Multiple ply insulating glass unit having a relaxed film forming a third ply and method of making same

Abstract

An insulating glass unit and method of forming the same, the insulating glass unit including a pair of parallel and spaced apart glass sheets, at least one edge spacer between adjacent edges of the pair of glass sheets and at least a primary sealant to provide an overall sealed unit defining a space therebetween, and at least one transparent film within the space between the pair of glass sheets, the at least one transparent film being secured to one of a support structure and the at least one edge spacer, wherein the film is positioned in a spaced apart parallel relationship between the pair of glass sheets, and wherein the film is annealed to a relaxed state prior to positioning the film between the pair of glass sheets.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 150222, filed February 17, 2021, and U.S. Patent Application No. 17 / 670859, filed February 14, 2022, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] This invention relates to a multi-layer insulating glass unit having a third pane formed by a relaxed membrane supported by a flexible frame or edge spacers, and a method for manufacturing the same. Background Technology

[0004] Insulating glass units having a third layer or even more layers in the form of a plastic sheet or multilayer film supported between a pair of glass sheets are known. The glass sheets are connected to each other via at least one circumferential spacer provided along the edges of the glass sheets, at least a primary sealant, and a secondary sealant. The third layer forms a space between each glass sheet, which can be filled with air or gas to reduce heat conduction through the window structure. Any inert, low-heat-conductivity gas can be used, including krypton, argon, sulfur hexafluoride, carbon dioxide, etc. This filling gas can contain a significant amount of oxygen to prevent yellowing of the internal plastic third layer or to minimize yellowing. An example of an insulating glass unit is... Figure 1 As shown. In this design, the third layer comprises a low-e coating PET film, a high-cost component. This third layer is attached to the circumferential spacer, primary sealant, and secondary sealant. This process requires that at least the secondary sealant be fully thermo-cured first to support the film during the heat-curing step. The fully assembled unit results in very inefficient heat transfer to the film, requiring 2–4 hours to assemble, typically closer to 4 hours. Besides the long assembly time, one of the main drawbacks of this design is that the film frequently wrinkles, necessitating the disposal of the entire unit as the film is fully integrated into the system. Even if the film is attached to the spacer, any twisting of the unit during transport or service, even without leakage, can cause the film to wrinkle. In designs involving multiple intermediate layers, an additional interface between the intermediate layers, primary sealant, and secondary sealant is necessary, increasing the risk of air ingress.

[0005] Many existing technologies with two-layer insulating glass units do not offer better thermal performance than R5.

[0006] There is a need in the art for an insulating glass unit in which wrinkling of the third layer has been minimized and which can be easily assembled in a short time. There is also a need in the art for an insulating glass unit that allows for the presence of additional intermediate layers without creating additional interfaces. Summary of the Invention

[0007] According to one aspect, this disclosure relates to a barrier glass unit comprising a pair of parallel and spaced-apart glass sheets, at least one edge spacer, and at least a primary sealant located between adjacent edges of the pair of glass sheets to provide an integral sealing unit defining a space therebetween, and at least one transparent film located within the space between the pair of glass sheets. The at least one transparent film is fixed to one of a support structure and the at least one edge spacer, such that the film is positioned between the pair of glass sheets in a spaced-apart parallel relationship. Before positioning the film between the pair of glass sheets, the film is annealed to a relaxed state by heating it for a predetermined time.

[0008] The at least one transparent membrane is supported by a support structure or edge spacers. According to one embodiment, the membrane can be directly fixed to the edge spacers. According to another embodiment, the membrane can be fixed to a support structure, wherein the support structure includes at least one frame member located adjacent to the edge of the membrane. The at least one frame member can be flexible and have sufficient thickness to maintain its shape under its weight. According to one embodiment, a 1 / 16″ thick aluminum frame can be used. According to another embodiment, the support structure may include a pair of frame members clamping the edge of the membrane.

[0009] The membrane can be annealed before or after it is fixed to the support structure. The membrane is annealed to a relaxed state, wherein the relaxed state of the membrane has a tension of less than or equal to 0.1 psi.

[0010] Depending on the type of membrane used, the membrane is heated to a specific annealing temperature to induce stress-induced crystallization. According to one embodiment, the membrane can be heated to an annealing temperature of at least 70°C for approximately 10 minutes.

[0011] The membrane may include at least one of a polymer sheet, a thin glass sheet, and / or any other transparent sheet. According to one embodiment, the membrane may be a polymer sheet comprising polyethylene terephthalate (PET). The membrane may also include additional materials embedded therein or coated on one or both sides to control the transmission and / or reflection spectra. At least one surface of the membrane may include a low-e coating. The membrane may also be configured to function as a sound-generating membrane.

[0012] The membrane can be fixed to the support structure or at least one edge spacer by at least one of mechanical components, adhesives, and thermoplastic welding processes. The support structure can be fixed to the edge spacer.

[0013] According to one embodiment, the pair of glass sheets may include a first glass sheet and a second glass sheet, and the support structure may be configured to allow gas to move between a first chamber located between the first glass sheet and a first side of the membrane and a second chamber located between the second glass sheet and a second side of the membrane to ensure pressure balance between the first chamber and the second chamber.

[0014] According to another aspect, this disclosure relates to a method for forming an insulating glass unit, the method comprising providing a pair of glass sheets in a parallel and spaced-apart relationship, providing at least one film, stretching the film to remove wrinkles, securing the film to one of a support structure and at least one edge spacer, applying heat to the film to anneal the film to a relaxed state, wherein the annealing step of the film occurs before or after the step of securing the film to one of the support structure and the at least one edge spacer, positioning the film secured to the support structure between the pair of glass sheets such that the film and the support structure are positioned in a spaced-apart parallel relationship between the pair of glass sheets, and providing at least one edge spacer and a primary sealant between adjacent edges of the pair of sheets to provide an integral sealed unit defining a space therebetween.

[0015] According to one embodiment, the membrane can be directly fixed to the at least one edge spacer. Alternatively, the membrane can be fixed to a support structure, and the membrane and the support structure can be positioned between the pair of glass sheets at a location separated from the at least one edge spacer.

[0016] The support structure may include at least one flexible frame member located adjacent to the edge of the membrane, or a pair of flexible frame members sandwiching the edge of the membrane. According to one embodiment, the support structure may include at least one frame member located adjacent to the edge of the membrane, wherein the at least one frame member is flexible and has a sufficient thickness to not lose its shape under its weight. According to one embodiment, an aluminum frame of approximately 1 / 16″ thickness may be used.

[0017] The film is heated to a temperature and duration sufficient to induce stress-induced crystallization, such that the relaxed state of the film has a tension of less than or equal to 0.1 psi.

[0018] The method further includes trimming the membrane after annealing it to a relaxed state and securing it to one of a support structure and at least one edge spacer. The membrane can be secured to the support structure and at least one edge spacer by at least one of mechanical components, adhesives, and / or thermoplastic welding processes.

[0019] Compared to the 2-4 hours total wrinkle removal time of existing technologies, the polymer membrane of the separator of this invention, with its low thermal mass, can reach wrinkle removal temperature in less than an hour or even less, for example, less than a second. This invention also allows for various combinations of glass thickness, low-e coatings, and the placement of these coatings within the unit. This allows manufacturers to customize designs to provide the desired cost / performance trade-offs for a given building, geographic region, or regulatory requirement. Supporting the intermediate separator or third layer on a separate structure allows for easier offsetting of the separator from the unit's centerline compared to existing technologies. This allows for easier placement / addition of window slats while still improving thermal performance. Furthermore, unlike existing technologies that integrate intermediate layers into the unit, the system of this invention can be divided into sub-components for assembly. This allows for improved final system yield by allowing for the disposal of non-conforming parts earlier in the process. Additionally, incorporating multiple intermediate panels or layers within the unit becomes much easier. Attached Figure Description

[0020] The invention is illustrated in the accompanying drawings, wherein the same reference numerals identify the same parts throughout. Unless otherwise stated, the drawings are not drawn to scale.

[0021] Figure 1 It is a cross-sectional side view of a multi-layer insulating glass unit according to the prior art.

[0022] Figure 2 This is a cross-sectional side view of a multi-layer insulating glass unit according to an embodiment of the present invention.

[0023] Figure 3 According to the embodiments of the present invention Figure 2 An enlarged side perspective view of a portion of a multi-layered insulating glass unit.

[0024] Figures 4A-4D This is a cross-sectional side view of a multi-layer insulating glass unit according to an embodiment of the present invention, showing various arrangements for fixing a third layer within the glass unit.

[0025] Figures 5A-5C This is a partial cross-sectional view showing various arrangements for mounting the support structure within a multi-layered insulating glass unit.

[0026] Figure 6A This is a partial side view of the cross-section of the frame / third layer according to an embodiment of the present invention.

[0027] Figure 6B According to the embodiments of the present invention Figure 6A A perspective view of the frame.

[0028] Figure 7AThis is a partial side view of the cross-section of the frame / third layer according to an embodiment of the present invention.

[0029] Figure 7B According to the embodiments of the present invention Figure 6A A perspective view of the frame.

[0030] Figure 8A This is a partial side view of the cross-section of the frame / third layer according to an embodiment of the present invention.

[0031] Figure 8B According to the embodiments of the present invention Figure 6A A perspective view of the frame.

[0032] Figures 9A-9D The steps for fixing the third layer to the support structure according to an embodiment of the present invention are shown.

[0033] Figure 10A and 10B The graph illustrates the determination of the optimal temperature for pre-attached heating with membrane shrinkage versus application of pre-shrink or low-shrinkage membranes according to the present invention.

[0034] Figure 11 The graph shows the optical position of the center panel with respect to the optimal thermal performance of the features according to the invention.

[0035] Figure 12A-12D The partial cross-sectional view illustrates various arrangements for balancing the pressure between the panels of the multi-layer insulating glass unit according to the invention.

[0036] Figure 13A A perspective view of a multi-layered insulating glass unit including window panes according to an embodiment of the present invention is shown.

[0037] Figure 13B An embodiment of the present invention is shown. Figure 13A A partial cross-sectional view of a multi-layered insulating glass unit. Detailed Implementation

[0038] Spatial or directional terms used herein, such as “left,” “right,” “up,” “down,” etc., are relevant to the invention as illustrated in the accompanying drawings. It should be understood that the invention can take various alternative orientations, and therefore these terms should not be considered limiting.

[0039] As used herein, spatial or directional terms such as “left,” “right,” “inner,” “outer,” “above,” “below,” etc., relate to the invention as illustrated in the accompanying drawings. However, it should be understood that the invention can take various alternative orientations, and therefore these terms should not be considered limiting. Furthermore, as used herein, all figures representing dimensions, physical properties, process parameters, quantities of components, reaction conditions, etc., as used in the specification and claims, should in all cases be understood to be modified by the term “about.” Therefore, unless indicated otherwise, the numerical values ​​presented in the following specification and claims may vary according to the desired properties sought to be obtained according to the invention. At least, and not in an attempt to limit the application of the doctrine of equivalence to the scope of the claims, each numerical value should be interpreted at least according to the number of significant figures reported and by applying ordinary rounding techniques. Furthermore, all scopes disclosed herein should be understood to include both the starting and ending scope values ​​and any and all subscopes contained therein. For example, the recorded range “1 to 10” should be considered to include any and all subranges between the minimum value 1 (inclusive) and the maximum value 10; that is, all subranges that begin with a minimum value of 1 or greater and end with a maximum value of 10 or less, such as 1 to 3.3, 4.7 to 7.5, 5.5 to 10, etc. Furthermore, all documents mentioned herein, such as, but not limited to, published patents and patent applications, should be considered “incorporated in their entirety by reference”.

[0040] All figures used in the specification and claims should be understood to be modified by the term "about" in all cases. All ranges disclosed herein should be understood to include both the starting and ending range values ​​and any and all subranges contained therein. Ranges described herein represent average values ​​within a specified range.

[0041] All documents mentioned here should be considered as incorporated in their entirety by reference.

[0042] Unless otherwise specified, any quantity mentioned is a "percentage by weight".

[0043] The discussion of the invention herein may describe certain features as “particularly” or “preferred” within certain limitations (e.g., “preferred,” “more preferred,” or “even more preferred” within certain limitations). It should be understood that the invention is not limited to these specific or preferred limitations, but rather encompasses the entire scope of this disclosure.

[0044] As used herein, the transitional term “comprising” (and other equivalent terms such as “including” and “containing”) is “open-ended” and may include unspecified items. Although described using “comprising”, the terms “substantially consisting of” and “consisting of” are also within the scope of this disclosure.

[0045] This invention includes, constitutes, or substantially constitutes any combination of the following aspects of the invention. Various aspects of the invention are shown in separate drawings. However, it should be understood that this is merely for ease of illustration and discussion. In practice, one or more aspects of the invention shown in one drawing may be combined with one or more aspects of the invention shown in one or more other drawings.

[0046] Now for reference Figure 1 The diagram shows a cross-sectional side view of a multi-layer insulating glass unit according to the prior art, generally designated as 1. Unit 1 includes a pair of glass sheets 2a and 2b in a parallel and spaced-apart relationship. A third sheet in the form of a coating layer 4 is located between sheets 2a and 2b, forming open spaces or chambers 5a and 5b between sheets 2a and 2b and the membrane 4. The membrane 4 is secured to edge spacers 8a and 8b by means of a primary sealant 6. Edge spacers 8a and 8b extend generally around the periphery of their respective sheets 2a and 2b. Edge spacers 8a and 8b have the same dimensions in cross-section, such that the membrane 4 is positioned midway between the opposing sheets 2a and 2b. The shape of the edge spacers 8a and 8b is such that when sheets 2a and 2b are attached to the edge spacers 8a and 8b, sheets 2a and 2b are parallel to each other and parallel to the membrane 4. A secondary sealant 7 is provided to further secure the membrane 4 within unit 1. The manufacturing process of the glass unit 1 in the prior art includes the following steps: assembling the entire unit (including sheets 2a, 2b, film 4, edge spacers 8a, 8b, primary sealant 6, secondary sealant 7), curing the sealant (which may take up to 2 hours), shrinking film 4 in an oven (which may take an additional 2 hours), and then manually filling spaces 5a, 5b with an inert gas such as argon.

[0047] In existing designs, edge spacers 8a and 8b sandwiching the central membrane 4 form two interfaces with the primary sealant material 6, which extends further outward to make close contact with the second sealant 7, thereby providing mechanical support. This can result in shear stress being applied to the seal, which can increase the likelihood of seal failure. Furthermore, these two additional interfaces create additional failure points for air ingress, which can degrade the thermal performance of unit 1. Additionally, constructing unit 1 can take several hours, approximately 3-5 hours or longer.

[0048] Now for reference Figure 2 and Figure 3 , Figure 2 and Figure 3A multi-layered insulating glass unit, generally designated 10, is shown according to an embodiment of the present invention. Unit 10 includes a pair of glass sheets 12a, 12b in a parallel and spaced-apart relationship. At least one edge spacer 18 is disposed between the glass sheets 12a, 12b. A first or primary sealant 16 is located between adjacent edges of the pair of sheets 12a, 12b to provide an integrally sealed unit defining a space 15 therebetween. At least one transparent film 14 is located within the space 15 between the pair of glass sheets 12a, 12b. The at least one transparent film 14 is fixed to a support structure 20 (e.g., Figure 2 , 3 (as shown in 4A-4C) or at least one edge spacer 18 (as shown in 4A-4C) Figure 4D One of the two (shown) is positioned such that the membrane is positioned in a spaced-apart parallel relationship between the pair of glass sheets 12a, 12b to form a pair of spaces 15a, 15b. The support structure 20 can be a single frame or a pair of frames 20a, 20b. Spaces 15a, 15b can be filled with air or gas to reduce heat conduction across the window structure. Any inert, low-heat-conductivity gas can be used, including krypton, argon, sulfur hexafluoride, carbon dioxide, etc. Combinations and / or different gases can be used in spaces 15a, 15b to achieve the desired reduction in thermal conductivity. This filling gas can contain a significant amount of oxygen to prevent or minimize yellowing of the inner membrane 14.

[0049] The membrane 14 is annealed before being positioned between a pair of glass sheets 12a, 12b. Annealing reduces the internal stresses in the membrane that are typically introduced during manufacturing, giving the membrane greater ductility during forming or any further processing and reducing the likelihood of breakage, especially when exposed to temperature fluctuations.

[0050] The annealing step releases the tension in the film 14 through stress-induced crystallization. This step typically takes several minutes, depending on the material used for the film 14 and the temperature at which the film 14 is heated to anneal it.

[0051] Depending on the type of film 14 used, film 14 is heated to a specific annealing temperature to induce stress-induced crystallization. If the film is a plastic material, the annealing process may include heating the film to half its melting temperature, holding it for a period of time, and then cooling the film to allow it to relax. If the film is a metallic material, it is typically annealed by heating the metal above its recrystallization temperature, holding it at the appropriate temperature for an appropriate time, and then cooling it. Films formed from glass undergo a controlled cooling process to prevent cracking or breakage. According to one embodiment, the film may be heated to at least... The annealing temperature at C is maintained for approximately 10 minutes. According to other embodiments, the film can be heated to above [temperature missing]. C C or C.

[0052] according to Figure 2 , 3 In the embodiments shown in 4A-4C, the at least one transparent membrane 14 is supported by a support structure or frame 20. The membrane 14 may be fixed to the support structure or frame, wherein the frame 20 is located adjacent to the edge and extends around the periphery of the membrane 14. The at least one frame 20 may be flexible and have sufficient thickness to maintain its shape under its weight without losing it. According to one embodiment, an aluminum frame of about 1 / 16″ thickness may be used. It is understood that, depending on the material used for the frame, the thickness of the frame may be less than or greater than 1 / 16″. According to another embodiment, the support structure may include a pair of frames 20a, 20b that clamp the edge of the membrane 14 and extend around the periphery of the membrane 14.

[0053] exist Figure 4A In this arrangement, a single edge spacer 18 is located between sheets 12a, 12b, and a single frame 20 is provided to support the membrane 14. The edge spacer 18 may be a C-shaped member having vertical sides 28 and horizontal top and bottom 29. The edge spacer 18 typically extends around the periphery of sheets 12a, 12b. The frame 20 may be mechanically or adhesively fixed to the edge spacer 18, or fixed by any other known technique. The frame 20 and the membrane 14 may be equidistantly located between sheets 12a, 12b to create equal spaces 15a, 15b between the membrane 14 and sheets 12a and 12b. Alternatively, the frame 20 and the membrane 14 may be located between sheets 12a, 12b such that one of the spaces 15a or 15b is larger than the other of the spaces 15a, 15b. A primary sealant 16 may be used to secure the edge frame 18 to the sheets 12a, 12b and may extend along the vertical side 28 of the edge spacer 18.

[0054] Figure 4BThe arrangement shows a pair of edge spacers 18a, 18b for supporting the frame 20. In this arrangement, the membrane 14 is fixed to a single frame 20, and the frame 20 is mounted between the edge spacers 18a, 18b and secured therein with adhesive 22. The edge spacers 18a, 18b generally extend around the periphery of their respective sheets 12a, 12b. The edge spacers 18a, 18b may have the same dimensions in cross-section; however, because the frame 20 is inserted between the spacers 18a, 18b, the membrane 14 is not positioned in the middle between the opposing sheets 12a, 12b, and one of the spaces 15a, 15b is larger than the other. The shape of the edge spacers 18a, 18b is such that when the sheets 12a, 12b are attached to the edge spacers 18a, 18b, the sheets 12a, 12b are parallel to each other and parallel to the membrane 14. Primary sealant 16 may be located between edge member 18 and sheet 12, and secondary sealant 17 may be provided along the vertical sides of spacers 18a, 18b to seal unit 10.

[0055] Figure 4C The arrangement shows a pair of edge spacers 18a, 18b for supporting the frame 20. This arrangement is consistent with... Figure 4B The arrangement is similar in that the membrane 14 is fixed to a single frame 20, which is mounted between edge spacers 18a and 18b and secured therein with adhesive 22. In this arrangement, the frame 20 is thinner and can be shaped, for example, L-shaped, having vertically extending legs 24 positioned on the vertical sides 28 adjacent to the edge spacers 18 and horizontally extending legs 26 positioned on the horizontal tops 29 adjacent to the edge spacers 18. The edge spacers 18a and 18b generally extend around the periphery of their respective sheets 12a and 12b. The edge spacers 18a and 18b may have the same dimensions in cross-section; however, because the horizontal legs 26 of the frame 20 are inserted between the spacers 18a and 18b, the membrane 14 is not positioned in the middle between the opposing sheets 12a and 12b, and one of the spaces 15a and 15b is larger than the other. The shapes of the edge spacers 18a and 18b are such that when the sheets 12a and 12b are attached to the edge spacers 18a and 18b, the sheets 12a and 12b are parallel to each other and parallel to the membrane 14. A primary sealant 16 can be positioned between the edge spacers 18a and 18b and the sheets 12a and 12b, and a secondary sealant 17 can be provided along the vertical sides of the spacers 18a and 18b to seal the unit 10.

[0056] according to Figure 4DIn one embodiment, the membrane 14 can be directly fixed to the edge spacers 18a, 18b. The membrane 14 can be adhered to the edge spacers 18a, 18b using a first sealant 16 or a separate adhesive (not shown). The edge spacers 18a, 18b generally extend around the periphery of their respective sheets 12a, 12b. The edge spacers 18a, 18b can have the same dimensions in cross-section, such that the membrane 14 is equidistantly positioned between the opposing sheets 12a, 12b, and the spaces 15a, 15b are substantially the same size. Alternatively, one of the edge spaces 18a, 18b can be larger than the other, such that the membrane is not positioned in the middle between the opposing sheets 12a, 12b, and one of the spaces 15a, 15b is larger than the other. The shape of the edge spacers 18a, 18b is such that when the sheets 12a, 12b are attached to the edge spacers 18a, 18b, the sheets 12a, 12b are parallel to each other and parallel to the membrane 14. Primary sealant 16 may be located between edge spacers 18a, 18b and sheet 12, and secondary sealant 17 may be provided along the vertical sides of spacers 18a and 18b to seal unit 10.

[0057] Now for reference Figures 5A-5C It shows various arrangements for securing the support structure 20 to the edge spacer 18. Figure 5A An arrangement is shown in which the frame 20 holding the membrane 14 is positioned inside and within the edge spacer 18. Figure 5B An arrangement is described in which the frame of the clamping membrane 14 is placed in the unit 10, such that it is outside the edge spacer 18 and inside the visible area 13 of the unit 10. Figure 5C Another arrangement is shown in which the frame 20 holding the membrane 14 is located inside the visual area 13, but is snapped into the edge spacer 18 by means of the clip 6.

[0058] Membrane 14 can be annealed before or after being fixed to the support structure. Membrane 14 is annealed to a relaxed state, wherein the relaxed state of membrane 14 has a tension of less than or equal to 0.1 psi.

[0059] The membrane 14 can be formed from at least one of a polymer sheet, a thin glass sheet, and / or any other transparent sheet. The polymer sheet may include a reinforcing organic material. According to one embodiment, the membrane 14 may be a polymer sheet comprising polyethylene terephthalate (PET). The PET membrane 14 may have a thickness of 0.5-10 mils, 0.5-5 mils, or even 0.5-2 mils. At least one surface of the membrane 14 may include a low-e coating. It has been found that by including a low-e coating on one or more surfaces of the glass sheet layers 12a, 12b and / or the membrane 14, the insulating glass unit 10 of the present invention can achieve significantly better thermal performance than prior art arrangements. In particular, it has been found that the unit 10 of the present invention can achieve R5 performance over a wider range of total thicknesses using low-cost argon (Ar), or R9 or better performance using krypton (Kr).

[0060] According to one embodiment, adhesive 22 can be used to fix the membrane 14 to the support structure 20, such as... Figure 4C As shown. Alternatively, an adhesive can be used to secure the membrane 14 to the edge spacer 18 (not shown). The adhesive 22 can be any known adhesive, including contact adhesives, pressure-sensitive adhesives, UV-curing adhesives, thermosetting adhesives, or chemically curing adhesives. According to another embodiment, the membrane 14 can be secured to the edge spacer 18 using a primary sealant 16. According to yet another embodiment, the membrane can be heated and melted to bond with the support structure 20 or the edge spacer 18 without the need for an adhesive or sealant.

[0061] According to an implementation plan, and with reference to Figure 6A , 6B 7A, 7B, 8A, and 8B, the membrane 14 can be secured to the support structure 20 or at least one edge spacer 18 using mechanical components. The support structure 20 may include a pair of frames 20a, 20b, with the membrane sandwiched between them. According to one embodiment, the frames 20a, 20b are held together at the corner by a key or other mechanical fastening device or connecting structure (not shown), such as a dovetail, an adhesive covering at least a portion of the side members, and a transparent plate adhered to the side members by the adhesive. Another arrangement may include support frames 20a, 20b with corners formed by notches in the sides, the sides being folded to form the corners, an adhesive covering at least a portion of the side members, and a transparent membrane 14 adhered to the sides by the adhesive. According to yet another embodiment, it has been found that using frames without corner clips allows for additional space for the membrane and prevents the membrane from cramping up at the corners and forming wrinkles within the membrane.

[0062] The membrane 14 can be attached to the pair of frames 20a, 20b by means of mechanical clips or other fixing devices. As described below, the mechanical fixing of the membrane 14 can be achieved using a pair of frames formed by pins / locks.

[0063] For example, such as Figure 6A and 6B As shown, the pin / lock member may be a plurality of conical discrete members 52a, 52b extending along the edges of the frame members 20a, 20b, which are configured to mechanically engage with the membrane 14 located between them. Figure 7A and 7B A series of pin / lock bar-shaped rounded members or parallelograms 54a, 54b extending along the length of the edges of frame members 20a, 20b are shown. Figure 8A and 8B A series of pin / lock rod-shaped tapered members 56a, 56b extending along the length of the edges of frame members 20a, 20b are shown.

[0064] Continue to refer to Figure 2 and Figure 3 and further reference Figures 9A-9D The method of forming the insulating glass unit 10 includes providing a pair of glass sheets 12a, 12b in a parallel and spaced-apart relationship. For example... Figure 9A As shown, at least one film 14 is provided and stretched to remove wrinkles using a bow-shaped roller, vacuum roller, or pressure roller type wrinkle removal system 30 or any other anti-wrinkle system. This process typically takes less than one minute to complete. Figure 9B As shown, the next step of the process involves securing the membrane 14 to the support structure 20 or at least one edge spacer 18. This step takes several seconds to complete. Figure 9C As shown, heat is applied as indicated by arrow 34 to anneal the membrane 14 to a relaxed state. Figure 9D As shown. Although Figure 9CIt is shown that heat is applied to the membrane 14 after it is secured to the support structure 20 or at least one edge spacer 18, but it is understood that annealing of the membrane 14 can occur before it is secured to the support structure 20 or at least one edge spacer 18. This annealing step can be completed within minutes, depending on the material used to form the membrane 14. After annealing, the membrane 14 is positioned between the pair of glass sheets 12a, 12b such that the membrane 14, with or without the support structure 20, is positioned in a spaced-apart parallel relationship between the pair of glass sheets 12a, 12b. At least one edge spacer 18 and a primary sealant 16 are provided between adjacent edges of the pair of glass sheets 12a, 12b to provide a complete sealing unit 10 defining a space 15 therebetween. It is understood that steps 9A-9D can be performed on a machine with articulated movement, thereby allowing any or all of the steps to be completed automatically.

[0065] According to one embodiment, the membrane 14 can be directly fixed to at least one edge spacer 18. Alternatively, the membrane 14 can be fixed to the support structure 20, and the membrane 14 and the support structure 20 can be positioned between the pair of glass sheets 12a, 12b, separated from at least one edge spacer 18, for example, within the visual area of ​​the unit 10.

[0066] The support structure 20 may include at least one flexible frame member 20a located adjacent to the edge of the membrane 14, or a pair of flexible frame members 20a, 20b sandwiching the edge of the membrane 14. According to one embodiment, the support structure 20 may include at least one frame member 20a located adjacent to the edge of the membrane 14, wherein the at least one frame member 20a is flexible and has a sufficient thickness to maintain its shape under its weight. According to one embodiment, an aluminum frame of approximately 1 / 16″ thickness may be used. The frames 20a, 20b may be formed using any known method, including molding, stamping, 3D printing, etc.

[0067] The membrane 14 can be heated at a temperature and time sufficient to induce stress-induced crystallization, such that the relaxed state of the membrane 14 has a tension of less than or equal to 0.1 psi.

[0068] The method further includes trimming the membrane 14 after annealing it to a relaxed state and securing it to one of the support structure 20 and at least one edge spacer 18. The membrane 14 can be trimmed using a knife, blade, laser, or the like. The membrane 14 can be secured to one of the support structure 20 and at least one edge spacer 18 by at least one of mechanical components, adhesives, and thermoplastic welding processes.

[0069] It is understood that the membrane 14 may also include at least one material embedded therein or coated on one or both sides to control the transmission and / or reflection spectrum. Patterns may be printed on the membrane 14 before or after it is fixed to the support structure 20 or the spacer 18. The membrane 14 may be coated with or have aesthetic materials in portions visible to the end user, allowing for additional designs that are visually appealing to the end user. At least one surface of the membrane 14 may include a low-e coating. According to one embodiment, the optical haze of the BK Gardner Hazegard measuring unit 10 may be less than 3%, and preferably less than 1.5%, and more preferably less than 1%.

[0070] The membrane 14 can also be configured to function as a sound-generating element to produce, for example, music, denoising, or white noise, to mask acoustic pickup by laser reflection from, for example, conversations within a room. The driving element can be the membrane 14 itself (with suitably positioned electrodes) or a transducer with attachments. The absence of a rigid mechanical connection between the central support structure 20 and the spacer 18 allows one or more intermediate membranes 14 to be used as acoustic membranes without transmitting sound waves to the spacer 18, reducing the likelihood of failure, and / or preventing sound waves from being transmitted to the building structure, thereby controlling the area and location of sound wave emission into the environment.

[0071] In addition, along with the material embedded in the membrane 14, or by applying a coating to one or both surfaces 14a, 14b of the membrane 14, the membrane 14 can be designed to have thermochromic functionality for passively controlling optical (visible and / or IR region) transmission and / or reflection spectra.

[0072] refer to Figure 10A It shows the optimal temperature determination for the pre-attachment heating (i.e., film shrinkage) step. Figure 10B Temperature measurements using pre-shrink or low-shrinkage films are shown, where thermally stabilized films are not required. The heat distribution (i.e., the relationship between temperature and time) makes the film wrinkle-free, and the stress results in virtually no force being applied to the frame 20 of the spacer 18.

[0073] refer to Figure 11 This diagram shows the optical position of the film 14 with respect to the optimal thermal performance of unit 10. (See diagram for example.) Figure 11 As shown, the optimal position of the film 14 is on the centerline between the inner surfaces of the outer glass sheets 12a and 12b. However, as... Figure 11 As shown, the membrane 14 can also be positioned at an offset position on the center line of the space 15 between the inner surfaces of the outer glass layers 12a and 12b, while still achieving improved thermal performance compared to the double-layer insulating glass unit.

[0074] Continue to refer to Figure 2 and Figure 3 and4A -4D, and further reference Figure 12A-12D The pair of glass sheets 12 may include a first glass sheet 12a and a second glass sheet 12b. A space or first chamber 15a is located between the first glass sheet 12a and a first side 14a of the membrane 14, and a space or second chamber 15b is located between the second glass sheet 12b and a second side 14b of the membrane 14. Openings may be provided to allow gas to move between the first chamber 15a and the second chamber 15b to ensure pressure balance between the first chamber 15a and the second chamber 15b. Figure 12A In the illustrated embodiment, where the membrane 14 is integrated with spacers 18a and 18b, an opening 44a can be provided in the membrane 14. Figure 12B In the illustrated embodiment, where the membrane 14 is fixed to the support structure 20 and the support structure 20 and the membrane 14 are located within the visible area 13 of the unit 10, an opening 44b can be provided in the support structure 20. Figure 12C In the illustrated embodiment, where the support structure 20 and the membrane 14 are located within the spacer 18, a plurality of openings 44c in the form of openings can be provided in the support structure 20. Figure 12D In the illustrated embodiment, the support structure 20 is secured inside the visible area 13 of the unit 10 by a clip 46 that mates with the spacer 18. In this embodiment, an opening 44d is provided in the support structure 20.

[0075] Referring now to Figures 13a and 13b, a window pane strip 40 is shown. The window pane strip 40 may be attached to an edge spacer 18 (not shown) or a support structure / frame 20a or 20b, or both. The window pane strip 40 may be attached with or without clips. According to one arrangement, the window pane strip 40 may be inserted into a recess 42 within the upper frame 20a, and the film 14 may be attached to the lower frame 20b. Alternatively, the window pane strip 40 may be printed onto a film.

[0076] The invention is further described in the following numbered clauses.

[0077] Clause 1: An insulating glass unit comprising: a pair of parallel and spaced-apart glass sheets; at least one edge spacer located between adjacent edges of the pair of glass sheets and at least a primary sealant to provide an integral sealing unit defining a space therebetween; and at least one transparent film located within the space between the pair of glass sheets, the at least one transparent film being fixed to one of a support structure and the at least one edge spacer, wherein the film is positioned between the pair of glass sheets in a spaced-apart parallel relationship, and wherein the film is annealed to a relaxed state prior to positioning the film between the pair of glass sheets.

[0078] Clause 2: The insulating glass unit as described in Clause 1, wherein at least one transparent film is supported by the support structure, and the support member is separate from the edge spacer.

[0079] Clause 3: The insulating glass unit according to Clause 2, wherein the support structure includes at least one frame member located adjacent to the edge of the membrane.

[0080] Clause 4: The insulating glass unit according to Clause 3, wherein the at least one frame member is flexible and has a sufficient thickness to maintain its shape under its weight.

[0081] Clause 5: The insulating glass unit as described in Clause 4, wherein at least one frame member is aluminum with a thickness of approximately 1 / 16″.

[0082] Clause 6: An insulating glass unit according to any one of Clauses 2-5, wherein the membrane is annealed before or after it is fixed to the support structure.

[0083] Clause 7: An insulating glass unit according to any one of Clauses 1-6, wherein the relaxed state of said membrane has a tension of less than or equal to 0.1 psi.

[0084] Clause 8: An insulating glass unit according to any one of Clauses 1-7, wherein the film is heated to an annealing temperature of at least 70°C for about 10 minutes.

[0085] Clause 9: An insulating glass unit according to any one of Clauses 1-8, wherein the membrane comprises at least one of a polymer sheet, a thin glass sheet, and any other transparent sheet.

[0086] Clause 10: The insulating glass unit as described in Clause 9, wherein the membrane is a polymer sheet comprising polyethylene terephthalate.

[0087] Clause 11: An insulating glass unit according to any one of Clauses 1-10, wherein the membrane is fixed to the support structure or the at least one edge spacer by at least one of mechanical components, adhesives, primary sealants and thermoplastic welding.

[0088] Clause 12: The insulating glass unit according to Clause 2, wherein the support structure is fixed to the edge spacer.

[0089] Clause 13: The insulating glass unit according to Clause 2, wherein the pair of glass sheets comprises a first glass sheet and a second glass sheet, and wherein the support structure is configured to allow gas to move between a first chamber located between the first glass sheet and a first side of the membrane and a second chamber located between the second glass sheet and a second side of the membrane, to ensure pressure balance between the first chamber and the second chamber.

[0090] Clause 14: An insulating glass unit according to any one of Clauses 1-13, wherein the membrane comprises at least one of materials embedded therein or coated on one or both sides to control the transmission and / or reflection spectrum.

[0091] Clause 15: A method of forming an insulating glass unit, the method comprising: providing a pair of parallel and spaced-apart glass sheets; providing at least one film; stretching the film to remove wrinkles; securing the film to one of a support structure and at least one edge spacer; applying heat to the film to anneal the film to a relaxed state, wherein the step of annealing the film occurs before or after the step of securing the film to one of the support structure and the at least one edge spacer; positioning the film secured to one of the support structure and the at least one edge spacer between the pair of glass sheets such that the film is positioned between the pair of glass sheets in a spaced-apart parallel relationship; and providing the at least one edge spacer and a primary sealant between adjacent edges of the pair of glass sheets to provide an integral sealing unit defining a space therebetween.

[0092] Clause 16: The method according to Clause 15, wherein the membrane is fixed to the support structure, and the membrane and the support structure are positioned between the pair of glass sheets at a location separated from the at least one edge spacer.

[0093] Clause 17: The method according to Clause 15 or 16, wherein the support structure includes at least one flexible frame member located adjacent to the edge of the membrane.

[0094] Clause 18: The method according to any one of Clauses 15-17, wherein the membrane is heated to a temperature and duration sufficient to induce stress-induced crystallization such that the relaxed state of the membrane has a tension of less than or equal to 0.1 psi.

[0095] Clause 19: The method according to any one of Clauses 15-18 further includes trimming the membrane after annealing it to the relaxed state and fixing it to one of the support structure and the at least one edge spacer.

[0096] Clause 20: The method according to any one of Clauses 15-19, wherein the membrane is fixed to one of the support structure and at least one edge spacer by at least one of mechanical components, adhesives, primary sealants and thermoplastic welding processes.

[0097] Clause 21: The method according to any one of Clauses 15-20, wherein the support structure comprises at least one frame member located adjacent to the edge of the membrane, wherein the at least one frame member is flexible and has a sufficient thickness to maintain its shape under its weight.

[0098] Clause 22: The method according to Clause 22, wherein the at least one frame member comprises aluminum with a thickness of about 1 / 16″.

[0099] While this disclosure is described as having an exemplary design, further modifications can be made to this disclosure within its spirit and scope. Therefore, this application is intended to cover any variations, uses, or alterations of this disclosure using its general principles. Furthermore, this application is intended to cover modifications of this disclosure within the scope of known or conventional practice in the art to which this disclosure pertains and within the limitations of the appended claims.

Claims

1. An insulating glass unit, comprising: A pair of parallel and spaced-apart glass sheets; At least one edge spacer and at least one primary sealant are located between the inwardly facing adjacent edges of the pair of glass sheets to seal at least one edge spacer to the inwardly facing adjacent edges of the pair of glass sheets, thereby providing an integral sealing unit that defines a space therebetween; and At least one annealed, relaxed transparent film is located in the space between the pair of glass sheets, the at least one transparent film is fixed to one of a support structure and the at least one edge spacer, wherein the film is wrinkle-free and positioned between the pair of glass sheets in a spaced parallel relationship.

2. The insulating glass unit according to claim 1, wherein the at least one transparent film is supported by the support structure, and the support structure is separate from the edge spacer.

3. The insulating glass unit according to claim 2, wherein the support structure includes at least one frame member located adjacent to the edge of the membrane.

4. The insulating glass unit according to claim 3, wherein the at least one frame member is flexible and has a sufficient thickness to maintain its shape under its weight.

5. The insulating glass unit according to claim 4, wherein the at least one frame member is a solid aluminum member with a thickness of 1 / 16″ in its width.

6. The insulating glass unit of claim 1, wherein the relaxed state of the membrane has a tension of less than or equal to 0.1 psi.

7. The insulating glass unit of claim 1, wherein the film is heated to at least The annealing temperature of C is maintained for 10 minutes.

8. The insulating glass unit according to claim 1, wherein the membrane comprises at least one of a polymer sheet and a thin glass sheet.

9. The insulating glass unit according to claim 8, wherein the membrane is a polymer sheet comprising polyethylene terephthalate.

10. The insulating glass unit of claim 1, wherein the membrane is fixed to the support structure or the at least one edge spacer by at least one of a mechanical component, an adhesive, a primary sealant, and thermoplastic welding.

11. The insulating glass unit according to claim 2, wherein the support structure is fixed to the edge spacer.

12. The insulating glass unit of claim 2, wherein the pair of glass sheets comprises a first glass sheet and a second glass sheet, and wherein the support structure is configured to allow gas to move between a first chamber located between the first glass sheet and a first side of the membrane and a second chamber located between the second glass sheet and a second side of the membrane to ensure pressure balance between the first chamber and the second chamber.

13. The insulating glass unit of claim 1, wherein the film comprises at least one of a material embedded therein or coated on one or both sides to control the transmission and / or reflection spectrum.

14. A method for forming an insulating glass unit, comprising: A pair of glass sheets are provided in a parallel and spaced-apart relationship; Provide at least one membrane; Stretch the membrane to remove wrinkles; The membrane is fixed to one of the support structure and at least one edge spacer; Heat is applied to the membrane to anneal the membrane to a relaxed state, wherein the annealing step is performed before or after the step of fixing the membrane to one of the support structure and the at least one edge spacer. The membrane, which is fixed to one of the support structure and the at least one edge spacer, is positioned between the pair of glass sheets such that the membrane is positioned between the pair of glass sheets in a spaced parallel relationship. and At least one edge spacer and a primary sealant are provided between adjacent edges of the pair of glass sheets to provide an integral sealing unit that defines a space therebetween.

15. The method of claim 14, wherein the membrane is fixed to the support structure, and the membrane and the support structure are positioned between the pair of glass sheets at a location separated from the at least one edge spacer.

16. The method of claim 14, wherein the support structure comprises at least one flexible frame member located adjacent to the edge of the membrane.

17. The method of claim 14, wherein the membrane is heated to a temperature and duration sufficient to induce stress-induced crystallization such that the relaxed state of the membrane has a tension of less than or equal to 0.1 psi.

18. The method of claim 14, further comprising trimming the membrane after annealing it to the relaxed state and securing it to one of the support structure and the at least one edge spacer.

19. The method of claim 14, wherein the membrane is fixed to one of the support structure and the at least one edge spacer by at least one of mechanical components, adhesives, primary sealants and thermoplastic welding processes.

20. The method of claim 14, wherein the support structure comprises at least one frame member located adjacent to the edge of the membrane, wherein the at least one frame member is flexible and has a sufficient thickness to maintain its shape under its weight.

21. The method of claim 20, wherein the at least one frame member comprises aluminum with a thickness of 1 / 16″.

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