p2), to a number of different angled positions (pn) between a horizontal angle (90 degree angle) to a vertical angle (0 degree angle).

[0021] In some embodiments, the conveyance device is configured with at least one set of rollers, where the rollers are configured to move the glass as it is air floated.

[0022] In some embodiments, the plurality of holes are configured with an average diameter size in the range of 0.5 mm to 20 mm.

[0023] In some embodiments, the plurality of holes are configured with an average diameter size in the range of 0.5 mm to 5 mm.

[0024] In some embodiments, the system is configured with a glass surface treatment device, which is configured to apply a coating to at least one major surface of the thin glass sheet or safety pane.

[0025] In another aspect, the system is provided for manufacturing safety panes which can be configured as a center pane in a thin triple or quad pane insulated glazing units (IGUs). (meet or exceed) the safety glazing requirements set out in ANSI Z97.1 (windows) and / or CPSC 16 CFR Part 1201 (for doors).

[0026] In another aspect, a method of making a safety glazing is provided the method including: directing a thin glass ply into a laminator; positioning a film relative to a major surface of the thin glass ply, wherein the film comprises an adhesive layer and a polymeric layer; contacting the adhesive layer of the film onto an area adjacent to a leading edge of the major surface of thin glass ply; and continuously applying the film to the thin glass ply, while at least one of the thin glass ply and the film move relative to each other until the film is applied to the thin glass ply to provide a safety glazing.

[0027] In some embodiments, the method further comprises applying pressure along the upper surface of the film to promote adhesion between the adhesive layer and the major surface of the thin glass ply.

[0028] In some embodiments, the method comprises curing the adhesive.

[0029] In some embodiments, the method comprises controlling the directing, positioning, contacting, and applying steps via a control system.

[0030] In some embodiments, the control system is configured to control one or more of the following variables, including: the speed of the thin glass ply; the speed of the filmAttorney Docket No. SP24-313PCT role / laminator head; the direction and speed of cutting; the contact pressure and / or force of the rollers; the heat of the glass conveyance plate, glass, and / or laminator components (e.g. rollers, film, etc), and pretreatment, inspection sensors, and post processing.

[0031] In some embodiments, the thin glass ply is configured in a vertical or near vertical configuration (i.e. not greater than 15 degree tilt from vertical).

[0032] In some embodiments, the thin glass ply is configured in a tilted or angled configuration (i.e. greater than 15 degrees to about 60, and not more than 75 degrees (e.g. taking the angle from the glass if it were in a vertical configuration).

[0033] In some embodiments, the thin glass ply is configured in a horizontal or near flat configuration (i.e. not greater than 15 degree tilt from vertical). In this embodiment, the thin glass ply can be conveyed horizontally through the laminator via a positive pressure / vacuum table that can actuate via the control system. In another embodiment, the laminator is configured with rollers having a coating or constructed of a material that will provide frictional engagement with a major surface of the thin glass ply to convey it, while not marking and / or scratching the surface of the glass.

[0034] In some embodiments, a major surface of the thin glass ply is adjacent to a backer member and is directed through the laminator in a non-contact position on the major surface.

[0035] In some embodiments, the backer member is configured with a plurality of holes which is configured with a series of holes that blow positive pressure or pull a vacuum in order to maintain the glass in a position while the thin glass ply moves through the laminator.

[0036] In some embodiments, a lowermost edge of the thin glass ply is configured to contact a conveyor belt of the laminator, which moves the thin glass ply through the laminator.

[0037] In some embodiments, a robot arm (e.g. configured with frictional engagement or automated suction engagement on the opposing major surface of the thin glass ply) is configured to direct the glass through the laminator device, optionally with the conveyor along the lower edge or independently of a conveyor belt engagement (e.g. for non-flat edges and / or specialty thin glass ply shapes).

[0038] In some embodiments, the backer member is configured with a plurality of rollers, wherein the rollers are coated or constructed of a polymeric material that will contact but not scratch or mark the thin glass ply.

[0039] In some embodiments, the step of positioning a film relative to a major surface of the thin glass ply, further comprises unrolling the film.Attorney Docket No. SP24-313PCT

[0040] In some embodiments, the step of positioning the film further comprises cutting the film to size with one or more cutters configured to move relative to the sheet during or after it is unwound from the film backing.

[0041] In some embodiments, the step of cutting comprises cutting the film with a smaller areal dimension than the thin glass ply.

[0042] In some embodiments, the step of cutting comprises cutting the film with a larger areal dimension than the thin glass ply.

[0043] In some embodiments, the step of cutting comprises cutting the film to correspond to the areal dimension of the thin glass ply.

[0044] In some embodiments, the film is configured with a polymeric side and an adhesive side.

[0045] In some embodiments, the continuously applying the film to the thin glass ply further comprises moving the thin glass ply relative to the film coming from the film roll (e.g. a lamination head depositing the film).

[0046] In some embodiments, the continuously applying the film to the thin glass ply further comprises moving the film coming from the film role relative to the thin glass ply.

[0047] In some embodiments, the continuously applying the film to the thin glass ply further comprises moving the thin glass ply from an inlet to the outlet of the laminator, while also moving the film coming from the film role in an opposing direction.

[0048] In some embodiments, the unrolling step further comprises maintaining tension on the film after removing the film backing while maintaining the adhesive portion free from particles and contaminants.

[0049] In another aspect, a method of making a safety glazing is provided, the method including: transferring a plurality of thin glass ply from a thin glass storage cart into a thin glass cleaner; washing and drying the plurality of thin glass plys in the thin glass cleaner to remove debris from the thin glass plys to yield clean dry thin glass plys; directing a plurality of thin glass plys through a laminator in series; for each thin glass ply, laminating a cut-to-size-film to each thin glass ply in the laminator to yield a safety glazing; inspecting each safety glazing for defects as it exits the laminator; transferring each safety glazing via the safety glazing transfer into the safety glazing storage cart.

[0050] In another aspect, a method of making safety glazings is provided, the method comprising: transferring a plurality of thin glass ply from a thin glass storage cart into a thin glass cleaner; washing and drying the plurality of thin glass plys in the thin glass cleaner toAttorney Docket No. SP24-313PCT remove debris from the thin glass plys to yield cleaned thin glass plys; pretreating the cleaned thin glass plys to provide a major surface of the thin glass ply configured for lamination.

[0051] In some embodiments, the method comprises directing a plurality of thin glass plys through a laminator in series.

[0052] In some embodiments, the method comprises for each thin glass ply, adhering a cut-to-size-film to each thin glass ply in the laminator to yield a safety glazing.

[0053] In some embodiments, the method comprises inspecting each safety glazing for defects as it exits the laminator.

[0054] In some embodiments, the method comprises: transferring each safety glazing via the safety glazing transfer into the safety glazing storage cart.

[0055] In some embodiments, the pretreating step includes at least one of: applying a surface treatment, applying a surfactant, applying a directional surface polish to remove particles and / or promote static charge; heating to promote a pre-heated thin glass ply; directing gas through blowers to remove particulates from the major surface of the thin glass ply, and / or combinations thereof.

[0056] In some embodiments, the laminating step is completed in a low particulate zone, which includes, a clean room (e.g. class 10,000), a clean tent, a positive pressure zone, blowers, vacuum, and / or combinations thereof.

[0057] In some embodiments, the control system is configured to control one or more of the following variables, including: the speed of the thin glass ply; the speed of the film role / laminator head; the direction and speed of cutting; the contact pressure and / or force of the rollers; and pretreatment, inspection sensors, and post processing. In some embodiments, the control system is configured to integrate modules and / or devices set forth herein with the laminator control system. In some embodiments, the control system is configured to control each of the automated modules / devices and the laminator device, wherein the control system checks the size of each thin glass ply and / or target film offset from the thin glass ply to correspond the devices in the laminator system to produce safety glazings that correspond to the target safety glazing products.

[0058] In some embodiments, the safety glazing post processing includes at least one of: heating the safety glazing, curing the safety glazing, applying pressure to the polymeric surface of the safety glazing; nip rolling the laminate, applying secondary rollers, cleaning / polishing the glass surface or polymeric surface of the safety glazing, and / or combinations thereof.Attorney Docket No. SP24-313PCT

[0059] In another aspect, a method is provided, comprising: laminating a film to a thin glass ply to provide a safety glazing having a first major surface that is a glass and a second major surface that is polymeric; and building a multi-pane insulating glass unit, by configuring the safety glazing in spaced relation to at least one pane and creating at least one sealed gas cavity between the safety glazing and the pane, wherein the polymeric portion of the safety glazing is in contact with the sealed gas cavity.

[0060] In some embodiments, the laminator is configured with one or more rewind rollers to collect the waste (e.g. film backing and film still on backing cut).

[0061] In some embodiments, the film is configured as a self-adhesive, dry laminate.

[0062] In another aspect, a safety glazing is provided, comprising: a thin glass ply having a first major surface and a second major surface, a thickness of not greater than 2.2 mm a film comprising a polymer layer and an adhesive layer, wherein the adhesive layer is adhered to the first major surface of the thin glass ply to define a safety glazing having a first major surface that is the polymer layer and the second major surface of the glass ply.

[0063] In some embodiments, the safety glazing is configured in an architecturally sized areal dimension (e.g. one edge having a length of: at least 1 foot, at least 3 feet, at least 5 feet, at least 7 feet, or at least 10 feet; when configured in a product, sized for windows (3x5, 5x7), doors, patio doors, or curtain walls).

[0064] In some embodiments, an inset of the film is at least 0.5 mm to not greater than 5 mm from the outer edge of the thin glass ply.

[0065] In some embodiments, the film edges that are square edges, arcuate, curved, and / or combinations thereof.

[0066] In some embodiments, the safety glazing is configured on the second major surface of the glass substrate, thereby defining a safety glazing having an inner thin glass substrate sandwiched by two safety films, one on each major surface of the thin glass ply.

[0067] In some embodiments, the thin glass ply comprises a thickness in the range of at least 0.4 mm to not greater than 1.6 mm.

[0068] In another aspect, an insulating glass unit (IGU) is provided, comprising: a first pane comprising a transparent material; a second pane comprising a safety glazing as set forth in one or more of the embodiments disclosed herein; and a third pane comprising a transparent material, wherein the third pane is configured in spaced relation from the second pane; and at least one spacer material positioned adjacent an outer edge and connecting the first pane, the second pane and the third pane, such that; a first gas cavity is defined between the spacer, theAttorney Docket No. SP24-313PCT first pane and the second pane and a second gas cavity is defined between the spacer, the second pane and the third pane.

[0069] In some embodiments, via the safety laminate, the first pane, the second pane, and the third pane of the IGU are configured to pass the International Building Code safety glazing standard, including at least one of ANSI Z97.1 (in the U.S.) and EN 12600 (in the EU).

[0070] In some embodiments, the IGU configured with a secondary seal and a frame in a window, wherein the window meets the ENERGY STAR V.7 requirements.

[0071] In some embodiments, the film is further configured with a color, a tint, a reflective layer, acoustic dampening, or combinations thereof.

[0072] In some embodiments, the first pane and the third pane are glass or a polymer.

[0073] In some embodiments, the first pane and the third pane are strengthened (e.g. tempered, heat strengthened, chemically strengthened, ion exchanged).

[0074] In some embodiments, the thin glass has a coefficient of thermal expansion (CTE) of less than 7 x 10-6 / K.

[0075] In some embodiments, the first pane, the thin glass ply of the safety glazing, and the third pane are selected from: a soda lime silicate glass; alumina borosilicate glass; an alkalialuminosilicate glass, an alkaline earth boro-aluminosilicate glass; or an alkali-free boro- aluminosilicate glass.

[0076] In some embodiments, the first pane comprises a soda lime silicate glass layer, the second pane comprises an alumina borosilicate glass layer, and the third pane comprises a sodalime silicate glass layer.

[0077] In some embodiments, the second pane / thin glass ply comprises a soda lime silicate glass layer having a thickness of 2.2 mm, or 2 mm, or 1.6 mm or 1.3 mm, or 1.1 mm, or 1 mm, or 0.7 mm, or 0.5 mm, or 0.3 mm.

[0078] In some embodiments, the total thickness of the IGU (spanning from the first pane to the third pane) is not greater than 35 mm.

[0079] In some embodiments, the total thickness of the IGU (spanning from the first pane to the third pane) is least %” to not greater than 1”.

[0080] In some embodiments, the first pane and the third pane are composed of the same type of glass.

[0081] In some embodiments, the IGU is configured in a window, a door, a skylight, a curtain wall, and / or combinations thereof.Attorney Docket No. SP24-313PCT

[0082] In some embodiments, the IGU configured as an architectural product or an automotive product.

[0083] In some embodiments, the first gas cavity and the second gas cavity are: configured with the same cross-sectional thicknesses or are configured with different cross- sectional thicknesses (i.e. the first gas cavity is thicker than the second gas cavity of the first gas cavity is thinner than the second gas cavity).

[0084] In some embodiments, the first gas cavity and second gas cavity are filled with a non-reactive gas or insulating gas.

[0085] In some embodiments, the first gas cavity and second gas cavity are filled with at least one of air, krypton, argon, or combinations thereof.

[0086] In some embodiments, the IGU is configured to pass a safety test as set out in at least one of ANSI Z97.1 and EN 12600 standard for safety glazing, when measured in accordance with the standard.

[0087] In some embodiments, the IGU is configured to pass a weighted noise reduction metric Rw of at least 35 dB, when measured in accordance with ISO 717-1 standard.

[0088] In one aspect, a window apparatus is provided comprising: an IGU as set out in a previous embodiment, and a frame assembly.

[0089] In some embodiments, the film is configured with the pane to provide a safety glazing, where the film has an inset from the edge of the thin glass layer. In this embodiment, the spacer contacts and is adhered to the surface of the thin glass ply.

[0090] In some embodiments, the film is configured with the pane to provide a safety pane where the film has an inset from the edge of the pane. In this embodiment, the spacer contacts and is adhered to the at least a portion of the film (e.g. at the comers), while the majority of the spacer is adhering to the surface of the thin glass ply.

[0091] In some embodiments, the film is configured with the pane to provide a safety pane where the film has a flush edge, configured to extend to the edge of the pane. In this embodiment, the spacer contacts and is adhered to the surface of the film.

[0092] In some embodiments, the film is configured with the pane to provide a safety pane where the film has a flush edge (or an inset relative to the outer edge of the pane) further wherein the region where the spacer is configured is deleted and / or removed, to enable an adhering contact between the spacer and the major surface of the thin glass ply. the spacer is applied partially to the film and partially to the glass pane.Attorney Docket No. SP24-313PCT

[0093] In some embodiments, the film can be oriented on either major surface of the thin glass ply in order to configure a safety laminate. In some embodiments, the spacer extends a distance from the glass edge that is greater than the inset of the film from the same glass edge. As a result, the spacer partially covers the film leaving no exposed glass at the interior spacer edge. This provides a spacer-to-glass seal at the outside for hermiticity, while allowing for uniform optical properties within the IGU vision area. In some embodiments, the film can be applied to the pane with an inset “X” OR the film can be applied fully to the edge or inset and then removed to an inset of “X” where the spacer is applied fully to the glass pane. In some embodiment, the film can be applied to the pane fully to the edge of the pane or with an inset “X” such that the spacer is applied directly to glass pane by means of removal of the film in the location the spacer will be bonded or applied. In some embodiments, the film is used with a pocket spacer, such that the pocket spacer is applied to the center pane along its edge showing on both faces of the internal pane so that the pane can be adhered to its outer panes or additional inner panes. In this configuration, the film can be fully to the edge of the pane or inset, so that the spacer is bonded partially or fully to film, glass, or both of the interior pane.

[0094] In some embodiments, the spacer is bonded, applied, or configured to attach to the thin glass and / or the film. In some embodiments, the film is applied to a major surface of the thin glass and edge deleted along an edge region corresponding to the spacer region and outer edge of the thin glass, to define a path for the spacer application (e.g. direct bond to thin glass).

[0095] In some embodiments, the film is applied to a major surface of the thin glass and edge deleted along a channel to define a path with no film along a spacer path, with edges defined by film (e.g. extending towards the inner portion of the thin glass and towards the edge of the thin glass (optionally extending to the edge or to a portion a set distance from the edge of the thin glass)).

[0096] In some embodiments, triple pane assemblies (e.g. windows) with a center pane laminate have shown improved acoustic performance (as measured by standard metrics such as ASTM E413, ASTM E1332, and ISO 717-1). In some embodiments, the via the third pane, the IGU is configured as a safety glazing in accordance with ANSI Z97.1 or EN 12600 standards. In some embodiments, the IGUs station assembly comprises a weighted sound reduction metric Rwof at least 35 dB, when measured in accordance with ISO 717-1 standard.

[0097] In some embodiments, the low emissivity coatings are configured to provide an improved Solar heat gain coefficient and / or U-value. In some embodiments, solar heat gainAttorney Docket No. SP24-313PCT coefficient is quantified and / or measured in accordance with ANSI / NFRC 200 - 2017_E0Al Procedure for Determining Fenestration Product Solar Heat Gain Coefficient and Visible Transmittance at Normal Incidence. In some embodiments, thermal insulation (U-value) is quantified and / or measured in accordance with ASTM E1423-14 Standard Practice for Determining Steady State Thermal Transmittance of Fenestration Systems and / or ANSI / NFRC 100 - 2017 E0A2 Procedure for Determining Fenestration Product U-factors. For example, the low emissivity coating can be comprised of a combination of metals and oxides, including nonlimiting examples of: silicon nitride, metallic silver, silicon dioxide, tin oxide, zirconium oxide, and / or combinations thereof, to name a few.

[0098] One or more of the aforementioned fenestration assembly embodiments are utilizable with one or more of the aforementioned methods set forth herein.

[0099] Additional features and advantages will be set forth in the detailed description which follows and will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

[0100] It is to be understood that both the foregoing general description and the following detailed description are merely exemplary and are intended to provide an overview or framework to understanding the nature and character of the disclosure as it is claimed.

[0101] The accompanying drawings are included to provide a further understanding of principles of the disclosure, and are incorporated in, and constitute a part of, this specification. The drawings illustrate one or more embodiment(s) and, together with the description, serve to explain, by way of example, principles and operation of the disclosure. It is to be understood that various features of the disclosure disclosed in this specification and in the drawings can be used in any and all combinations. By way of non-limiting examples, the various features of the disclosure may be combined with one another according to the following aspects.BRIEF DESCRIPTION OF THE DRAWINGS

[0102] These and other features, aspects and advantages of the present disclosure are better understood when the following detailed description of the disclosure is read with reference to the accompanying drawings, in which:

[0103] FIG. 1 depicts schematic cut-away side views of an embodiment of a safety pane for architectural applications, more specifically depicting a thin glass substrate withAttorney Docket No. SP24-313PCT a film applied along a major surface of the thin glass substrate, in accordance with various aspects of the present disclosure.

[0104] FIG. 2 depicts a schematic depiction of an embodiment of a glass processing system, in accordance with one or more aspects of the present disclosure.

[0105] FIG. 3 depicts an embodiment of a glass conveyance device configurable within the laminator module is depicted, in accordance with one or more aspects of the present disclosure.

[0106] FIG. 4 depicts another embodiment of a glass conveyance device configurable within the laminator module is depicted, in accordance with one or more aspects of the present disclosure.

[0107] FIG. 5A and FIG. 5B depict schematic embodiments of another embodiment of a conveyor device, showing the patterning and spacing of holes of different sizes configured across the table portion of the conveyance device, with 5A showing the full table and 5B showing an enlarged portion of the table, in accordance with one or more aspects of the present disclosure.DETAILED DESCRIPTION

[0108] In the following detailed description, for purposes of explanation and not limitation, example embodiments disclosing specific details are set forth to provide a thorough understanding of various principles of the present disclosure. However, it will be apparent to one having ordinary skill in the art, having had the benefit of the present disclosure, that the present disclosure may be practiced in other embodiments that depart from the specific details disclosed herein. Moreover, descriptions of well-known devices, methods and materials may be omitted so as not to obscure the description of various principles of the present disclosure. Finally, wherever applicable, like reference numerals refer to like elements.

[0109] Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. As a non-limiting example, about means less than 10% of the referenced value.Attorney Docket No. SP24-313PCT

[0110] Directional terms as used herein - for example up, down, right, left, front, back, top, bottom - are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0111] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps, or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; the number or type of embodiments described in the specification.

[0112] As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a “component” includes aspects having two or more such components, unless the context clearly indicates otherwise.

[0113] One or more embodiments described herein are directed towards integrating a laminator into an IGU line, where the laminator is configured to laminate a pane of glass, which is incorporated into a multi-pane IGU. More specifically, embodiments described herein are directed towards laminating a thin glass, which is incorporated into the center pane of a multi-pane IGU (e.g. thin triple IGU) via an IGU line, such that the center pane is configured such that the IGU is safety compliant with regulations. As shown in the drawings and as set forth herein, the laminator device is incorporated into various positions / locations in the IGU manufacturing line, in accordance with several general embodiments.

[0114] In some embodiments, the integration of the laminator device is configured after the pane of glass has been loaded onto inlet conveyor of the system.

[0115] Fig. 1 depicts a schematic cut-away side view of a safety laminate 20 for architectural applications, more specifically depicting a thin glass substrate 14 with a safety film 22 applied along a major surface of the thin glass substrate.

[0116] Generally, referring to FIG. 2, the system 1000 for processing thin glass has one or more of the following components, also referred to in the drawings with these corresponding reference numbers: a laminator device 1900, configured to laminate or apply a film (e.g. safety film) or laminate onto a pane of glass and at least one glass transfer deviceAttorney Docket No. SP24-313PCT1700. FIG. 1 depicts two glass transfer devices, an inlet glass transfer device and an outlet glass transfer device.

[0117] Further, the system 1000 can include a glass transfer device 1700 between various process steps, in order to move or direct the glass from one location to the next. As non-limiting examples, the glass transfer device 1700 includes conveyors, robot arms, shuttles, rollers, float / vacuum tables, and / or a combination thereof.

[0118] As used herein, thin glass includes glass having a thickness that is not capable of being strengthened (heat strengthened or tempered); Thin means less than 2.2 mm thick.

[0119] Processing means incorporating a coating a film, or surface treating the thin glass substrate. As non-limiting examples, the coating includes a low emissivity coating, an anti -reflective coating, an acoustic coating, a tinted coating, and / or combinations thereof.

[0120] The shuttle device 2400 are configured (e.g. when the glass is a thin glass) such that individual thin glass plies can be indexed from the storage cart and directed, via at least one of a conveyor, a robotic arm (suction capabilities), a table equipped with rollers and / or a table equipped with float mechanism (positive pressure and vacuum through small through holes to enable a non-contact or a nearly non-contact engagement with the thin glass) as it is directed from the cart into the cutting device 1100, the cleaning device 1200, the laminating device 1900, or during other processing steps, as required.

[0121] The laminator device 1900, when applying a film or laminate to thin glass, is configured to receive the thin glass ply with tailored edge protection of the thin glass and with sufficient force to promote adhesion of the film onto the thin glass ply but not exceed the bend strength of the glass, causing breakage.

[0122] In some embodiments, the system, 100 is configured with a glass surface treatment device 2100, which is configurable to surface treat at least one major surface of the glass (for example, to tailor the glass with a coating for the end use application).

[0123] Fig. 2 depicts a schematic embodiment of processing the thin glass, which includes laminating the thin glass with a safety film via a laminator device 1900 or glass surface treatment device 2100, in accordance with one or more aspects of the present disclosure.

[0124] Referring to Fig. 3, the laminator device 1900 is configured with a laminator head 910, a cutting device 920, a film roll / film roll retention device 930, a film roller device 940, and a glass conveyance device 950, with a control system 960. As a thin glass plyAttorney Docket No. SP24-313PCT enters the laminator 1900 via the glass conveyance 950, the laminator head 910 is configured to unroll a film roll 930, simultaneously / concomitant with the unrolling of the film from the film roll, cut the film to the desired size via the cutter(s) 920, which can be configured in an x- y-z direction to cut horizontally, vertically, or to cut specialty shapes for desired insets on the safety glazing and / or specialty IGU shapes.

[0125] Once cut, the head 910 directs the film onto the thin glass ply and adheres the film adjacent to an edge of the thin glass ply, while the rollers 940 engage with the polymeric portion of the film and through pressure / frictional engagement with the polymeric portion, promote adhesion of the adhesive layer with the thin glass ply, to laminate the safety glazing.

[0126] The control system 960 is configured to actuate the glass conveyance 950, robotic arm assist, the head 910, roller 930, and cutters 920 to tailor the film to the desired inset. In some embodiments, the laminator 1900 is configured with multiple film rolls in the film roll device 930, such that the control system can direct certain thin glass plys to have a first film and others to have a second or other film(s) to create tailored safety glazings based on the instructions from the control system.

[0127] As depicted in Fig. 4, and in reference to Fig. 3 depicting the laminator 1900, an embodiment of the glass conveyance device 950 is shown. Here, the glass conveyance device is configured as a backer member, and in some embodiments, the backer member is configured with a larger dimension than the thin glass that it will be engaged within the laminator. The backer member is configured with a plurality of through holes, where the through-holes are each configured to supply either a positive pressure or a negative pressure (vacuum) on the glass substrate, such that the backer member is configured to enable a float conveyance of the thin glass substrate as it travels into the laminator, is retained in the laminator during lamination, and / or is directed out of the laminator after lamination. The through-holes are configurable with a control system to enable a float configuration, where the positive pressure and vacuum are engaged in order to retain the thin glass in a set position and / or distance from the backer member. As non-limiting examples, the positive pressure and vacuum can be simultaneously engaged, or engaged in an intermittent manner, or engaged in a pattern in order to configure the glass in a float position or a retained position in the backer member.

[0128] Moreover, as another non-limiting example the through holes are configured to actuate the thin glass in a vacuum pattern, such that the thin glass is securely retained against the backer member during processing and / or lamination. In this embodiment,Attorney Docket No. SP24-313PCT the backer member is configured in a vertical or near vertical position, and is able to tilt from a vertical position (e.g. during lamination) to an angled position (e.g. during transport) to promote processing of the thin glass. As shown, the lower region of the backer plate is configured with a conveyor, where such conveyor is configured to frictionally engage with a lowermost edge of the thin glass and direct the glass laterally into and / or out of the laminator. In some embodiments, the conveyor engages with the lowermost edge of the thin glass while the through holes retain the glass in a float position.

[0129] In some embodiments, a combination of conveyance components aforementioned are utilized in order to promote stabilization, sufficient structural support, and / or appropriate positioning of the architecturally-sized, large thin glass substrate as it enters, is laminated (e.g. specifically designed to promote complete adhesion during lamination), and exits the laminator module.

[0130] In some embodiments, the glass conveyance is configured as a conveyor belt, which contacts at least a portion of the lower-most edge of the thin glass substrate.

[0131] In some embodiments, the glass conveyance is configured as a backer member, configured with rollers to facilitate thin glass contact and / or engagement with the rollers to move through the laminator.

[0132] In some embodiments, the glass conveyance is configured with a plurality of suction cups, which actuate on the major surface (back) of the thin glass that is not engaging with the film to be laminated.

[0133] In some embodiments, the glass conveyance is a configured as a backer member, that is configured with a coating to facilitate low friction glass movement and nonscratching surface (e.g. PTFE).

[0134] In some embodiments, the glass conveyance is configured as a backer member that is configured with a plurality of through-holes, such that the through holes are configured with a combined pressure and vacuum system to enable a float on the thin glass, frictionless maintained movement along the back-major surface, such that the thin glass is conveyed (at least partially or fully) through the laminator during lamination.

[0135] In some embodiments, the backer member, with through holes and configured with positive / vacuum pressure to enable float, is further configured with tilt capabilities, to enable a slight vertical angle during float conveyance (e.g. up to 12 degrees tilt), and to enable a vertical (or near vertical, e.g. not more than 3 degrees or not more than 6 degrees from vertical positioning) during lamination.Attorney Docket No. SP24-313PCT

[0136] In some embodiments, during lamination, the float (positive pressure) is disabled, to enable the vacuum portion to retain the thin glass in place as it is being laminated.

[0137] In some embodiments, the glass conveyance is configured with one or more of the aforementioned technologies (one or more conveyor belt, positionable conveyor belt (in lateral and vertical directions); suction cups (e.g. along lower edge of the glass or interspaced along the back major surface of the thin glass); backer member configured with tilting angle from vertical to near vertical / incline, backer member configured with non- stick / non- scratching coating for thin glass engagement (e.g. PTFE); backer member configured with a plurality of interspaced through holes configured to engage with the thin glass through the vias with either (1) a combination of positive pressure and vacuum, configured to float the thin glass (e.g. retain the thin glass in a non-contact manner with the backer member and retain position in a spaced relation with the backer member) or (2) in vacuum, to retain the thin glass in position on the backer member during lamination, pre-processing, post-processing, inspection, or a combinations thereof).

[0138] In some embodiments, the positive pressure is set to not greater than 2 psi and the negative (vacuum) is set to not greater than - 2 psi.

[0139] In some embodiments, the pressure and vacuum are configured to the thickness of the thin glass (to enable controlled float, maintaining pre-determined distance between the thin glass substrate and the backer member).

[0140] As a non-limiting example, thin glasses on the order of 2.2 mm to not greater than 1.7 mm have a pressure / vacuum setting in the range of not greater than 0.9 psi and not lower than -0.9 psi. As a non-limiting example, thin glasses on the order of 2.2 mm to not greater than 1.7 mm have a pressure / vacuum setting in the range of not greater than 0.7 psi and not lower than -0.7 psi. As a non-limiting example, thin glasses on the order of 2.2 mm to not greater than 1.7 mm have a pressure / vacuum setting in the range of not greater than 0.5 psi and not lower than -0.5 psi. As a non-limiting example, thin glasses on the order of 2.2 mm to not greater than 1.7 mm have a pressure / vacuum setting in the range of not greater than 0.3 psi and not lower than -0.3 psi. As a non-limiting example, thin glasses on the order of 1.7 mm to not greater than 1 mm have a pressure / vacuum setting in the range of not greater than 0.8 psi and not lower than -0.8 psi. As a non-limiting example, thin glasses on the order of 1.7 mm to not greater than 1 mm have a pressure / vacuum setting in the range of not greater than 0.6 psi and not lower than -0.6 psi. As a non-limiting example, thin glasses on the order of 1.7 mm to not greater than 1 mm have a pressure / vacuum setting in the range of not greater than 0.4 psi andAttorney Docket No. SP24-313PCT not lower than -0.4 psi. As a non-limiting example, thin glasses on the order of 1.7 mm to not greater than 1 mm have a pressure / vacuum setting in the range of not greater than 0.3 psi and not lower than -0.3 psi. As a non-limiting example, thin glasses on the order of 1 mm to not greater than 0.3 mm have a pressure / vacuum setting in the range of not greater than 0.7 psi and not lower than -0.7 psi. As a non-limiting example, thin glasses on the order of 1 mm to not greater than 0.3 mm have a pressure / vacuum setting in the range of not greater than 0.5 psi and not lower than -0.5 psi. As a non-limiting example, thin glasses on the order of 1 mm to not greater than 0.3 mm have a pressure / vacuum setting in the range of not greater than 0.45 psi and not lower than -0.45 psi. As a non-limiting example, thin glasses on the order of 1 mm to not greater than 0.3 mm have a pressure / vacuum setting in the range of not greater than 0.35 psi and not lower than -0.35 psi. As a non-limiting example, thin glasses on the order of 1.6 mm to not greater than 0.3 mm have a pressure / vacuum setting in the range of not greater than 0.9 psi and not lower than -0.9 psi. As a non-limiting example, thin glasses on the order of 1.6 mm to not greater than 0.3 mm have a pressure / vacuum setting in the range of not greater than 0.7 psi and not lower than -0.7 psi. As a non-limiting example, thin glasses on the order of 1.6 mm to not greater than 0.3mm have a pressure / vacuum setting in the range of not greater than 0.45 psi and not lower than -0.45 psi. As a non-limiting example, thin glasses on the order of 1.6 mm to not greater than 0.3 mm have a pressure / vacuum setting in the range of not greater than 0.25 psi and not lower than -0.25 psi.

[0141] In some embodiments, the pressure setting and the vacuum setting are positive and negative equal forces, in some embodiments, the pressure setting and the vacuum setting are not equal to each other (e.g. the pressure setting is a greater force than the vacuum force, or the vacuum force is greater than the pressure force). In some embodiments the through-holes on the backer member are configured to apply equal force (whether pressure or in vacuum mode). In some embodiments, some holes are only configured for pressure while others are only configured for vacuum. In still other embodiments, some regions are configured for positive pressure, and other regions of the backer member through holes are configured for vacuum (negative pressure). In some embodiments, the control system is configured to actuate / change the positive pressure and vacuum through each of the through holes in a pattern through the plurality of holes to maintain the float of the thin glass.

[0142] In some embodiments, the glass conveyance is configured with all of these technologies use a customized float conveyor that will have the ability to move from anAttorney Docket No. SP24-313PCT inclined position (transport) to a vertical position, which is the preferred position for the lamination process.

[0143] In some embodiments, a plurality of suction engaging members (e.g. vacuum cups) are configured along the lowermost region of the thin glass substrate, where the suction engaging members are configured to attach to the thin glass substrate and move the thin glass in an x, y, and / or z direction (towards and away, up and down, and left and right) relative to the laminator module.

[0144] The embodiments described herein provide the technical advantages to thin glass processing and lamination including, but not limited to improved yield rates and quality, as the use air float in the glass transfer device and / or glass conveyance device is configured to avoid contact with the major surfaces of the thin glass sheet, thereby avoiding scratching or dirtying of the thin glass sheet.

[0145] In some embodiments, the system is configured to enable higher yield rate and improved quality of safety laminates, as the laminator is configured to use vacuum actuation to retain the thin glass sheet on the back plate of the laminator, avoiding any mechanical clamping which could scratch, break, or introduce stresses into the glass unnecessarily.

[0146] In some embodiments, the system is configured to accommodate inlet / upstream processes and / or outlet (downstream processes or storage) at one or more adjustable positions / tilt angles. In some embodiments, the conveyor tilt angle is 6°; a vertical position, a horizontal position, and / or any tilt angles between vertical and horizontal tilt angles.

[0147] In some embodiments, the table / plate is configured such that the first holes and second holes are sized to impact the optical quality of the film laminated glass as air and vacuum forces are applied to the major surface of the thin glass sheet.

[0148] In some embodiments, the laminator is configured with a shuttle plate retaining the thin glass sheet that is moving, while the lamination head is in fixed position. In one embodiment, a vertical lamination is provided where the shuttle plate is configured to tilt. In another embodiment, the lamination head is configured to tilt, such that the lamination process in the laminator device occurs with the thin glass sheet positioned in an angled position (e.g. from horizontal to vertical, or near vertical, including as one example, an angle of 5 to 12 degrees, or 5 to 8 degrees, or 6 degrees.

[0149] In still another embodiment, there is no tilting during lamination, but there is transverse motion to remove the safety pane from the laminator device once laminationAttorney Docket No. SP24-313PCT is completed. In this configuration, the conveyor device and the laminator head have the same tilt angle, such that the laminator head is configured to retract, or the shuttle plate is configured to move when the safety pane formation is completed. As contemplated by the inventors, additional combinations and permutations of tilting, conveyance and lamination are included herein, where the shuttle plate may be configured to move or be fixed, the lamination head may be configured to be moving for fixed, and the lamination head or shuttle plate may be configured as tilting or not tilting.

[0150] Many variations and modifications may be made to the above-described embodiments of the disclosure without departing substantially from the spirit and various principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.Reference Numbers:Laminator Device 1900Inlet Glass Transfer Device 1700Outlet Glass Transfer Device 1700Laminator device components head 910 (optional film conveyance / robot) cutter(s) 920 film roll 930 film roller 940 glass conveyance 950 control system 960 safety pane 20 thin glass ply 14 film 22

Claims

Attorney Docket No. SP24-313PCTClaims:What is claimed is:

1. A system for processing thin glass for architectural products, the system comprising: a. a thin glass processing device; and b. a glass transfer device, configured to securely retain a cross-sectionally thin, dimensionally large piece of thin glass and convey the thin glass sheet at least one of: to, from, or through the thin glass processing device. The system of claim 1, wherein the thin glass processing device is selected from: a laminator device and a glass surface treatment device.3 The system of claim 2, the thin glass processing device is a laminator device, wherein the laminator device, is configured to receive the thin glass sheet from glass transfer device and apply a film onto a major surface of the thin glass sheet, to yield a laminated glass sheet. The system of claim 1, wherein the glass transfer device is configured as a glass conveyance device, in which glass is air floated onto the laminator device via a shuttle plate.5 The system of claim 4, wherein the thin glass sheet is retained in place on a back plate of the glass conveyance device thru the use of vacuum force.6 The system of claim 4, wherein the thin glass sheet and the back plate of the glass conveyance device is configured to be movable to adjust to a vertical, horizontal, or angled position, where such positioning is configured for lamination via the laminator device.7 The system of claim 4, wherein the back plate of the glass conveyance device is configured to receive the safety pane (after lamination) and transfer the safety pane out of the laminator device.8 The system of claim 4, wherein the laminator device is configured to apply a film to a thin glass sheet during glass conveyance, while the thin glass sheet is retained on the back of the glass conveyance device.9 The system of claim 4, wherein the conveyor device is configured to move glass from a first position to a second position, while enabling the glass to be positioned at different angles toAttorney Docket No. SP24-313PCT retain the glass, while configured to convey the lower-most edge of the thin glass via frictional engagement and while configured to convey the major surface of the thin glass sheet via vacuum and / or positive pressure (push-pull floating the thin glass sheet to avoid sliding engagement with the major surface of the thin glass sheet.

10. The system of claim 4, wherein the conveyance table is configured with a table configured with a plurality of holes.

11. The system of claim 4, wherein the plurality of first holes having an average size configured to enable vacuum / negative pressure applying a pulling force on the major surface of the thin glass sheet.

12. The system of claim 4, wherein the plurality of second holes have an average size configured to enable positive pressure / air blowing out of the holes towards the surface of the thin glass sheet.

13. The system of claim 4, wherein the table is configured to be supplied with air (positive pressure) through a plurality of holes configured in a first pattern (density and spacing) in the table surface) and vacuum (negative pressure) through a plurality of holes configured in a second pattern (density and spacing) in the table surface.

14. The system of claim 4, wherein the table is configured to be adjustable in tilt angle from a first position (pl), to a second position (p2), to a number of different angled positions (pn) between a horizontal angle (90 degree angle) to a vertical angle (0 degree angle).

15. The system of claim 4, wherein the conveyance device is configured with at least one set of rollers, where the rollers are configured to move the glass as it is air floated.

16. The system of claim 4, wherein the plurality of holes are configured with an average diameter size in the range of 0.5 mm to 20 mm.

17. The system of claim 4, wherein the plurality of holes are configured with an average diameter size in the range of 0.5 mm to 5 mm.

18. A system for manufacturing insulated glazing units (IGUs), the system comprising:Attorney Docket No. SP24-313PCT a. a laminator device, configured to apply a film onto a major surface of a thin glass sheet to provide a safety laminate; and b. at least one versatile push / pull tilting shuttle to transport the thin glass either to and / or from the laminator device.

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