Spacer frame assembly and method of manufacturing

A method of drawing differing sheet stock through a feeder press station, the method comprising the steps of:

• feeding an elongated length of sheet stock from an uncoiler into a feeder press;
• drawing said elongated length of sheet stock through a set of pinch rollers along a process axis formed by a path in which the sheet stock travels during processing;
• and
• translating said pinch rollers from a first position to a second position to accommodate the processing of different types of sheet stock, wherein said translating occurs in a direction transverse to said process axis.

A method of roll forming differing sheet stock through a roll forming station, the method comprising the steps of:

• feeding an elongated length of sheet stock from a feeder roller into a roll former;
• drawing said elongated length of sheet stock through a plurality of roll forming dies along a process axis formed by a path in which the sheet stock travels during processing;
• and
• translating a drive roller from a first position to a second position to accommodate different types of sheet stock, wherein said translating is in a direction transverse to said process axis.

A method of forming a portion of a thermal spacer frame, the method comprising the steps of:

• feeding a u-shaped formed spacer frame from a feed roller into a forming station;
• advancing an anvil along a direction transverse to an axis defined by a flow of material to a position in which said anvil engages said u-shaped formed spacer frame;
• advancing a first die along a second axis formed said direction transverse to said axis defined by said flow of material to a position in which said first die engages said u-shaped spacer frame;
• advancing a second die along said second axis formed said direction transverse to said axis defined by said flow of material to a position in which said second die engages said u-shaped spacer frame such that a plane is formed by contact of said u-shaped spacer and said first die, said second die, and said anvil;
• and
• further advancing said second die along said second axis beyond said plane to form a channel in a portion of a peripheral wall of said u-shaped channel.

A system comprising an assembly line for manufacturing a metallic spacer frame and a thermal spacer frame from a continuous sheet stock that is formed into a spacer frame through a series assembly stations comprising:

• a feeder press station that receives an elongated length of continuous sheet stock from an uncoiler during use;
• a set of pinch rollers along a having process axis formed by a path in which the continuous sheet stock travels during processing;
• said pinch rollers comprise a transfer assembly for translating from a first position to a second position to accommodate the processing of different types of continuous sheet stock, wherein said translating occurs in a direction transverse to said process axis;
• a roll forming station for receiving said continuous sheet stock from said feeder roller station into a roll former arrangement;
• said roll former arrangement comprising a plurality of roll forming dies along said process axis formed by a path in which the continuous sheet stock travels during processing;
• and
• a drive roller that translates from a first position to a second position to accommodate different types of continuous sheet stock, wherein said translating is in a direction transverse to said process axis;
• and
• a swaging station comprising said process axis formed by the continuous sheet stock;
• an anvil and two-stage die assembly that are activated when said continuous sheet stock includes a thermal barrier, the anvil and two-stage die assembly generating a formed trough in a portion of said continuous sheet stock during operation.