Adhesive bonding and miscellaneous chemical manufacture – Surface bonding means and/or assembly means therefor – With means applying wave energy or electrical energy...
Reexamination Certificate
1999-11-04
2001-12-25
Maki, Steven D. (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Surface bonding means and/or assembly means therefor
With means applying wave energy or electrical energy...
C156S538000, C156S583100
Reexamination Certificate
active
06332948
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to the fabrication of insulated glass (“IG”) units. In particular, the present invention relates to an apparatus and method of sealing a spacer between a pair of spaced apart substrates.
BACKGROUND OF THE INVENTION
In the conventional manufacture of sealed insulated units comprising an assembly of two spaced apart parallel sheets of substrate (usually glass) and a bondable and/or curable spacer therebetween, assembled units are positioned in a press and the entire unit is heated to melt and/or cure the spacer allowing the spacer to bond to the substrates. Heating of the entire unit causes problems since it increases the temperature of the entire unit including the air between the substrates. In addition, if the entire unit is being heated in the vertical position, a “chimney” effect occurs whereby the upper zone of the unit may become overheated relative to the lower zone with problems resulting.
For example, in U.S. Pat. No. 5,567,258, an IG unit containing an aluminum spacer, aluminum tape corner keys and a thermoset resin sealant is placed within a tunnel having microwave generators on each side. The unit passes through the tunnel and the entire IG unit is subjected to microwave energy to bond the spacer to the substrates. Conventional presses ensure that the spacer is firmly bonded to the substrates. The entire spacer however, is heated which can result in softening of the spacer and changes in the shape of the spacer.
U.S. Pat. No. 4,683,154 discloses a window panel held in a spaced apart manner by glass beads and sealed by welded glass obtained by welding the bead spacers together with a laser beam while positioned in a vacuum furnace. The laser welding occurs while the IG unit is in the furnace and is directed around the perimeter of the IG unit by a combination of rotating the IG unit and aiming the laser with mirrors.
Drawbacks of the conventional art include higher energy consumption, higher heat dissipation requirement, increased fabrication time and overheating of the IG assembly and spacer. It is an object of the present invention to overcome the disadvantages of the prior art by using localized zonal heating or other energy source to heat or otherwise induce an effect (e.g. for curing) within the spacer of the IG assembly in the zone(s) of the assembly where the spacer is positioned between the substrates.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided an improved apparatus to seal a spacer between a pair of spaced apart substrates, wherein thermal or other energy is applied locally to selected zones of the assembly where the spacer contacts the substrates.
According to another aspect of the present invention, there is provided in the above type of apparatus a press adapted to provide sealing between a pair of spaced part substrates (conveniently glass) and a bondable spacer, including heat sources adapted to move with glass substrates, specifically movably positioned to heat the edges of the glass substrates or IG unit.
According to another aspect of the present invention, there is provided in the above type of apparatus a vertical press adapted to provide sealing between a pair of spaced apart glass substrates in generally vertical orientation and a bondable spacer, including guide roller means.
According to yet another aspect of the present invention, multiple localized energy applicator heads, preferably one per side of the IG unit are employed.
In a still further aspect of the present invention, there is provided in the above type of apparatus a vertical glass press adapted to provide sealing between a pair of spaced apart glass substrates and a bondable spacer, having at least one heating means synchronized to travel a desired distance with the leading edge of a glass substrate. The apparatus may further include a second heating means synchronized to travel a desired distance with the trailing edge of a glass substrate.
According to another aspect of the invention, there is provided in the above type of apparatus a glass press adapted to provide sealing between a pair of spaced apart glass substrates and a bondable spacer, comprising a plurality of spaced-apart compression means such as rollers or ball bearings between which a glass assembly is adapted to pass whereby said rollers apply compressive force to the spaced apart glass substrates, means for advancing a glass assembly to and through said apparatus, a plurality of spaced apart heating means adapted to provide localized heating to said spacer in selected areas of said glass assembly where said spacer is located and without providing direct heat to the balance of said glass assembly.
According to a further aspect of the invention, there is provided in the above type of apparatus a preferred heating means comprising two pairs of spaced-apart heating assemblies, at least one pair of said spaced apart heating assemblies comprising at least one adjustable heater adapted to move in a generally parallel direction relative to the other heater of said one pair.
According to a still further aspect of the invention there is provided in the above type of apparatus wherein said heating assembly includes a first pair of spaced apart heaters, one of said heaters being mounted in a fixed relationship to said press and the other of said heaters of said one pair being movable in a generally parallel relationship to said fixed heater, and means for effecting movement of said one movable heater.
According to an aspect of the present invention there is provided in the above type of apparatus wherein the other of said pair of heaters comprises at least one movable heater movable in a second direction relative to the direction of movement of said first pair of heaters, and means for effecting movement of the movable heater of said second pair of heaters.
In another aspect of the present invention there is provided a method of sealing an insulated assembly having a pair of spaced apart substrates and a spacer therebetween, comprising;
(a) providing an insulated assembly,
(b) providing an energy source,
(c) selectively applying energy to selected zones of said assembly where said spacer is located without providing direct energy to the balance of the assembly.
In still another aspect of the present invention there is provided a method of sealing an insulated assembly having a pair of spaced apart substrates and a spacer therebetween, comprising selectively applying energy to selected zones of said assembly where said spacer is located without providing direct energy to the balance of the assembly.
According to a further aspect of the present invention there is provided in the above type of apparatus wherein there is provided two pairs of heater assemblies each pair being mounted in an angular relationship to the other pair of heaters, each heater means comprising an individual heater adapted to direct a heat source to a selected portion of a glass assembly containing a spacer element.
According to another aspect of the present invention there is provided a method of bonding a spacer to a pair of spaced apart glass substrates in which the spacer is positioned between the substrates; the method includes the steps of providing a glass assembly having a spacer between a pair of spaced apart glass substrates and in which the glass substrates of the assembly are loosely bonded by said spacer, providing a plurality of heat sources of an elongated relatively narrow width compared to the overall surface area of the glass assembly, positioning said plurality of heat sources in operative relationship to a glass surface beneath which the elongated spacer is located and selectively applying heat to said spacer along an elongated narrow strip of the glass assembly whereby the spacer is preferentially heated relative to other areas of the glass assembly.
In accordance with one aspect of the present invention, there is provided in the above type of apparatus a vertical press adapted to provide sealing between a pair of substrates and a bondable spac
Haran John T.
Maki Steven D.
McFadden Fincham
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