GB2053034A - Method and apparatus for making insulated frame members - Google Patents

Abstract

A method and apparatus is provided for making heat insulating, frame members for curtain walls and the like, each frame member including a pair of elongated metal elements (22 and 24), structurally interconnected with a joining element of heat insulating material (26). The system includes at least one movable pallet (30) having mechanical clamping fixtures (34) for holding the elongated metal elements securely in precisely aligned relation with respect to each other, with a lower one (24) having a pocket in position ready to receive the heat insulating material which is introduced in liquid form into the pocket to form a securing structure around the tongue (22b) of an upper metal element extending into the pocket. The metal elements are moved through a preheating area, a filling and a curing area on the pallets. <IMAGE>

Description

SPECIFICATION Method and apparatus for making insulated frame members The present invention relates to a novel method and apparatus for making heat insulating framing members used in curtain walls and the like. Each frame member includes a pair of elongated metal elements structurally interconnected with a joining element formed of heat insulating material and a frame work of these members provides support for the glazing or other wall panels in a wall or window system.

Heat insulating framing members for use in curtain walls and the like have been developed wherein a heat insulating material in liquid form is dispensed into a continuous pocket in an elongated metallic frame member. After the liquid material has solidified, it is necessary to physically remove a portion of the metal pocket wall in order to provide a thermal break between spaced apart portions of the metal. One such apparatus for making thermal insulating frame members is shown in the Holiday et al U.S. Patent No. 3,624,885 and this system suffers from the disadvantage that it is costly and time consuming to remove a portion of metal pocket wall from the metal portion in order to provide the thermal ''break' or ''barrier'' The requirement for metal removal or 'debridging" of wall portions of the pockets limits the choice of structural shapes and designs that are available to a curtain wall designer. Another system for making thermally Insulating frame members is shown and described In the Sukolics, U.S.

Patent No. 3,729.354, and in this system, an endless belt is provided to form the bottom wall of a pocket for receiving the heat insulating material In liquid form, The material is introduced Into the pocket adjacent one end of the belt and solidifies by the time it has reached the opposite end of the belt.

The present Invention Is a method of making an elongated composite heat Insulating frame member used for curtain walls and the like. which member Includes a pair of spaced apart. discrete metal elements interconnected by a heat Insulating element of solid material In a joint area Including an integral pocket formed entirely In one metal element for receiving heat insulating material In liquid form flowed around the tongue of the other metal element, said method comprising positioning said discrete metal elements at different levels in parallel spaced apart relation with the tongue of an upper element extending Into the pocket of a lower element aligned to open upwardly to receive said tongue: holding said metal elements in said spaced apart relationship with said tongue spaced from said pocket without spacing means disposed therebetween providing a continuous open space along the length of said elements; dispensing a flow of heat insulating hardenable solid resinous material in liquid form along the length of said upwardly open pocket of said lower element downwardly along and against said tongue of said upper element; and hardening said resinous material in said pocket to form a rigid heat insulating joining element structurally interconnecting said metal elements with a thermal barrier therebetween.

The present invention is also apparatus for making an elongated heat insulating frame member used for curtain walls and the like, which member includes a pair of spaced apart discrete metal elements interconnected with a heat insulating element of solid material formed in an upwardly opening elongated pocket provided entirely in one metal element adjacent a tongue of the other metal element extending downwardly into said pocket, said apparatus comprising means for rigidly supporting a pair of said discrete metal elements in fixed parallel spaced apart relation at different levels with said pocket opening upwardly and positioned for receiving said tongue extending downwardly into said pocket with an opening along said tongue; means for downwardly dispensing a flow of heat Insulating material in liquid form into said opening of said pocket along the length thereof to contact said tongue; means providing relative longitudinal movement between said dispens ing means and said supporting means: and means for solidifying said liquid heat Insulating material into rigid condition forming said heat insulating element for Interconnecting said metal elements.

Briefly, the foregoing and other oblects and advantages of the present Invention are provided In one embodiment of the Invention for making heat insulated frame members for use in curtain walls and the like, wherein the frame members include a pair of elongated metal elements structurally interconnected by a joining element formed of heat Insulating material. The apparatus includes at least one movable fixture or pallet having a pair or more of operable clamping assemblies thereon for holding a pair of elongated metal elements In secure and precisely aligned parallel, spaced apart relation, When clamping m position. a lower metal element having a pocket Is aligned in position with the pocket facing upwardly to receive heat insulating material which Is Introduced Into the pocket in liquid form. The tongue of an upper metal element Is positioned to extend into the pocket and the liquid heat insulating material IS flowed into the pocket around the tongue to form 3 secure bond between the tongue and the adia- cent walls of the pocket along the entire length of the elements, The elongated metal elements are preheated In an oven to an elevated temperature and are positively supported on the fixture which is guided for longitudinal travel adjacent a stationary, liquid dispensing station. At the dispensing station a precisely metered flow of resinous heat insulating material in liquid form is discharged in a continuous stream into the awaiting pocket around the tongue. After the pocket Is filled, the fixture is positioned in a holding or curing area where the metal elements are retained In rigidly held relation until the heat insulating material in the pocket has fully solidified and bonded with the metal elements. After curing, the clamping assemblies on the pallet or fixture are opened to release the completed unitary frame member which Is then unloaded from the fixture which is moved away ready to accept the next pair of metal elements which are clamped in place. A number of fixtures or pallets may be provided In the system so that a continuous flow of work will be in progress at various stages of completion in the described method of operation.

An embodiment of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure l is a plan view in schematic style of a new and improved apparatus constructed in accordance with the features of the present invention and especially adapted for making elongated. heat insulating frame members in accordance with the features of the present invention; Figure 2 is a fragmentary, vertical crosssection taken substantially along lines 2-2 of Fig. 1, Figure 3 is a fragmentary, vertical crosssection taken substantially along lines 3-3 of Fig. 1, Figure 4 is a fragmentary, elevational view looking in the direction of arrows 4-4 of Fig.

3; Figure 5 is an elongated, schematically styled, vertical sectional view taken substantially along lines 5-5 of Fig. 1.

Figure 6 is a fragmentary. vertical sectional view taken substantially along lines 6-6 of Fig. 1, Figure 7 Is a fragmentary, enlarged crosssectional view taken substantially along lines 7-7 of Fig. 1.

Figure 8 is a fragmentary, side elevational view looking in the direction of the arrows 8-8 of Fig. 7: Figure 9 is a top plan view of the fixture of Figs. 6, 7 and 8.

Figure 10 is a fragmentary, elevational view looking In the direction of arrows 10-10 of Fig. 1.

Figure 1 1 Is a fragmentary, sectional view taken substantially along lines 11-11 of Fig.

1.

Figure 12 is a fragmentary, enlarged crosssectional view similar to Fig. 7 showing an alternative embodiment; and Figure 131s a fragmentary side elevational view similar to Fig. 8 but showing the alternative embodiment of Fig. 1 2.

Referring now more particularly to the drawings, therein is illustrated a new and improved apparatus constructed In accordance with the features of the present Invention especially adapted to produce and improve elongated, heat Insulating, frame members which are referred to generally by the reference numeral 20 as best shown in Figs. 6 and 7. These type of heat insulating frame members 20 are especially useful in providing a heat insulating supporting frame work for curtain walls, window systems and the like which utilize heat insulating type glass and the particular frame members constructed in accordance with the features of the present invention are fully illustrated and described in copending United States Patent Application Serial No. 880,710, filed February 23, 1978.

In general, each elongated heat insulating frame member includes a pair of elongated metal elements 22 and 24 which are maintained in precisely aligned, spaced apart. parallel relation as best shown in Fig. 7 and which are structurally interconnected by a joining element 26 formed of resinous heat insulating plastic material which is introduced between the metal elements In liquid form in accordance with the present Invention. The lower metal element 24 includes a pocket 24a positioned to open upwardly in order to receive the heat insulating material which is introduced therein in liquid form. The upper metal element 22 includes a depending tongue 22a extending Into the pocket and having a transverse flange along a lower edge as illustrated. When the liquid heat insulating material eventually cures or hardens into rigid form, the joining element 26 is completed and positively interlocks the upper and lower elongated metal elements 22 and 24 into a composite structural frame work 20 having a thermal break between the metal portions.

The metal elements 22 and 24 are formed of extruded aluminum in convenient lengths of approximately 24 feet and in accordance with the invention, during the process, the upper metal element 22 and the lower metal element 24 are securely clamped and maintained in the illustrated spaced apart parallel relation (Fig. 7) on a movable fixture or pallet 30 which includes a generally rectangular, relatively thick strong base plate 32. The base has a planar upper surface and parallel long tudinal side edges as illustrated best In Figs.

6. 7 and 9. Each fixture 30 Includes a plural ity of clamping assemblies 34 mounted at longitudinally spaced intervals (Figs. 2 and 5) on the base 32.

Each fixture 30 Includes a set of clamping assemblies 34 and each clamping assembly includes an upstanding stop member 36 hav ing a vertical lower stop surface 38 adapted to be engaged by one side surface of a lower metal element 24 placed on the base 32 as shown in Fig. 7. The lower metal element is biased against the stop surface 38 by a short spring finger 40 which is secured to a notched edge portion of the base. In addition, another small spring finger 42 is provided to bias the element downwardly against the upper surface of the base 32. As illustrated, the elongated metal elements 24 are moved into place as shown and are maintained in this position by the spring fingers 40 and 42 with an inner side surface of the metal element abutting against the lower stop surfaces 38 on the stop members 36 of the clamping assemblies 34. Each stop member 36 also includes a pair of horizontally, outwardly, extending vertically spaced apart fingers 44 and 46 having vertical stop surfaces on the outer ends above the surface 38 and adapted to align and abut against the tongue 22a of an upper metal element 22 which is placed in position as shown, In addition, the upper stop finger 46 provides support for the bottom of an inner edge portion on the upper element 22 and also includes a relatively short stop surface 48 parallel of the lower stop surface 38 against which the inner edge is placed.

With the elements In precisely aligned, spaced apart parallel position as shown in Fig. 7, the tongue and flange 22a and 22b of the upper element are positioned in precision spaced apart, parallel relation within the pocket 24a of the lower metal element 24 so that the liquid resin material may be readily introduced into the pocket in a flowing stream from a liquid resin nozzle 50.

In order to securely clamp and hold the upper metal element 22 in position as shown while supported on the upper stop finger 46 against the upper stop surface 48, each clamping assembly 34 is provided with a clamping member 54 of generally J-shaped configuration having a curved. lower finger 54a with a rounded end adapted to bear against an outside surface of the tongue 22a to secure the tongue against the outer vertical stop surfaces on the ends of the stop fingers 44 and 46. In addition, each J-shaped member 54 is provided with a downwardly facing stop surface 54b which faces downwardly against the upper surface of a clamped upper metal element 22, to keep the element from rising while the liquid resinous material flows from the nozzle 50 into the pocket 24a around the tongue 22a and flange 22b. The clamping member 54 also includes an elongated main body portion which Is pivotally connected ro the upper end of a lever 56 by a pivot pin 58. and the lever 56 in turn is pivotally supported on the base 32 by a pivot pin 60 carried in a bifurcated bracket 62.

Intermediate the ends, the lever Is formed with a rectangular slot 56a and a pivot pin 64 extends between opposite walls forming the slot to pivotally support the outer end of an arm 66. The inner end of the arm is pivotally connected to an inner arm 68 by a pin 69 which also supports a channel shaped locking member 71 having an operating finger 71 a movable away from the arm 66 toward an unlocked position permitting free pivotal movement of the respective arms 66 and 68 about the connection pin 69. The inner arm 68 is pivotally connected by a pin 72 to the stop member 36 in a recess 36a. In order to secure the arms in the locked clamping position as shown, a key pin 70 with a ring on one end is inserted into aligned holes in the locking member 71 and arm 66 and this retains the arms 66 and 68 in longitudinally aligned relaticn to maintain the lever 56 in the upright position as shown. When the key pin 70 is withdrawn by an outward pull on the key ring, the arms 66 and 68 are then free to pivot relative to each other about the pin 69 and movement of the locking finger 71 a as shown by the arrow "F" provides a convenient means for pivoting the arms out of the locking position. When this occurs the lever 56 pivots in a counterclockwise direction toward a sloping position with the upper end of the lever being lowered and moved toward the stop element 36 as indicated by the arrow "A". This causes the clamping member 54 to move toward the left while pivoting in a clockwise direction and the rounded end of the finger 54a moves along a path indicated by the arrow 'B' When this occurs. the clamping finger moves out of holding engagement away from the tongue 22a of the upper element in a generally outward and upward direction as Indicated by the arrow 'B'' The clamping finger moves "linearly' and "rota- tionally" and the rounded end moves with precision out of the space between the facing edge portions of the metal elements 22 and 24 without contact therewith until finally reaching a position above the level of the upper element 22. During this unclamping action, an intermediate body portion of the Jshaped clamping member 54 Is guided between a pair of spaced apart upper and lower guide rolls 74 and 76 carried on axle pins 73 and 80, respectively, extending between a pair of upstanding fingers 82 formed at the upper ends of the stop member 36 on opposite sides of a central slot or recess 36 b defined therein. The upper guide roll 75 limits upward movement of the clamping member 54 which Is In the clamping position and the lower guide roll 76 limits downward travel thereof. Because of the lateral offset between the roll supporting axles 78 and 80. both linear as well as pivotal movement of the clamping member 54 is permitted as the arms 66 and 68 pivot away from the longitudinally aligned clamping position after being unlocked.

The clamping member as a whole, moves from right to left (Fig 7) and at the same time begins to rotate in a clockwise direction. This complex motion produces the desired type and direction of finger movement so that the finger 54a moves away from the tongue 22a and between the upper and lower metal elements as the clamping assembly 34 is opened up. Movement of the clamping member 54 from right to left continues until a lower, curved stop surface 54c on the underside of an outer portion of the member engages an upper portion of a vertical stop surface 84 of the stop member 36. As this engagement occurs, further pivoting between the arms 66 and 68 causes a more rapid rotation of the Jshaped clamping element 54 in a clockwise direction so that the finger 54 ends up spaced upwardly and out of the way in an open position above the level of the upper metal element 22. When all the respective clamping assemblies 34 on a fixture 30 are unlocked, the J-shaped clamping members are in upstanding or open position and the curved stop surface 54c of the members 54 are engaging the stop surfaces 84 on the upstanding stop members 36. In this open position, the rounded end of the fingers 54a are spaced above the level of the stop member 36 and as viewed in Fig. 7, the area to the left hand side of the stop is completely open with ready access for placement and removal of the upper and lower metal elements 22 and 24 into and out of position as shown.

In loading a fixture 30, a lower metal element 24 is first moved Into the position until it is held by the spring fingers 40 and 42 with the open pocket 24a facing upwardly. The upper metal element 22 is then rocked into position by first moving the tongue flange 22b into the opening of the pocket 24a and then rotating the element until the tongue 22a bears against the outer ends of the horizontal stop fingers 44 and 46.

The mechanical clamp 68 of the respective clamping assemblies are then actuated so that the piston rods 66 move outwardly and this causes the J-shaped clamping elements 54 to move towards the clamping position as shown. During movement from the open or unclamped position to the clamped position, the fingers 54a move both rotationaliy and linearly and the rounded outer ends pass between the facing left hand wall portions of the respective upper and lower metal elements 22 and 24 and until the rounded end of the fingers engage the tongue 22a of an upper metal element to hold the element tightly against the stop surfaces on the outer ends of the stop fingers 44 and 46. When the arms 66 and 68 are longitudinally aligned and locked In position by the locking member 71 with the key pin 70 inserted, an adequate clamping force Is provided to firmly secure the upper and lower metal elements In the parallel spaced apart precision alignment as shown, ready for the Introduction of liquid resinous heat insulating material into the pocket 24a around the tongue 22a and flange 22b.

Referring now to Figs. 1 and 2, a plurality of elongated metal elements 22 and 24 are stored in stacks on pallets in a loading station generally designated by the reference numeral 1 00. At the loading station, there is provided an elongated roller conveyor 102 on which a fixture 30 is positioned ready to be loaded with a pair of metal elements 22 and 24 In the manner as previously described. After the elements are mounted in place and securely clamped by the respective clamping assemblies 34, the loaded fixture is moved laterally off the conveyor in the direction of the arrows ''C' (Fig. 1) onto a plurality of transversely extending roller conveyors 104 which are provided in a preheating oven indicated generally by the reference numeral 106 and shown in cross-section in Fig. 2.

As indicated in Fig. 2, the oven 106 includes a plurality of insulating panels 108 forming a top wall and at opposite ends, a pair of insulating panels are provided to form opposite end walls of the oven enclosure. The bottom of the oven is open and the oven wall structure is mounted above the floor surface 110 on a support frame work which includes a plurality of upright legs 11 2 and a frame of lateral cross-members 11 4 interconnected with longitudinally extending cross-members (not shown). As the loaded fixtures 30 move through the oven 106 on the roller conveyors 104 in the direction of arrows "B" (Fig. 1) the temperature of the metal elements 22 and 24 is raised to the desired level by means of a plurality of heat lamps 11 6 which are positioned to radiate heat downwardly toward the metal elements moving therebelow. The spacing intervals between the heat lamps 11 6 is selected in order to provide the desired amount of temperature elevation for the metal elements on each loaded fixture as it passes through the oven. It has been found that an oven temperature of approximately 150oF provides a surface temperature of aproximately 110v-115 F on the metal elements 22 and 24 and this temperature range provides good bonding between the resin and metal and helps to more rapidly set or solidify the resin.

The loaded fixtures inside the heat oven structure move toward the opposite longitudinal side of the oven on the roller conveyors 1 1 4 which have a gentle downward slope.

After passing through the oven. the fixtures are loaded onto an elongated. main drive conveyor which Is indicated by the reference numeral 1 20 in Fig. 1 and which Is shown In transverse cross-section in Fig. 6. As lilus- trated In Fig. 6, the main drive conveyor includes a plurality of H-shaped support structures 1 22 spaced at intervals longitudinally along the length of the conveyor. Along the upper ends of the posts of the H-frames there are provided a pair of longitudinally extend ing, spaced apart, parallel guide rails 1 24 of angle cross-section. At appropriate intervals along the rails, pairs of support rolls 1 26 are provided for supporting the loaded fixtures 30 as they move longitudinally on a linear path on the drive conveyor. A plurality of pairs of side guide rolls 1 28 are provided to bear against opposite edges of the bases 32 of the loaded fixtures in order to provide precision guidance for the loaded fixtures past a resin dispensing station which is indicated generally by the reference numeral 1 30 in Figs 1 and 5.

Referring momentarily to Figs. 1 and 5, the preheated loaded fixtures 30 leave the oven 106 and move linearly along the main drive conveyor 1 20 from right to left past the stationary resin dispensing station 1 30 and during this travel the fixtures are supported on the rolls 1 26 and guided laterally by the side rolls 128. Motive power for moving the loaded fixtures along the main drive conveyor at a precisely controlled speed is provided by an endless chain 1 32 which is entrained around a drive sprocket 1 34 at one end and an idler sprocket 1 36 at the opposite end as illustrated in Fig. 5. A drive motor (not shown) is connected to rotate the drive sprocket 1 34 at the desired speed and at appropriate intervals along the endless chain 1 32 there are provided outwardly extending drive dogs 1 38 (Figs. 5 and 6), which dogs are adapted to seat within shallow recesses 32a (Fig. 9) formed in the end of the fixture bases 32 as best shown in Fig. 9. In practice, a conveyor speed of 24 feet per minute works well and thus, 24 feet long elements 22 and 24 can be filled with resin in approximately 1 minute.

The upper run of the endless drive chain 1 32 is spaced below the bottom surface of the loaded fixtures 30 coming off the conveyors 104 in the oven 106 and the fixtures are unloaded from the roller conveyors onto the support rolls 1 26 of the drive conveyor 1 20 In sequence with the movement of the endless drive chain 1 32 so that a drive dog 1 38 will Immediately engage a shallow recess 1 32a In the base plate 32 and start the fixture moving along the conveyor line.

The preheated fixtures are loaded from the oven roller conveyors onto the main drive conveyor by a plurality of indexing units 1 40 (Figs. 1 3 and 4). The spaced apart indexing units 1 40 are arranged to work In unison to pick up the loaded fixtures 30 from the oven roller conveyors 104 and place the fixtures on the main drive conveyor 1 20 with a proper time sequence so that the continuously moving pusher dogs 1 38 on the chain 1 32 will Immediately engage and move the fixture past the resin dispensing station 1 30 For this purpose a sequencing switch 1 21 (Fig. 6) IS positioned at the end of the conveyor so that when a drive dog 1 38 moves past. the switch is actuated. This initiates action by the index units to place a preheated fixture 30 onto the conveyor 1 20. Each indexing unit includes an elongated pick up arm or rail 1 42 having a free outer end portion 1 42a adapted to support a loaded fixture as shown in Fig. 3. The support rails are movable longitudinally back and forth as indicated by the arrow 'D" and the outer end portion 1 42a thereof is movable up and down as indicated by the arrow so that the loaded fixtures are lifted up, off of the oven roller conveyors 104 and are then moved outwardly over the main line drive conveyor chain 1 32. The fixtures are then lowered onto the drive conveyor in sequence ahead of a drive dog 1 38 which engages and moves the fixture toward the resin dispenser.

At the inner ends of the rails 142, there is provided a U-shaped element or supporting saddle 1 44 having a plurality of support rolls 146 for slidably supporting the pick up rail to permit longitudinal travel back and forth. The U-shaped saddle is mounted for rocking movement on a pair of bearings 1 48 which are mounted on a rotor shaft 1 50 supported on a pair of fixed outer bearings 1 52. The bearings 1 52 are fixedly mounted on a supportive frame work 1 54. The drive shaft 1 50 is rotatable on both a counterclockwise and a clockwise direction and is driven by a large gear 1 56 and endless chain 1 58 connected to a smaller drive pinion 1 60 on the output shaft 1 62 of a reversible hydraulic motor 164, fluid being supplied to the motor through suitable supply and return lines 1 66 from a source of pressurized hydraulic fluid (not shown). The respective hydraulic lines connected to the motor are alternately connected to high and low pressure fluid conduits to obtain the proper sequence of operation resulting In the desired direction of rotation of the shaft 162 and pinion gear 1 60 as indicated by the arrow 'G' A single hydraulic motor 1 64 is provided for driving all three of the separate indexing units 140 so that the units will operate In precise synchronization and for this purpose.

the shafts 1 62 of the respective indexes are interconnected with the single drive motor 1 64 by means of couplings 1 68 and connector shafts 170. From the foregoing it will be seen that the U-shaped saddle 1 44 is rockable back and forth about the longitudinal 3xis of the shaft 1 50 and this rocking action causes the outer end portion 1 42a of the support rail to move up and down for levat- ing and lowering the loaded fixtures 30 during movement between the oven roller conveyors 104 and the main drive conveyor 1 20 rod 1 74 Is extended upwardly. the free end portion 1 42a of a rail is elevated and this action rocks the saddle 1 44 on the shaft 1 50 in a clockwise direction. The rail is then moved longitudinally toward the left (Fig. 3) as indicated by the arrow 'D' and this movement is directed and controlled by a clockwise rotation of the drive shaft 1 50 as powered by the hydraulic motor 164. A drive gear 180 is mounted on the central portion of the shaft 1 50 and the gear engages a toothed rack 1 82 on the underside of the support rail. The upper portion of the gear projects upwardly through a slot 1 44a in the bottom of the saddle to engage the rail. After the piston rod 1 74 is moved upwardly to elevate the outer end of the rail 142a, the hydraulic motor 1 64 is supplied with hydraulic fluid to rotate the shaft 1 50 In the clockwise direction and this causes the drive gear 1 80 to move the rack and the rail 1 42 toward the left and during this time, the U-shaped support saddle 1 44 rocks In a clockwise direction about the axis of the drive shaft 1 50. Limits on the amount of rocking action are adjusted by a pair of stops 1 88. When the piston rod 1 74 is subsequently retracted into the cylinder 172, the outer end portion 1 42a of the rail is lowered and as this action occurs. a fixture 30 is deposited on the main drive conveyor 1 20.

Subsequently, the arm 1 42 is returned from right to left by reversing the direction of rotation of the shaft 1 50 to a counterclockwise direction. The hydraulic cylinder 1 72 Is provided with supply and return fluid through a pair of lines 1 84 and the direction of fluid flow is sequenced with the direction of fluid flow to and from the motor 1 64 through the fluid lines 166.

In an operating cycle, proper sequencing and operation of the indexing units 1 40 begins after the switch 1 21 is activated by a drive dog 1 38 on the conveyor chain 1 32.

The outer end portion 1 42a of the rails 142 is raised to pick up a loaded fixture 30 and the rails are then moved outwardly toward the left. At the limit of the outward travel, the rails are lowered to deposit the loaded fixture on the main drive conveyor 1 20. Subsequently, the rails return back to the starting position. In this sequence. the loaded fixtures 30 are picked up from the oven roller conveyors 104 and are moved outwardly over the main line conveyor 1 20. The fixtures are then lowered onto the conveyor just ahead of a drive dog 1 38 which Immediately engages the recess 323 in ihe end of the fixture base 32 and causes the loaded fixture to move longitudinally along the drive conveyor in a linear path at approximately 24 feet per minute past the resin fill station 1 30.

The preheated loaded fixtures 30 move along the main drive conveyor 1 20 supported on the rolls 1 26 and guided by the side rolls 1 28 so that the pocket 24a in the lower metal element 24 is ready to receive liquid resin at the dispensing station 1 30. In order to ensure that the pocket and the flanged tongue extending into the pocket are free from moisture and other foreign matter, a jet blast of hot air at approximately 1000"F Is directed into the pocket around the tongue by means of a hot air heating element and blower unit 1 90 (Fig.

1) spaced above the conveyor. The jet blast of hot air vaporizes any moisture in the pocket and removes any other impurities therefrom so that a good bond between the metal and the liquid resin will be obtained. At this point the average surface temperature of the metal elements 22 and 24 is approximately 110 to 115'F and this relatively high metal surface temperature aids in curing the resin which is introduced into the pocket around the tongue in liquid form through the nozzle 50.

As illustrated in Fig. 7, the nozzle 50 comprises a 3/8" diameter, hollow tube having a closed discharge end formed with a long narrow slot therein which forms a fan-like discharge of the flowing resin which is directed downwardly into the open pocket 24a of the lower metal element 24. This flow of resin engages the lower portion of the tongue 22a and flows around the transverse flange 22b and then moves up on the opposite side of the tongue until reaching a level approximately even with the resin level on the Im- tially filled side. By the time the resin in the pocket reaches the end of the main drive conveyor 120, approximately 1 minute after dispensing from the nozzle. it begins to harden or set and during this period, the temperature of the resin begins to rise because of the exothermic chemical reaction. At a conveyor speed of 24 feet per minute it takes approximately 1 minute to fill the entire length of a pocket and when the trailing end of each fixture passes the nozzle the resin at the leading end portion is beginning to set.

One type of an exceptionally strong resin system having excellent heat insulating characteristics is a polyurethane resin system which employs an isocyanate component mixed with a urethane resin containing a catalyst.

Azon Systems, Inc. of Kalamazoo, Michigan manufactures and sells a suitable resin system under the name 'A-Therm Thermal Barrier Compound' which has excellent characteristics for use as the joining element 26 between the aluminum metal elements 22 and 24 When cured, this system provides a thermal conductivity of approximately 98 BTU per hour. per square foot, per inch of thickness; a tensile strength of 6000 PSI; a co-efficient of expansion which is highly compatible with aluminum and which is not adversely affected by repeated temperature change; an elongation co-efficient of approximately 6-8"ó at ,7'F- a Durometer hardness of 82-0 + or - 2, and little or no shrinkage during field exposure.

The resin system can be applied in the pocket either before or after the aluminum elements 22 and 24 have been "clear anodized" and preferably if the aluminum elements are "hardcote anodized" the anodizing is done before the resin is applied. When baked-on paint finishes are applied to the aluminum extrusions, the finishes should be applied before the resin filling process and the paint finish should be kept to a minimum in the filling cavity.

The resin system employs a part "A" component which contains polymeric isocyanates and a part "B" component which contains tertiary amines and/or metallic catalyst. These components are mixed in the proper proportions at the resin filling station and are then passed through the nozzle into the pocket.

The mixture is of such a proportion so that the material will flow freely for approximately 1 minute before it 'kicks" or begins to set.

Subsequently, a curing time of approximately 4 1/2 to 6 minutes results in a strong heat insulating element 26 of sufficient rigidity so that the clamping assemblies 34 may be released without damage to the newly completed frame member 20 which can then be handled freely and removed from the fixture 30 to be placed on a pallet with other finished frame members.

As each loaded fixture departs the end of the main drive conveyor 120, it passes onto a plurality of longitudinally aligned, spaced apart, roller conveyors indicated in Fig. 1 by the reference numerals 192, 1 94, 1 96 and 1 98. From these roller conveyors, the fixtures are moved Into a curing area generally Indi- cated by the reference numeral 200 which includes a plurality of belt conveyors 202, 204 and 206 parallel of one another and extended transversely of the roller conveyors 192, 194. 196 and 198. The belt conveyors 202, 204 and 206 are driven at a relatively low speed by a common drive motor 208 which interconnects the respective conveyor through drive shaft 210 The conveyors are driven at a speed whereby the fixtures spend approximately 4 1/2 to 5 minutes after transverse movement off of the set of roller conveyors at the end of the main drive conveyor 1 20 In order to lift the loaded fixtures 30 from these roller conveyors and move the fixtures into the curing area 200. each of the belt conveyors 202 204 and 206 Includes an upstanding iift cylinder 21 2 at its entry end and these cylinders are activated in unison on a cylindrical basis to pick up each fixture 30 moved onto the set of roller conveyors for movement Into the curing area 200. After the resin is cured. the loaded fixtures 30 are moved onto another roller conveyor 214 at an unloading station Indicated generally by the reference numeral 2 1 6 At the unloading station the clamping assemblies 34 on the fixture are released as previously described and the completed insulating frame members 20 are removed from the fixture and onto a finished product pallet which is designated by the reference numeral 218. As indicated, the metal elements 22 and 24 were initially preheated in the oven 106 to a temperature of approximately 110' to 115"F before the resin filling operation as the elements were moved past the resin filling station 1 30. The resin is mixed at the filling station and is initially at a temperature of approximately 150"F as it is flowed into the pocket around the tongue of the pair of precisely aligned metal elements 22 and 24 moving by the nozzle. As the resin begins to 'kick" or set, the exothermic chemical action takes place and the heat released causes the resin to reach a maximum temperature of approximately 200 to 210"F while the resin is still on the main drive conveyor 1 20. During the subsequent final curing period of approximately 4 1/2 to 5 minutes, the resin begins to cool and by the time a fixture reaches the unloading station 216, the resin is cooled down to a temperature of approximately 130 F.

After a finished frame member 20 is removed from a fixture 30 at the unloading station 216, the empty fixture Is then recycled for another trip by movement onto a transfer roller conveyor 220. From this conveyor the fixtures are moved onto the loading station roller conveyor 102 wherein new metal elements 22 and 24 are placed in position and are clamped in place as previously described.

Referring now to Figs. 1 2 and 13, therein is illustrated another embodiment of the Invention wherein a modified fixture 330 is utilized for holding elongated aluminum extrusions 322 and 324 In precision alignment while liquid resin is introduced Into the pocket 324a of the lower element around the tongue 322a and flange 322 b to form the heat Insulating Joining element 326 of an elongated, heat insulating frame member 320 Only the differences between the embodiment of Figs. 1 2 and 1 3 and the previously describes embodiment will be described in detail hereinafter and similar reference characters with the prefix 3 will be used for Identifying components of that later embodiment with those of the former.

The fixture 330 Includes a base structure 332 on which are mounted a plurality of upstanding longitudinally spaced apart clamping assemblies 334 for holding the extrusions 322 and 324 in parallel aligned position as shown In Fig. 1 2 as the loaded fixture Is moved past the resin filling station and Is supplied with liquid resin through a resin filling nozzle 50.

Each clamping assembly 334 Includes an upstanding stop member 336 and the lower extrusion 324 is supported on one side In contact against a pair of vertical stop surfaces 337 provided on the lower portion of the stop members. The bottom wall of the lower extrusion is supported on headed buttons 333 provided on the base 332 of the fixture and the outside wall of the extrusion is held In position by a headed button 339 carried adjacent the upper end of a vertical stop 340 secured to the base 332. As in the previous embodiment the lower extrusion 324 is rocked into place between the stop surfaces 337 and buttons 339 of the clamping assemblies 334 with the pocket 324a facing upwardly to receive the tongue 322a and end flange 322b of the upper extrusion 322. The lower extrusion 324 is held down against the buttons 333 when In place by stop fingers 342 of the stop members 336 and the lower end surface of the stop fingers engage the upper edge of the inside wall of the extrusion 324 as shown.

Each stop member 336 is provided with a horizontally extending upper stop finger 346 having an upper surface which supports an intermediate rib 322c on the upper extrusion 322 and the lower edge of the inside wall thereof. The inside wall also bears against an upper stop surface 337 on the upstanding stop members 336 and the outer end of the stop fingers 346 provide a stop surface for the inside face of the tongue 322a of the upper extrusion when In place.

A modified form of clamping lever is provided for holding the upper extrusion 322 in place as shown In Fig. 1 2 when the clamping assemblies are in the locked or clamping position. For this purpose, the outside wall of the upper extrusion is engaged by a stop button 355 on an end finger 354a of the clamping lever. A stop surface 354b is provided on the lever arm for engaging an upper end wall of the upper extrusion 322 for holding the extrusion downwardly on the upper surface of the horizontal stop fingers 346.

The clamping lever 354 includes a cam surface 354c on the lower surface generally circular to the rounded surface 54 c on the lever 54 of the previous embodiment.

The cam surface 354c engages a roller 376 on an axle 380 extending between a pair of standing legs 382 on the stop member 336 similar to the previously described embodiment and the upper surface of the clamping lever 354 Is engaged against a roller 374 carried on an axle 378 which !ikewise extends horizontally between the legs 382. When the lever 354 Is first unclamped It rides upwardly and toward the left as viewed n Fig. 1 2 as the cam surface 354c rides upwardly on the roller 376 This movement continues until the lower apex of the cam surface passes the crown of the roller and when this occurs. the clamping lever 354 pivots rapidly In clockwise direction while moving upwardly toward an upstanding open or release position wherein the fingers 354a are well above the upper extrusion 322 so that the finished frame member 320 can be lifted out and removed from the fixture 330.

Movement of the clamping lever 354 between the clamped or locked position as shown and a release or open position is accomplished with a U-shaped handle 366 having vertical legs that are pivotally connected adjacent their lower ends by an axle pin 369 to the outer end of an arm 368. The arm includes an inner end which extends into a recess 336a and is pivotally connected by an axle pin 372 to the stop member 336. The axle pin 369 supports a locking roll 371 which is adapted to lock into a seat within a groove 356a provided on the inside surface of the lever arm 356 adjacent the lower end.

The lever arm 356 is pivotally connected at its lower end to a pair of brackets 362 with an axle pin 360 and at the upper end, the arm is pivotally connected to the outer end of the clamping lever 354 with an axle pin 358.

The lever 356 is biased in a counterclockwise direction about the lower axle pin 360 by a spring 375 having an outer end connected to the axle pin 358 and a lower inner end connected to a stud 373 offset from and lower than the axle pin 372 at the inner end of the link 368. Thus, when the locking handle 366 is in the vertical locking position as shown, the spring 371 tends to retain the locking roll seated in the groove 356a in the lever arm 356.

When the bight portion at the upper end of the handle 366 is raised upwardly, the locking roller 37 1 moves upwardly out of the recess 356a and this permits the spring 375 to pivot the arm 356 in a counterclockwise direction from the locked position as shown.

When this occurs, the outer end of the clamping lever 354 moves Inwardly and downwardly and the clamping finger 354a at the opposite end moves outwardly and upwardly toward the release or open position as described.

From the foregoing it will be seen that the clamping assemblies 334 are readily releasa ble and are lockable In a clamping position as described by vertical movement of the Ushaped handles 366.

From the foregoing. it will be seen that the described method In accordance with the pre sent invention is capable of producing high quality insulated frame members 20 on a mass production basis and the apparatus shown and described has a capability of pro ducing one 24' long frame member approxi mately every minute and a half. From the time a fixture 30 is initially loaded, until the time that the finished product 20 IS unclamped and the fixture returned to the starting point or loading station it takes approximately 1 5 min utes and a suitable number of fixtures 30 are provided so that a relatively continuous stream of fixtures are moving past the dispensing nozzle 50 of the resin filling station 1 30 to produce the frame members on a substantially continuous basis.

Claims (28)

1. A method of making an elongated composite heat insulating frame member used for curtain walls and the like, which member includes a pair of spaced apart, discrete metal elements interconnected by a heat insulating element of solid material in a joint area including an integral pocket formed entirely in one metal element for receiving heat insulating material in liquid form flowed around the tongue of the other metal element, said method comprising: positioning said discrete metal elements at different levels in parallel spaced apart relation with the tongue of an upper element extending into the pocket of a lower element aligned to open upwardly to receive said tongue; holding said metal elements in said spaced apart relationship with said tongue spaced from said pocket without spacing means disposed therebetween providing a continuous open space along the length of said elements; dispensing a flow of heat insulating hardenable solid resinous material in liquid form along the length of said upwardly open pocket of said lower element downwardly along and against said tongue of said upper element; and hardening said resinous material in said pocket to form a rigid heat insulating joining element structurally interconnecting said metal elements with a thermal barrier therebetween.

2. A method as claimed In claim 1. Including the step of preheating said metal elements to an elevated temperature before dispensing said resinous material Into said pocket.

3. A method as claimed in claim 1. Including the step of self-bonding said resinous material to confronting surfaces of said metal elements in said pocket on said tongue.

4. A method as claimed In claim 1. Including the step of cooling said metal elements and said resinous material after dispensing the same into said pocket.

5. A method as claimed In claim 1, including the step of maintaining said metal elements in said spaced apart relation while said resinous material is hardening.

6 A method as claimed In claim 3, Including the step of maintaining said metal elements in said spaced apart relation while said resinous material is bonding to said surfaces of said metal elements.

7. A method as claimed In claim 4. including the step of maintaining said metal elements In said spaced apart relation during said cooling step

8 A method as claimed in claim 1.

wherein said dispensing step comprises moving said metal elements past a resin dispensing station while said metal elements are maintained in said spaced apart relation.

9. Apparatus for making an elongated heat insulating frame member used for curtain walls and the like. which member includes a pair of spaced apart, discrete metal elements interconnected with a heat insulating element of solid material formed in an upwardly opening elongated pocket provided entirely in one metal element adjacent a tongue of the other metal element extending downwardly into said pocket, said apparatus comprising: means for rigidly supporting a pair of said discrete metal elements in fixed parallel spaced apart relation at different levels with said pocket opening upwardly and positioned for receiving said tongue extending downwardly into said pocket with an opening along said tongue; means for downwardly dispensing a flow of heat insulating material in liquid form into said opening of said pocket along the length thereof to contact said tongue; means providing relative longitudinal movement between said dispensing means and said supporting means; and means for solidifying said liquid heat insulating material into rigid condition forming said heat insulating element for interconnecting said metal elements.

10. Apparatus as claimed in claim 9, wherein said means for rigidly supporting said pair of metal elements includes a movable base having a first means thereon for holding said lower metal element in fixed position thereon with said pocket opening facing said dispensing means and second means for releasably supporting said upper metal element in an elevated position above said base with said tongue projecting Into said pocket.

11 Apparatus as claimed in claim 10.

wherein said first means Includes at least one upstanding stop on opposite sides of said lower metal element for holding said elements against lateral displacement on said base

1 2 Apparatus as claimed in claim 1 1 wherein said stops comprise a plurality of stop elements on opposite sides of said lower metal element at longitudinally spaced inter- vals with respect thereto on said base

1 3. Apparatus as claimed In claim 1 1 wherein said stops along one side of said lower metal element include upper portions diverging upwardly and away from said stops along the opposite side of said lower metal element for guiding said element Into fixed position on said base between said stops on opposite sides thereof.

1 4 Apparatus as claimed In claim 1 3.

wherein said stops on said one side are relatively short In height above said base with respect to said stops on the opposite side whereby said lower metal element can be inserted between said stop from said one side

15. Apparatus as claimed in claim 10, wherein said second means includes at least one upstanding stop along one side of said upper metal element with a support surface thereon for holding said element in position elevated above said base and at least one movable clamping member for engaging an opposite side of said metal element to hold the same against said upstanding stop in said elevated position.

16. Apparatus as claimed in claim 15, wherein said support surface comprises a finger on said upstanding stop extending out wardly toward said clamping member and having an end surface engaging one side of said tongue of said upper metal element.

1 7. Apparatus as claimed in claim 16, wherein said finger has a pair of vertically spaced apart end surfaces for engaging one side of said tongue and said clamping member Is positioned to engage the opposite side of said tongue at a level between said end surfaces.

1 8. Apparatus as claimed In claim 1 4, wherein said clamping member includes a finger having an end surface engageable with said opposite side of said tongue in a position of clamping engagement therewith and is movable upwardly and outwardly away from said tongue to a release position spaced from said upper metal element.

1 9. Apparatus as claimed in claim 18, including operator means on said base for moving said finger between said clamping and release position. said operator means moving said finger with rotational and linear movement from said release position toward said clamping position on said opposite side of said tongue.

20. Apparatus as claimed in claim 19, wherein said operator means Includes lever means connected to said finger and a fluid cylinder interconnected to said lever to move the same.

21 Apparatus as claimed In claim 20, including fluid reservoir means on said base and conduit means for fluid interconnection between said reservoir means and said cylinder means.

22. Apparatus as claimed in claim 21, including valve means for selectively controlling fluid flow between said reservoir and said fluid cylinder for moving said lever means between said clamping and said release position.

23. Apparatus as claimed in claim 10.

including oven means for preheating said upper and lower metal elements and conveyor means for moving said base with said metal elements in supported position thereon through said oven means toward said dispensing means.

24. Apparatus as claimed In claim 1 0.

including conveyor means for moving said base with said metal elements in supported position thereon past said dispensing means.

said dispensing means including a nozzle outlet aligned to dispense said liquid material to said opening of said pocket as said base moves by on said conveyor means.

25. Apparatus as claimed in claim 23.

including conveyor means for moving said base from said oven means past said dispensing means for receiving liquid form heat Insu- lating material in said pocket opening.

26. Apparatus as claimed in claim 25, including means for supporting said base with said metal elements in supported position thereon while said liquid heat insulating material solidifies to form said rigid heat insulating element Interconnecting said metal elements into a composite frame member.

27. A method of making an elongated composite heat insulating frame member used for curtain walls and the like, substantially as hereinbefore described with reference to the accompanying drawings.

28. Apparatus for making an elongated composite heat insulating frame member used for curtain walls and the like, substantially as hereinbefore described with reference to, and as shown in, the accompanying drawings.