CN100594286C - 一种形成隔热玻璃构件的方法 - Google Patents

一种形成隔热玻璃构件的方法 Download PDF

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CN100594286C
CN100594286C CN200580004034A CN200580004034A CN100594286C CN 100594286 C CN100594286 C CN 100594286C CN 200580004034 A CN200580004034 A CN 200580004034A CN 200580004034 A CN200580004034 A CN 200580004034A CN 100594286 C CN100594286 C CN 100594286C
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G·赖克特
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Abstract

一种将隔离部件放在玻璃板上以形成隔热玻璃构件的方法，包括将在隔离部件上涂覆密封剂的工艺与自动生产过程相结合的步骤。密封剂在生产线上被涂覆至隔离部件上从而带有密封剂的隔离部件无需手工操作即可放在玻璃板上。

Description

一种形成隔热玻璃构件的方法
技术领域
本发明主要涉及一种隔热玻璃构件，尤其涉及一种在隔离部件上涂抹密封剂以及形成带有密封剂的隔离部件的隔热玻璃构件的方法。更具体的，本发明涉及一种方法，该方法在隔离部件上涂抹密封剂，然后在不影响隔离部件上所敷密封剂的情况下形成玻璃构件，从而将密封剂破坏率降至最低。
背景技术
隔热玻璃构件通常包括被周边隔离部件隔开并固定的第一和第二玻璃板。现有技术中公知的隔离部件具有各种各样的构造。这些隔离部件的共同特征在于，当在玻璃板的周边提供密封时它们在物理上将第一和第二玻璃板隔开，而在玻璃板和隔离部件内侧之间界定出隔热空间。密封由至少穿过隔离部件和玻璃板间的交界面布置的主密封剂形成。密封可以全部由主密封剂或者通过主密封剂和隔离部件元件(例如金属箔)的结合而形成。
在现有技术的隔热玻璃制作系统中，对隔热玻璃构件严密密封的主密封剂是在不同的位置、以不同的方式和次数被涂覆于隔离部件上。在其中一个制作系统中，主密封剂被涂覆在由一对玻璃板与隔离部件的外围之间形成的凹槽里。例如美国专利3,759,771示出了此类系统。此类系统的缺点是主密封剂被设计为在隔离部件和玻璃上均需涂覆。因此。这种涂覆方法单独对哪一个部件都不是最优。在另一制作系统中，主密封剂是在隔离部件放入用于将隔离部件运送到隔热玻璃构件制造地的储运集装箱之前被涂覆在隔离部件上的。举例来说，美国专利4,431,691示出了这种类型的隔离系统。在此类系统中，将带有密封剂的隔离部件自存储集装箱中取出并施加至一块玻璃上从而形成周边框架。还可将带有密封剂的隔离部件先自其存储集装箱取出，形成框架，然后再施加至玻璃上。施加第二块玻璃板以形成外部凹槽。然后，让这些部件通过一滚筒热压机使得主密封剂浸透在玻璃上从而形成主密封。在这些实施例中，涂敷于隔离部件上的主密封剂可能会在存储、运输以及施加至玻璃之前的处理过程中受损。密封剂受损可能会形成漏隙，从而根据保用政策窗户生产商需要对窗户进行更换。这些系统的另一缺点在于当密封剂最初与玻璃接合时密封剂的温度很难掌控。解决这些问题的其中一个办法是加热和施压(例如让元件通过滚筒热压机)，从而保证密封剂和玻璃间的良好粘合。总之这些现有的工艺方法具有多处缺点且现有技术需要有克服上述缺点的解决办法。
发明内容
本发明的一个特征在于将密封剂涂覆步骤和隔热玻璃构件的生产过程结合起来。在隔离部件从其存储容器中取出之后，将密封剂在形成隔热玻璃构件的生产设备中施加于隔离部件上。本发明的又一特征是在密封剂被施加于隔离部件上之后，不对密封剂进行手工操作。本发明的再一特征是在密封剂和玻璃粘合之前将密封剂施加于隔离部件上，从而提供优化密封剂施加于隔离部件上的机会以及优化施过密封剂的隔离部件与玻璃之间的结合。本发明的又一特征在于当将密封剂施加于隔离部件和玻璃上时能对密封剂的温度进行控制。这些特征可以单独应用或者结合起来应用。
在一个实施例中，本发明提供了一种将隔离部件旋加于玻璃板上从而形成隔热玻璃构件的方法；该方法包括以下步骤：(A)将隔离部件置于存储容器中；(B)将隔离部件自该存储容器中取出；(C)在步骤(B)之后将密封剂施加于隔离部件上以形成带有密封剂的隔离部件；(D)将带有密封剂的隔离部件与第一玻璃板连接；以及，(E)在步骤(C)之后由带有密封剂的隔离部件形成一隔离框架；其中该方法省略了在步骤(C)之后对带有密封剂的隔离部件进行手工外理的步骤；步骤(E)包括将带有密封剂的隔离部件施加到玻璃上的同时形成所述隔离框架的步骤。
附图说明
图1为由本发明所述方法和隔离部件制成的示例性隔热玻璃构件的前视图，局部断开。
图2为在隔离部件被从其存储地点取出后，具有两个对隔离部件的两侧涂覆密封剂的喷嘴的示例性隔离部件的剖面图。
图3为施加至第一玻璃板的带有密封剂的隔离部件的剖面图。
图4沿着图3所示44线切开的俯视图。
图5为与图4相似的取自边角位置的俯视图，示出了用以形成角部的示例性边角凹口的俯视图。
图6为图5所示的凹口型隔离部件的俯视图，其中，带有密封剂的隔离部件弯成90度的角部。
图7为与图3相似的剖面图，示出了施加至隔离部件上的第二玻璃板。
图8为图7所示的隔离部件的剖面图，其中，向外设置的沟槽填充有密封剂。
图9为本发明所述方法和设备的示意图。
整个说明书中相同的附图标记表示相同的部件。
具体实施方式
在图1和9中，由本发明的方法制成的示例性隔热玻璃构件总体由附图标记6表示。隔热玻璃构件6一般包括将一对玻璃板22支承于间隔状态以在玻璃板22于隔离组件8的内表面之间限定出隔热腔室40的隔离组件8。隔离组件8至少包括一隔离部件10以及主密封剂18。在本申请的上下文中，主密封剂为在隔离部件的结构元件和玻璃之间形成密封的密封剂。隔离组件8可选择性地包括次密封剂44。隔离部件10可包括各种组合使用的元件中的任一种，并且可由各种材质制成。例如，隔离部件10可包括防潮层和用于将隔离部件10固定至玻璃板22上的粘合剂。在本发明的示例性实施方式中，隔离部件10由柔性泡沫材料制成。隔离部件10可选择性地带有干燥剂。
在一示例性实施方式中，隔离部件10被装在存储容器24中提供给隔热玻璃制造商。当柔性隔离部件10带有干燥剂时，存储容器24可被密封以保护干燥剂。举例来说，隔离部件10可以为柔性隔离部件，例如由俄亥俄州剑桥的Edgetech IG按经联邦政府注册的SUPER SPACER商标销售的隔离部件。美国专利4,831,799公开了隔离部件10的实施例，其公开内容在此引入作为参考。使用柔性隔离部件时，可将柔性隔离部件卷绕在容器24内的卷轴上。在示例性实施方式中，隔离部件10具有一个置于支撑粘合物14的一对肩部之间的金属箔防潮层12。粘合物14用来将隔离部件10固定在玻璃板22上。示例性隔离部件10限定出肩部下的凹口16。隔离部件10可限定出正好位于界定出隔热气穴的肩部之间的纵向开口。该开口同时也隔开了肩部之间的导热通道。
图9示出了本发明的在生产线上整体化涂覆密封剂的方法的示意图。为了通过整体化涂覆密封剂而形成隔热玻璃构件6，隔离部件10被从存储容器24中取出并置入将隔离部件施加至玻璃板上从而形成隔热玻璃构件6的设备。剥离器26将粘合层14的保护层15除去。之后隔离部件10与一将密封剂18涂覆至隔离部件10上的设备28相互作用。采用适当的装置将隔离部件10移动通过一密封剂涂覆器28以涂覆密封剂18。例如，这些装置可以包括合适的导轨和辊子。这种方法的优点在于设备28可构造成优化隔离部件10上的密封剂18的涂覆工艺，从而避免了形成气穴并且可适量的密封剂18涂覆在适当的位置。涂覆器28可包括一对相对设置的涂覆喷嘴20。密封剂18可通过不同的喷嘴20同时被施加于相对设置的凹口16中。喷嘴20可如图所示成角度设置，或者成直线设置从而彼此正对。在另一实施例中，密封剂18可通过第一位置处的第一喷嘴施加至边角凹口16中，且通过第一位置下游的第二位置处的第二喷嘴施加至另一边角凹口16中。涂覆器28可与将隔离部件10安装至玻璃22上的敷贴器一起放置或者随之移动。当置于此位置时，在密封剂被涂覆至隔离部件之后，密封剂几乎没有可能会受到污染。在与玻璃接合之前，密封剂也几乎没有冷却的时间。
然后如图3所示，隔离部件10被安装至玻璃板22上而无需任何离线存储步骤或者手工操作步骤。刚涂覆的密封剂18立即与玻璃粘连起来，几乎没有任何机会遭受不期望的污染。这样，密封剂18的涂覆过程以在此之前现有技术中未认识到的方式与生产过程揉成一体。在本发明的一个实施例中，框架是在带有密封剂的隔离部件被安装至玻璃22上时形成的。通过使用沿着玻璃22周边而行的自动设备，隔离部件10和密封剂18可以形成框架。也可通过手动敷贴器使隔离部件10和密封剂18形成边框。这样的手动敷贴器允许使用者手工将隔离部件10安装至玻璃上而无需手工操纵带有密封剂的隔离部件。
放上第二玻璃板22(如图7所示)以形成在两玻璃板22与隔离部件10之间限定出隔热腔室40的隔热玻璃构件8。通过自玻璃板22边缘向内放置隔离部件10还可限定出朝外的密封凹槽42。在一些实施例中，再将次密封剂44以现有技术公知的各种方法中的任意一种置于凹槽42中。根据隔热玻璃构件所要求的功能，密封剂44可以是与密封剂18相同的密封剂或者为基本不同的密封剂。密封剂18可以为本领域普通技术人员所知的可用于在隔热玻璃构件的隔离部件和玻璃22之间进行密封的各种密封剂中的任意一种。为了提供一个非限定性的实施例起见，密封剂18可以为聚异丁烯，热熔丁基，热熔材料，UV可固化材料，或者固化后可具有抗剪力的结构强度的材料。这些材料中的一些在涂覆开冷却后保持可流动，而另一些在固化之后变得不可流动。本方法可以采用的另一种类型的密封剂18为与玻璃交联从而实现密封剂和玻璃之间的粘合的密封材料。
本发明的一个优点在于密封剂的涂覆独立于玻璃安放步骤，从而玻璃22不会妨碍密封剂18往隔离部件10上的涂覆。这样，这种方法允许对两个步骤均进行单独优化。本发明的另一个优点在于能控制密封剂18的温度以便理想地涂覆至隔离部件10上，然后改变成不同的温度以便理想地施加至玻璃22上。在一些实施例中，当将密封剂18涂覆至玻璃22上时，使用者可能希望使密封剂18从图2中的较高温度冷却至图3中的较低温度，同时仍然在密封剂18中保持一定的热量。当被涂覆至隔离部件10上时，密封剂18通常被加热至高于室温。对于部分密封剂18而言，其需要保持其升高的温度直至其被贴在玻璃上。对于另一些密封剂而言，自图2的位置至图3的位置，密封剂18可能需要升温。在又一些其它实施例中，使用者可能希望自图2的位置至图3的位置能保持恒定的温度。在上述每一个实施例中，可使用适当的冷却/升温装置29(例如气刀或者蓄电池或者加热器)可用来调整密封剂18所具有的温度。
本发明的的又一优点在于密封剂18一体化在线涂覆使得密封剂18受污染的几率降到最低。四周的密封剂18在图2的位置与图3的位置之间的温度可被严格控制在理想的密封条件下。这样，由于在涂覆密封剂和连接带密封剂的隔离部件与玻璃之间无需任何手工操作，所以这个方法还避免了现有技术中当在将隔离部件放到玻璃22上之前对其进行处理所产生的问题。这种方法同样还避免了在储存和运输过程中密封剂形状受损的问题。在存储和运输过程中当密封剂流动(如果其为易流动材料且尤其是其被置于热容器中)时密封剂会变形。在运输过程中当遭受到其他相邻的隔离部件包裹的重压时密封剂也会变形。
在一独立实施例中，本发明提供了一种当隔离部件10被放到玻璃22上时形成角部的新方法。图5和图6所示的角部形成方法独立于上述的密封剂涂覆方法，但是可以和上述方法一起使用。图5和图6示出了(经放大)该新的角部形成方法。图5示出了隔离框架的角部位置。当敷贴器到达角部位置时，敷贴器在隔离部件10上切口从而在隔离部件10中形成一个局部凹口30。凹口30仅在隔离部件10的肩部之间沿内部主体部分32的厚度方向延伸。凹口30可以是圆形，三角形，矩形，或者任何其他的形状。由于凹口30仅部分地通过隔离部件10的肩部区域，所以凹口30并没有影响到密封剂18，并当隔离部件10被弯曲为如图6所示的90度时形成一突起区域34。凹口30可完全延伸穿过肩部区域以使得主体10更易于围绕角部弯曲。密封剂18的突起有助于在隔离体框架的角部形成牢固的密封。角部区域通常是最难进行密封的区域，而局部切口保证了隔离部件10在角部的扩展，以及密封剂18在角部的扩展。
在前边的描述中，为了简明、清楚和理解起见使用了一些术语。因为这些术语被用来进行描述并且进行宽泛的解释，所以对于超出现有技术要求的部分无需进行不必要的限定。
此外，本发明的说明书和附图仅为示例，且本发明并不局限于所示出或者描述出的具体细节。

Claims (9)

1、一种将隔离部件放在玻璃板上从而形成隔热玻璃构件的方法；该方法包括以下步骤：
(A)将隔离部件放置于存储容器中，其中隔离部件包括一对带有粘结剂的侧面，所述侧面适用于连接到隔热玻璃构件的玻璃板的内表面上；
(B)将隔离部件自该存储容器中取出；
(C)在步骤(B)之后将密封剂涂覆至隔离部件上以形成带有密封剂的隔离部件；
(D)将带有密封剂的隔离部件的带有粘结剂的侧面之一黏附地连接到第一玻璃板上；以及
(E)在步骤(C)之后由带有密封剂的隔离部件形成一隔离框架；其特征在于，该方法省略了步骤(C)之后的对带有密封剂的隔离部件进行手工操作的步骤；步骤(E)包括将带有密封剂的隔离部件施加到玻璃上的同时形成所述隔离框架的步骤。
2、如权利要求1所述的方法，进一步包括通过敷贴器前端将带有密封剂的隔离部件连接至玻璃板上，并在敷贴器前端将密封剂涂覆至隔离部件上的步骤。
3、如权利要求1所述的方法，其中所述的隔离部件以盘绕状态置于存储容器中，并进一步包括在步骤(B)中将至少一部分隔离部件自存储容器中展开的步骤。
4、如权利要求1所述的方法，进一步包括提供带干燥剂的柔性泡沫材料形式的隔离部件的步骤。
5、如权利要求1所述的方法，其中步骤(C)包括将密封剂间隔施加在隔离部件的相对侧上的步骤。
6、如权利要求1所述的方法，进一步包括在步骤(C)之后以及在将带有密封剂的隔离部件连接至玻璃构件的玻璃板之前使密封剂冷却的步骤。
7、如权利要求6所述的方法，进一步包括在步骤(C)之前将密封剂加热至高于环境温度的步骤，以及在密封剂的温度降到环境温度之前执行步骤(D)的步骤。
8、如权利要求1所述的方法，进一步包括在步骤(C)之后以及在将带有密封剂的隔离部件连接至玻璃构件的玻璃板之前对密封剂进行加温的步骤。
9、如权利要求1所述的方法，进一步包括在两玻璃板和隔离部件之间形成外向密封剂凹槽以及用一种材料填充外向密封剂凹槽的步骤。
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