U.S. patent application number 14/097646 was filed with the patent office on 2014-07-03 for method and apparatus for forming a vehicle window assembly using induction soldering.
This patent application is currently assigned to Pilkington Group Limited. The applicant listed for this patent is Pilkington Group Limited. Invention is credited to Charles E. Ash, Charles Sitterlet.
Application Number | 20140183181 14/097646 |
Document ID | / |
Family ID | 51015974 |
Filed Date | 2014-07-03 |
United States Patent
Application |
20140183181 |
Kind Code |
A1 |
Ash; Charles E. ; et
al. |
July 3, 2014 |
METHOD AND APPARATUS FOR FORMING A VEHICLE WINDOW ASSEMBLY USING
INDUCTION SOLDERING
Abstract
Induction soldering via an assembly fixture is utilized to bond
one or more items of hardware to a vehicle window to form a vehicle
window assembly. A method of operating the assembly fixture to bond
the one or more items of hardware to a vehicle window by induction
soldering is also an aspect of the invention.
Inventors: |
Ash; Charles E.;
(Perrysburg, OH) ; Sitterlet; Charles; (Northwood,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Pilkington Group Limited |
Lathom |
|
GB |
|
|
Assignee: |
Pilkington Group Limited
Lathom
GB
|
Family ID: |
51015974 |
Appl. No.: |
14/097646 |
Filed: |
December 5, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61746179 |
Dec 27, 2012 |
|
|
|
Current U.S.
Class: |
219/616 ;
219/635; 219/647 |
Current CPC
Class: |
B23K 2101/006 20180801;
B23K 1/002 20130101; B23K 1/0008 20130101 |
Class at
Publication: |
219/616 ;
219/647; 219/635 |
International
Class: |
B23K 1/002 20060101
B23K001/002; B23K 1/00 20060101 B23K001/00; B23K 37/047 20060101
B23K037/047 |
Claims
1. A method of forming a vehicle window assembly comprising:
providing a vehicle window having a major inner surface with an
electrically conductive material disposed on at least a
predetermined area thereof, a major outer surface and a peripheral
edge portion therearound; placing the vehicle window on an assembly
fixture having one or more induction coil assemblies and one or
more movable assembly aids mounted on the assembly fixture, wherein
the major outer surface of the vehicle window faces the assembly
aid; disposing one or more items of hardware having a predetermined
amount of solder thereon, in the one or more movable assembly aids;
energizing the one or more induction coil assemblies proximate the
major outer surface of the vehicle window to selectively direct one
or more electromagnetic fields through the vehicle window causing
heating of the one or more areas of the major inner surface of the
vehicle window upon which the electrically conductive material is
disposed to a temperature sufficient to liquefy the solder on the
one or more items of hardware; and moving the one or more assembly
aids into a position proximate the one or more heated areas of the
major inner surface of the vehicle window and causing one or more
items of hardware in the one or more assembly aids to move into
bonding contact with the one or more heated areas of the major
inner surface of the vehicle window.
2. The method defined in claim 1, wherein the one or more assembly
aids is moved proximate the vehicle window by a rotating assembly
in an arc-like manner.
3. The method defined in claim 1, wherein the electrically
conductive material is heated to a temperature of between
100.degree. F. and 600.degree. F.
4. The method defined in claim 3, wherein the electrically
conductive material is heated to the desired temperature in less
than 20 sec at a power output of >1000 W per induction coil
assembly.
5. A method of forming a vehicle window assembly comprising:
providing a vehicle window having a major inner surface with an
electrically conductive material disposed on one or more
predetermined areas thereof, a major outer surface, and a
peripheral edge portion; placing the vehicle window on an assembly
fixture comprising a major component mounting surface, having at
least the following components mounted thereon: one or more
resilient vertical gaseous positioning members; one or more
induction coil assemblies; one or more fixed or movable x-y
positioning members, and one or more movable assembly aids having
as a component thereof, one or more hardware holding members, each
hardware holding member having one or more items of hardware
disposed therein, each item of hardware having a predetermined
amount of solder disposed thereon, wherein the major outer surface
of the vehicle window faces the major component mounting surface of
the assembly fixture; activating the one or more x-y positioning
members to properly position the vehicle window on the assembly
fixture in an x-y plane; applying a negative gaseous pressure
through the one or more resilient vertical gaseous positioning
members to draw the major outer surface of the vehicle window into
intimate contact with a resilient portion of the one or more
resilient vertical gaseous positioning members through movement in
a z direction and proximate, but not in intimate contact with, the
one or more induction coil assemblies; energizing the one or more
induction coil assemblies proximate the major outer surface of the
vehicle window to selectively direct one or more electromagnetic
fields into the vehicle window, causing heating of the major inner
surface of the vehicle window particularly in the one or more
predetermined areas thereof having the electrically conductive
material disposed thereon, wherein the electrically conductive
material is heated to a temperature of between 100.degree. F. and
600.degree. F. in less than 20 sec at a power output of >1000 W
per induction coil assembly; activating the one or more assembly
aids to move the one or more hardware holding members into a
position proximate the one or more heated areas of the major inner
surface of the vehicle window; discharging the one or more items of
hardware from the one or more hardware holding members so that the
one or more items of hardware come into bonding contact with the
one or more predetermined areas of the major inner surface having
the electrically conductive material disposed thereon, the major
inner surface of the vehicle window and/or the item of hardware
being heated to a temperature sufficient to melt the solder
disposed on the one or more items of hardware, wherein the bonded
area between the item of hardware and the heated portion of the
vehicle window is >50% of the total possible bonding area;
de-energizing the one or more induction coil assemblies to allow
the vehicle window to cool and the one or more items of hardware to
bond to the major inner surface of the vehicle window;
discontinuing the negative gaseous pressure applied through the one
or more resilient vertical gaseous positioning members; and
removing the vehicle window with one or more items of hardware
bonded to the major inner surface thereof from the assembly
fixture.
6. The method defined in claim 5, wherein the electrically
conductive material comprises a ceramic frit material.
7. The method defined in claim 5, wherein the one or more hardware
holding members are attached to a first end of one or more support
arms.
8. The method defined in claim 7, wherein a second end of the one
or more support arms is connected to a rotatable shaft.
9. The method defined in claim 8, wherein the shaft is rotated thus
causing the attached assembly aid to move in an arc-like fashion,
the arc being up to about 180.degree., so as to position the
hardware holding member proximate the major inner surface of the
vehicle window.
10. The method defined in claim 5, wherein one or more recesses for
holding items of hardware are formed in the hardware holding
member.
11. The method defined in claim 10, wherein at least a portion of
the one or more recesses extends through the material of the
assembly aid to form an opening therein.
12. The method defined in claim 11, wherein at least one pneumatic
cylinder having an extendable anterior member is aligned with the
one or more openings in the assembly aid.
13. The method defined in claim 12, wherein the anterior member of
the at least one pneumatic cylinder is activated so as to extend
through the opening in the assembly aid and contacts an item of
hardware disposed in the at least one recess in the assembly aid,
causing the item of hardware to be discharged from the assembly aid
and to come into bonding contact with the heated major inner
surface of the vehicle window.
14. An assembly fixture for forming a vehicle window assembly
comprising: a major component mounting surface having at least the
following components mounted thereon: one or more resilient
vertical gaseous positioning members located so as to support a
vehicle window a predetermined distance above the major component
mounting surface, wherein the resilient vertical positioning member
is connected to a source of positive and negative gaseous pressure;
one or more induction coil assemblies comprising: a base member
mounted to the major component mounting surface; one or more
induction coils mounted on the base member and extending a
predetermined vertical distance above the base member; at least one
non-abrasive material covering the portion of the induction coil
which is proximate a major outer surface of the vehicle window,
when such vehicle window is placed on the assembly fixture; one or
more fixed or movable x-y positioning members; one or more assembly
aids comprising: a base plate mounted to the major component
mounting surface; at least one bearing mount attached to the base
plate a rotatable shaft extending through the at least one bearing
mount; the rotatable shaft also extending through a second end of
at least one support arm; at least one hardware holding member
attached to a first end of the at least one support arm; one or
more hardware retention recesses formed in the hardware holding
member; one or more openings extending through the hardware
retention recess and being connected to a source of positive and
negative gaseous pressure; the rotatable shaft connected to a
motor, wherein the operation of the components of the assembly
fixture is controlled by one or more electronic controllers, and
the one or more electronic controllers are connected to a source of
electric power.
15. The assembly fixture defined in claim 14, wherein the assembly
aid comprises at least one pneumatic cylinder having an extendable
anterior member is aligned with the one or more openings in the
hardware retention recess.
16. The assembly fixture defined in claim 14, wherein the assembly
aid comprises at least one hydraulic cylinder having an extendable
anterior member is aligned with the one or more openings in the
hardware retention recess.
17. The assembly fixture defined in claim 14, wherein the major
component mounting surface comprises a metal plate.
18. The assembly fixture defined in claim 14, wherein the one or
more induction coil assemblies each have a power output >1000
W.
19. The assembly fixture defined in claim 18, wherein the power
output of the induction coil assembly is capable of being
selectively directed into an area of the substrate >10
mm.sup.2.
20. The assembly fixture defined in claim 19, wherein the induction
coil assembly is capable of heating the chosen area of the
substrate to a temperature up to 600.degree. F. in less than 20
sec.
Description
RELATED APPLICATION
[0001] This application is claiming the benefit under 35 U.S.C.
119(e), of the provisional application filed Dec. 27, 2012 under 35
U.S.C. 111 (b) which was granted Ser. No. 61/746,179. This
provisional application is hereby incorporated by reference in its
entirety.
BACKGROUND
[0002] The present invention relates to a method and apparatus for
bonding an item to a substrate. More particularly, the invention
relates to bonding an item of hardware to a glass substrate by
induction soldering, utilizing an assembly fixture.
[0003] Induction heating for soldering has been described in the
patent literature, for example:
[0004] U.S. Pat. No. 4,128,449 describes a fixture for applying
discrete adhesive-backed articles to a support surface through the
use of induction heat. Aligning and positioning means are
associated with the faces of U-shaped cores to keep the end faces
of the core in abutting relationship with the article being heated,
but is said to permit the article and core combination to move
slightly in a compound direction to accommodate support surface
variations or curvature.
[0005] U.S. Pat. No. 5,977,527 describes a fixture for an induction
brazing station including a removable front plate on which a work
piece holder is mounted. The base of the induction unit mounts to a
back plate lying coplanar with the front plate on the work surface.
The coil of the induction unit is uniquely matched to the front
plate and the work piece holder. The induction coil removably
mounts to the front plate when not in use such that the front plate
may be removed from the work surface with the work piece holder and
coil mounted thereon. A different front plate may then be mounted
upon the work surface having a different coil configuration and
work piece holder.
[0006] U.S. Pat. No. 6,849,837 describes a method for using
magnetic fields to heat magnetically susceptible materials within
and/or adjacent to adhesives so as to bond, bind or fasten solid
materials to one another. The system uses alternating magnetic
fields that induce eddy currents and generate heat within
susceptors. An induction heating tool is used to emit the magnetic
field at its work coil and an electronic controller measures the
energy being used by a power converter that generates the
alternating current driving the work coil which creates the
magnetic field.
[0007] U.S. Pat. No. 8,299,401 describes an apparatus and a method
of using induction heating to solder an item of hardware to a glass
substrate, wherein the glass substrate is preferably a vehicle
window, the substrate and bonded items(s) of hardware forming a
vehicle window assembly.
SUMMARY OF THE INVENTION
[0008] The present invention relates to a method and apparatus for
bonding an item to a substrate. More particularly, the invention
relates to bonding an item of hardware to a glass substrate by
induction soldering utilizing an assembly fixture.
[0009] A vehicle window typically has two major surfaces and a
peripheral edge portion. The two major surfaces are herein
identified as major inner and major outer surfaces. An electrically
conductive material, such as a conductive ceramic frit is typically
disposed on one or more predetermined areas of the major inner
surface of the vehicle window.
[0010] An assembly fixture has a major surface on which various
components for making the vehicle window assembly may be mounted,
such as: one or more resilient vertical gaseous positioning
members, one or more induction coil assemblies, one or more fixed
or movable x-y positioning members and one or more movable assembly
aids. The one or more assembly aids have one or more items of
hardware disposed therein. Typically, the items of hardware have a
predetermined amount of solder disposed thereon.
[0011] In the method according to the invention, when a glass
substrate such as a vehicle window is placed on the assembly
fixture, the major outer surface of the vehicle window faces the
major component mounting surface of the assembly fixture. To ensure
that the vehicle window is properly positioned on the assembly
fixture, the one or more x-y positioning members are utilized, and
then, preferably, a negative gaseous pressure is exerted through
the one or more resilient vertical gaseous positioning members to
draw the major outer surface of the vehicle window into intimate
contact therewith through movement in a z direction. In this
positioning process, the one or more induction coil assemblies will
be positioned proximate, but preferably not in intimate contact
with, the major outer surface of the vehicle window. In particular,
it is desirable that the one or more induction coil assemblies
is/are positioned opposite the one or more portions of the major
inner surface of the vehicle window on which the electrically
conductive material has preferably been disposed.
[0012] Sequentially or simultaneously, the one or more induction
coil assemblies are energized to selectively direct one or more
electromagnetic fields into the one or more predetermined areas of
the vehicle window whereon the electrically conductive material has
been disposed, causing heating thereof by heating substantially
through the thickness of the glass comprising the vehicle window,
and the one or more assembly aids are activated so as to move into
a predetermined position proximate the one or more heated areas of
the major inner surface of the vehicle window.
[0013] From the assembly aid positioned proximate the major inner
surface of the vehicle window, one or more items of hardware are
discharged so as to come into bonding contact with the one or more
heated areas of the major inner surface of the vehicle window.
Alternatively, or additionally, the one or more items of hardware
may be heated by the one or more induction coil assemblies. The one
or more heated areas of the major inner surface of the vehicle
window and/or the item of hardware to be bonded will be heated to a
temperature sufficient to melt the solder disposed on the one or
more items of hardware. The method of heating the one or more
predetermined areas of the major inner surface of the vehicle
window by the one or more induction coil assemblies located
proximate the major outer surface of the vehicle window has been
found to improve, among other things, the effective bonded area
between the item of hardware and the major inner surface of the
vehicle window compared to known bonding methods.
[0014] The one or more induction coil assemblies are then
de-energized, allowing the vehicle window to cool and the molten
solder to solidify, creating the desired bonding of the item of
hardware to the major inner surface of the vehicle window. The
vehicle window is then released from its position on the assembly
fixture and a vehicle window assembly with one or more items of
hardware bonded thereon is ready for additional processing, or for
installation in a vehicle.
[0015] In a preferred configuration, the one or more assembly aids
is a component of a rotatable assembly such that the assembly aid
moves in an arc-like path from its at-rest position to its position
proximate the major inner surface of the vehicle window, where it
may discharge the one or more items of hardware disposed therein
into bonding contact with the one or more predetermined areas of
the major inner surface of the vehicle window, as previously
described.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above, as well as other advantages of the present
invention will become readily apparent to those skilled in the art
from the following detailed description when considered in the
light of the accompanying drawings in which:
[0017] FIG. 1 shows a perspective view of an assembly fixture
according to the invention.
[0018] FIG. 2 shows a perspective view of the assembly fixture
according to the invention with a vehicle window disposed on the
assembly fixture.
[0019] FIG. 3 shows a perspective view of an induction coil
assembly according to the invention.
[0020] FIG. 4 shows a perspective view of a movable assembly aid
according to the invention.
[0021] FIG. 5 shows a cross-sectional view of an assembly fixture
with the assembly aid movable relative to the vehicle window
disposed on the assembly fixture according to the invention.
[0022] FIG. 6 shows a cross-sectional view of an induction coil
assembly according to the invention.
[0023] FIG. 7a shows a plan view of a hardware holding member with
an item of hardware contained therein.
[0024] FIG. 7b shows a cross-sectional view of the same hardware
holding member as shown in FIG. 7a and a system of negative gaseous
pressure which can be used to hold an item of hardware in place in
the hardware holding member according to the invention.
[0025] FIG. 8 shows a cross-sectional view of a hardware holding
member and a mechanical means which may be utilized to mechanically
push an item of hardware from the hardware holding member via the
one or more recesses through the hardware holding member according
to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] The present invention relates to a method and apparatus for
bonding an item to a substrate. More particularly, the invention
relates to bonding an item of hardware 8 to a glass substrate by
induction soldering, utilizing an assembly fixture 10.
[0027] A vehicle window 12 is typically made of glass. A vehicle
window 12 typically also has two major surfaces (14, 16) and a
surrounding peripheral edge portion 18. The two major surfaces (14,
16) are herein identified as the major inner surface 14 and major
outer surface 16. An electrically conductive material 20, such as
an electrically conductive ceramic frit, preferably containing an
electrically conductive metal, for example silver, is disposed on
one or more predetermined areas of the major inner surface 14 of
the vehicle window 12 by any known method, for example, by screen
printing.
[0028] An assembly fixture 10 such as shown in FIG. 1 is the
preferred apparatus to form a vehicle window assembly according to
the invention. A base plate 22, having a major component mounting
surface 24, preferably has mounted thereon: [0029] one or more
resilient vertical gaseous positioning members 26 located so as to
evenly support a vehicle window 12 a predetermined substantially
uniform vertical distance above the major component mounting
surface 24, the one or more resilient gaseous positioning members
26 preferably being connected to a source of positive and/or
negative gaseous pressure (not shown); [0030] one or more induction
coil assemblies 28 which include a base member 30 mounted to the
major component mounting surface 24, one or more induction coils 32
attached to the base member 30 and preferably extending a
predetermined substantially uniform vertical distance above such
base member 30; [0031] at least one non-abrasive material 34
preferably covering the portion of the induction coil 32 which is
proximate a major outer surface 16 of the vehicle window 12 when
such vehicle window 12 is placed on the assembly fixture 10, more
particularly, in contact with the one or more resilient vertical
gaseous positioning members 26; [0032] one or more assembly aids 36
which preferably include: a base plate 37 mounted to the major
component mounting surface 24, at least one bearing mount 38
attached to the base plate 37, a rotatable shaft 40 extending
through the at least one bearing mount 38, the rotatable shaft 40
also extending through a second end 42 of at least one support arm
44, at least one hardware holding member 46 attached to a first end
of the at least one support arm 44, the hardware holding member 46
having one or more hardware retention recesses 50 formed therein
and one or more openings 52 extending through the hardware
retention recess 50 and preferably connected to a source of
positive and/or negative gaseous pressure 53, the rotatable shaft
40 being connected to a motor 54 of any suitable kind, for example,
an electric motor.
[0033] The operation of the components of the assembly fixture 10
is controlled by one or more electronic controllers (not shown) of
any suitable conventional type(s). Such controllers are connected
to a source of electric power by any suitable conventional
means.
[0034] The base plate 22 of the assembly fixture 10 having the
major component mounting surface 24 may be any suitable geometric
shape, but is preferably square or rectangular, and may be made
from any suitable material, but is preferably a metal such as
aluminum.
[0035] The one or more resilient vertical gaseous positioning
members 26 can be mounted in any suitable location on the major
component mounting surface 24, but are preferably located so as to
securely support the vehicle window 12 at a uniform height relative
to the major component mounting surface 24. The vertical gaseous
positioning member 26 includes a vertical support portion 56 and a
resilient contact portion 58. The vertical support portion 56 is
preferably a hollow tube of a predetermined length made from a
durable and dimensionally stable material such as a metal. The
resilient contact portion 58 is typically connected to an upper end
of the vertical support portion 56 and, when a vehicle window 12 is
placed on the assembly fixture 10, is in intimate contact with a
portion of, typically the major outer surface 16 of, the vehicle
window 12. As the vehicle window 12 is usually made from glass,
which can be scratched, the resilient contact portion 58 is
desirably made from a flexible, non-abrasive material, such as a
plastic or rubber material. The one or more induction coil
assemblies 28 as shown in FIG. 3 can include one or more induction
coils 32 such as are generally commercially available, or are
custom-fabricated. Such suitable induction coils 32 are made by,
for example, Magneforce, Inc. of Warren, Ohio. The configuration of
the coil 32 itself can be any suitable configuration best suited to
direct the electromagnetic field generated by electromagnet 33 in,
for example, a broad or very focused pattern, as desired. While the
power output of each induction coil assembly 28 can be the same or
different, in a preferred configuration, each induction coil
assembly 28 preferably has a power output of at least 1,000 W.
[0036] As the induction coil 32 is typically made of a metal
material which can abrade the glass of the major outer surface 16
of the vehicle window 12 when the two come into contact, it is
desirable to prevent such damage to the glass, preferably by
covering the portion of the induction coil 32 which is proximate
the major outer surface 16 of the vehicle window 12 with one or
more layers of a durable, but non-abrasive material 34 when the
vehicle window 12 is positioned on the assembly fixture 10. Such
materials may include, for example, fiberglass, stainless steel
mesh, suitable plastic and rubber materials, suitable silicone
materials and cotton cloth. Alternatively, the induction coils
themselves may be coated with a suitable epoxy material.
[0037] A method of forming a vehicle window assembly utilizing the
assembly fixture 10 previously described will now be set out.
[0038] A vehicle window 12 having a major inner surface 14 with an
electrically conductive material preferably disposed on one or more
predetermined areas thereof, a major outer surface 16 and a
peripheral edge portion 18 therearound is placed on an assembly
fixture 10 with the major outer surface 16 of the vehicle window 12
in intimate contact with one or more resilient vertical gaseous
positioning members 26 which are mounted on a major component
mounting surface 24, and proximate one or more induction coil
assemblies 28 also mounted on the major component mounting surface
24. Proximate the peripheral edge portion 18 of the vehicle window
12 are preferably located one or more positioning members (60, 62)
which may be fixed or movable, so as to precisely position the
vehicle window 12 on the assembly fixture 10 in both the x and y
directions of the plane of the vehicle window 12. Preferably, the
positioning members in the x direction are fixed 60, and the
positioning members 62 in the y direction are movable, as shown,
for example, in FIG. 1. Once the vehicle window 12 is precisely
positioned on the assembly fixture 10 in the x and y directions, a
negative gaseous pressure is preferably applied through one or more
openings in the one or more resilient vertical gaseous positioning
members 26 so as to draw down the vehicle window 12 in a z
direction into even more intimate positioning contact with the one
or more resilient vertical gaseous positioning members 26. Further,
the now precisely positioned vehicle window 12 has the one or more
portions thereof with the electrically conductive material 20
preferably disposed thereon proximate one or more induction coil
assemblies 28.
[0039] The one or more induction coil assemblies 28 are then
energized so as to selectively direct the one or more
electromagnetic fields generated by the induction coil assemblies
28 into the glass comprising the vehicle window 12, causing heating
of the one or more areas of the major inner surface 14 of the
vehicle window 12 having the electrically conductive material 20
disposed thereon. To make the inventive method compatible with
high-volume glass manufacturing operations, the electrically
conductive material 20 is preferably heated to a temperature of
between 100.degree. F. and 600.degree. F. in less than 20 sec, at a
power output of .gtoreq.1,000 W per induction coil assembly 28.
[0040] One skilled in the art will appreciate that the
electromagnetic fields generated by the electromagnet 33 of the one
or more induction coil assemblies 28 readily pass through the
thickness of the dielectric glass sheet comprising the vehicle
window 12, but impart the bulk of their energy to the item of
hardware 8 to be bonded and the solder disposed thereon and to the
electrically conductive material 20, such as a conductive ceramic
frit on the major inner surface 14 of the vehicle window 12.
[0041] A further aspect of the invention relates to the one or more
movable assembly aids 36 by which items of hardware 8 are moved
into a position proximate the heated electrically conductive
material 20 disposed on the major inner surface 14 of the vehicle
window 12. The portion of the assembly aid 36 in which the one or
more items of hardware 8 is disposed is referred to herein as a
hardware holding member 46, which is preferably made from a
dielectric material, such as a resin or other polymeric material.
Preferably, recesses 52 are formed in the hardware holding member
46 to hold the one or more items of hardware 8 in preparation for
bonding such items of hardware 8 to the vehicle window 12. In a
preferred configuration, a portion of the recess 52 extends through
the thickness of the material of the hardware holding member 8,
which extended recess 52 may be connected to a source of positive
and/or negative gaseous pressure 53. Application of negative
gaseous pressure can assist in positively retaining the items(s) of
hardware 8 in the hardware holding member 46, while application of
positive gaseous pressure may be used to discharge the one or more
items of hardware 8 from the hardware holding member 46.
[0042] As an alternative to utilizing positive gaseous pressure to
discharge items of hardware 8 from the hardware holding member 46,
it may be desirable to utilize a mechanical means 68 to push the
items of hardware 8 from the one or more recesses 52 in the one or
more hardware holding members 46. Such mechanical means 68 may
include a cylinder having an extendable anterior member 70 aligned
with the one or more extended recesses 52 in the hardware holding
members 46. Such cylinders may be, for example, a pneumatic or a
hydraulic cylinder. Activation of the cylinder causing the
extendable anterior member 70 to extend into the recess 52 will
then discharge the item of hardware 8 in the recess 52 for purposes
of causing such item of hardware 8 to bondingly contact the major
inner surface of the vehicle window 12 upon which the electrically
conductive material 20 has been disposed. Mechanical means can also
be utilized to retain the item(s) of hardware 8 in the hardware
holding member 46.
[0043] The movable assembly aid 36, of which the hardware holding
member 46 is a component, is activated so as to cause, by any
suitable means, the hardware holding member 46 to move to a
position proximate the one or more portions of the major inner
surface 14 of the vehicle window 12 on which the electrically
conductive material 20 is preferably disposed and which is heated
by the one or more induction coil assemblies 28. The subject
portions of the major inner surface 14 of the vehicle window 12
and/or the items of hardware 8 are heated to a temperature
sufficient to melt the solder preferably disposed on the one or
more items of hardware 8.
[0044] In a preferred configuration, the hardware holding member 46
is attached to a first end 48 of one or more support arms 44. A
second end 42 of the one or more support arms 44 is connected to a
rotatable shaft 40. The rotatable shaft 40 also extends through one
or more bearing mounts 38 or like structure which are mounted to
the major component mounting surface 24 of the assembly fixture 10.
One end of the rotatable shaft 40 is connected to a motor 54. When
the shaft 40 rotates, the assembly aid 36, in particular the
hardware holding member or members 46, is caused to move,
preferably in an arc-like manner, for example, an arc of up to
about 180.degree., so as to position the hardware holding member 46
proximate the major inner surface 14 of the vehicle window 12. The
items of hardware 8 are then discharged from the hardware holding
member 46 as previously described herein.
[0045] The induction coil assemblies 28 are de-energized so as to
allow the vehicle window 12 and the solder to cool, and the one or
more items of hardware 8 to bond to the major inner surface 14 of
the vehicle window 12. At an appropriate time, the negative gaseous
pressure applied through the one or more resilient vertical gaseous
positioning members 26 is discontinued, and the finished vehicle
window assembly is removed from the assembly fixture 10.
[0046] When made by the method described, the inventors have found
that the bonded area between the item of hardware 8 and the heated
portion of the vehicle window 12 is significantly increased over
known methods, for example, the bonded area is >50%, preferably
>90%, of the total possible bonding area as "wetting out" of the
solder is improved. It has also been found that wear on components
such as the induction coil assemblies 28 and on the assembly aids
36 is reduced from known methods. Additionally, solder does not
build up on the induction coil assemblies 28, as they are on the
opposite side of the vehicle window 12 from the assembly aids
36.
[0047] In accordance with the provisions of the patent statutes,
the present invention has been described in what is considered to
represent its preferred embodiments. However, it should be noted
that the invention can be practiced otherwise than as specifically
illustrated and described without departing from its spirit or
scope.
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