Abstract: Method and Apparatus for fabricating a spacer frame for use in an insulating glass unit. One of a multiple number of possible spacer frame materials is chosen for the spacer frame. An elongated strip of the material is moved to a notching station where notches are formed at corner locations. The character of the notches is adjusted based on the selection of the metal strip material and more particularly to achieve bending of the material in a repeatable, straightforward manner. Better control over the notching process is also achieved by exhaust flow control of a double acting cylinder. A positioning spacer achieve very accurate side to side positioning of a die and anvil to precisely notch and deform the metal strip. Downstream from the notching station the metal strip is bent into a channel shaped elongated frame member having side walls. Further downstream a leading strip of channel shaped material is severed or separated from succeeding material still passing through the notching and bending station.

Abstract: An apparatus and method is provided for forming a spacer frame assembly used in the construction of insulating glass unit windows. The apparatus comprises a head arrangement having a body with first and second ends, the first end for coupling to a cylinder that advances and retracts the head arrangement in a reciprocating motion during operation. The second end includes an annular wedge-shaped ridge for coupling to a second annular wedge-shaped ridge of a die support, collectively the wedge-shaped ridge and second wedge-shaped ridge form a contact region to form a torus surface. The die support has at least one die for engaging a spacer frame assembly during operation. The apparatus further comprises a collar having a torus-shaped recess corresponding with the torus surface to nest and couple the body to the die support.

Abstract: An apparatus for sealing an insulating glass unit includes a frame for supporting first and second clamping arrangements. The clamping arrangements support the insulating glass unit during a sealing operation. First and second dispensing assemblies are connected to the frame and movable relative to the frame. Each first and second dispensing assembly includes a nozzle for controlled dispensing of a sealant along a prescribed portion of the supported insulating glass unit during the sealing operation.

Abstract: This invention describes a process flow and method to assemble triple IG units without contaminating the center glass lite. A non-contact vacuum pad is used to lift a glass lite off from a horizontal or vertical support that conveys it from a glass washer to an assembly station. Each of multiple pads has a capacity to lift approximately seven to ten pounds. Use of multiple pads per glass sheet or lite allows lites having dimensions up to 70 by 100 inches (assuming glass thickness of one quarter inch) to be assembled.

Abstract: A spacer frame assembly and method of assembly includes a substantially linear channel having first and second ends. The substantially linear channel that when assembled includes at least four sides and corresponding corners between each of the sides. The spacer frame assembly also has a connecting structure located at one of the first and second ends and an opposite frame end located at the other of the one of first and second ends. The opposite frame end has an inner channel for receiving a nose portion of the connecting structure. The spacer frame assembly also includes a stop extending from the connecting structure for locating the opposite frame end when in the assembled position.

Abstract: A spacer frame assembly and method of assembly includes a substantially linear channel comprising two lateral walls and a base wall. The channel has first and second ends that when assembled, includes at least three sides and corresponding corners between each of said sides. The first end includes a connecting structure and the second end includes an opposite frame end. The opposite frame end has an opposite channel for receiving a nose portion of said connecting structure. The opposite channel includes stiffening flanges extending inwardly from the lateral walls relative to the channel. The connecting structure further includes a first aperture in the base wall comprising a first projection into the channel and the opposite channel comprises a second aperture in the base wall comprising a second projection into the channel. Wherein the first projection tactilely interweaves with the second projection when the spacer frame is assembled.

Abstract: An apparatus and method is provided for forming folds at a corner in a spacer frame assembly used in the construction of insulating glass unit windows. The apparatus comprises a carriage supporting first and second crimping fingers. The crimping fingers are spaced about a path of travel for the passage of metal strips during operation. The apparatus comprises an encoder to determine a velocity of the strips, and a motor coupled to a ball screw assembly. The ball screw assembly moves the carriage during operation along the path of travel. The apparatus comprises an electrical gearing arrangement for accelerating the carriage along the path. The electrical gearing arrangement includes a controller and a double acting rack assembly, the controller being coupled to the motor, the encoder, and the double rack assembly. The double rack assembly simultaneously actuates the fingers at a direction substantially transverse to the path.

Abstract: A system and method that automatically determine a type of material at a machine input to prevent damage to the machine. A user interface receives a selection of a material type to be loaded into the machine. A controller performs a safety check before starting a process using the machine by matching the selected material type to a material type at the machine input determined based on signals received from a plurality of sensors. The plurality of sensors comprise a material present sensor, a material type sensor opposed by a different material having a inductive sensor correction factor of 0.5 or less, and a material color sensor.

Abstract: A fluid application system and method having a support structure for guiding a plurality of pallets along a path of travel through the system. The plurality of pallets for arranging a medium that receives fluid during operation. The system further includes an application assembly for applying fluid and energy to a medium arranged on the plurality of pallets and a conveyance arrangement comprising first and second conveyors for transferring the one or more pallets through the fluid application system. The first and second conveyors have a dedicated trolley selectively coupled to one of the plurality of pallets during movement along a first direction of the path of travel and selectively decoupled from the one of the plurality of pallets during movement along a second direction of the path of travel.

Abstract: A method and apparatus for heating and/or pressing sealant of an insulating glass unit. The apparatus may include an oven and a press. The oven includes a detector that detects an optical property of the insulating glass unit. The detected optical property is used to regulate the amount of energy applied to the insulating glass unit to adjust the amount of energy applied to the sealant. The press may include a displacement transducer that detects a pre-pressed thickness of the insulating glass unit. The measured pre-pressed thickness is used to automatically select a press thickness from a set of pressed IGU thicknesses.

Abstract: Method and Apparatus for fabricating a spacer frame for use in an insulating glass unit. One of a multiple number of possible spacer frame materials is chosen for the spacer frame. An elongated strip of the material is moved to a notching station where notches are formed at corner locations. The character of the notches is adjusted based on the selection of the metal strip material and more particularly to achieve bending of the material in an repeatable, straightforward manner. Downstream from the notching station the metal strip is bent into a channel shaped elongated frame member having side walls. Further downstream a leading strip of channel shaped material is severed or separated front succeeding material still passing through the notching and bending station.

Abstract: An insulating glass unit (IGU) assembly line apparatus capable of interleaving double and triple pane IGUs in accordance with an IGU production schedule. Visual indicators or prompts instruct operators at the assembly line in configuring a sequence of IGUs. Triple pane IGUs are assembled with minimal contamination of a center glass lite. A non-contact Bernoulli pad is used to lift a glass lite off from a horizontal or vertical support that conveys it from a glass washer to an assembly station. Each of multiple pads has a capacity to lift approximately seven to ten pounds. Use of multiple pads per glass sheet or lite allows lites having dimensions up to 70 by 100 inches (assuming glass thickness of one quarter inch) to be assembled.

Abstract: A spacer frame assembly and method of assembly includes a substantially linear channel having first and second ends. The substantially linear channel that when assembled includes at least four sides and corresponding corners between each of the sides. The spacer frame assembly also has a connecting structure located at one of the first and second ends and an opposite frame end located at the other of the one of first and second ends. The opposite frame end has an inner channel for receiving a nose portion of the connecting structure. The spacer frame assembly also includes a stop extending from the connecting structure for locating the opposite frame end when in the assembled position.

Abstract: This invention describes a process flow and method to assemble triple IG units without contaminating the center glass lite. A non-contact vacuum pad is used to lift a glass lite off from a horizontal or vertical support that conveys it from a glass washer to an assembly station. Each of multiple pads has a capacity to lift approximately seven to ten pounds. Use of multiple pads per glass sheet or lite allows lites having dimensions up to 70 by 100 inches (assuming glass thickness of one quarter inch) to be assembled.

Abstract: A film application system having multiple film application stations. Each film application station has a support for an elongated plastic component (typically vinyl) having an input and an output side. A properly positioned and oriented transfer head includes a heated roller which applies heat and pressure to the elongated film as the component moves through the application station. The roller is most preferably heated with multiple IR heaters controllably energized to achieve a desired roller temperature without too large a gradient of temperature difference across the film application contact surface of the roller.

Abstract: Method and Apparatus for fabricating a spacer frame for use in an insulating glass unit. One of a multiple number of possible spacer frame materials is chosen for the spacer frame. An elongated strip of the material is moved to a notching station where notches are formed at corner locations. The character of the notches is adjusted based on the selection of the metal strip material and more particularly to achieve bending of the material in an repeatable, straightforward manner. Better control over the notching process is also achieved by exhaust flow control of a double acting cylinder. A positioning spacer achieve very accurate side to side positioning of a die and anvil to precisely notch and deform the metal strip. Downstream from the notching station the metal strip is bent into a channel shaped elongated frame member having side walls. Further downstream a leading strip of channel shaped material is severed or separated from succeeding material still passing through the notching and bending station.

Abstract: A film application system having multiple foil application stations. Each foil application station has a support for an elongated plastic component (typically vinyl) having an input and an output side. A drive moves successive elongated components along a path through the application station from the input side to the output side as decorative foil is applied to a surface of the component. A properly positioned and oriented transfer head applies heat and pressure to the elongated film as the component moves through the application station. The disclosed system must accommodate different style and shape components corresponding to different style windows, doors, or sashes. A backing fixture that is configured to support a given configuration component is positioned to support the component as the component moves through the application station in a region of the transfer head.

Abstract: A stock supply station for use in a insulated glass unit component production line includes a plurality of rotatable sheet stock coils, an indexing mechanism, and an uncoiling mechanism. The indexing mechanism is coupled to the sheet stock coils for indexing a selected one of the sheet stock coils to an uncoiling position. The uncoiling mechanism selectively uncoils sheet stock from a sheet stock coil indexed to the uncoiling position to thereby provide sheet stock to a downstream processing station.

Abstract: A stock supply station for use in a insulated glass unit component production line includes a plurality of rotatable sheet stock coils, an indexing mechanism, and an uncoiling mechanism. The indexing mechanism is coupled to the sheet stock coils for indexing a selected one of the sheet stock coils to an uncoiling position. The uncoiling mechanism selectively uncoils sheet stock from a sheet stock coil indexed to the uncoiling position to thereby provide sheet stock to a downstream processing station.