Method for manufacturing hollow glass unit

Abstract

Methods of making a three-layer hollow glass unit (IGU) having a thin center pane (regardless of CTE or glass type / composition) in the IGU are provided, including various embodiments for reducing, preventing and / or eliminating edge warpage when using a heated adhesive as spacer material in the IGU.

Description

[0001] Cross - reference to related applications

[0002] This application claims the benefit of priority of U.S. Provisional Application No. 63 / 428,495, filed on November 29, 2022, under 35 U.S.C.§119, the content of which is incorporated herein by reference in its entirety. Technical field

[0003] Generally, the present disclosure relates to a triple - pane IGU configured with TPS spacers having a thin (e.g., less than about 2.5 mm thick) center pane and methods of manufacturing the same. More specifically, the present disclosure relates to an IGU and a method of manufacturing an IGU that meet thermal requirements (e.g., ENERGY STAR v7) while reducing and / or eliminating edge warping caused by deposition of the spacer (during manufacturing). Background art

[0004] Currently, building codes and energy standards are constantly changing, with increasing emphasis on sustainability, energy utilization, and thermal efficiency of buildings and building products. With recent proposed changes to energy certification programs and recent building trends of increasing window sizes and / or the number of windows in homes and buildings, insulating glass unit (IGU) manufacturers, window manufacturers, and builders have a strong desire to reduce the weight of IGUs and windows while meeting new and more stringent energy certifications in various jurisdictions. Summary of the invention

[0005] Surprisingly, the inventors of the present case have determined that when using extruded thermoplastic spacers (TPS), high - temperature spacer beads may cause undesired edge warping in thin glass substrates used as the center pane in a thin triple - pane insulating glass unit (IGU) during extrusion / deposition. This edge warping is believed to be caused by local heat - affected zones generated by the deposition of the TPS spacer near the edges of the pane. When deposited, the spacer is extruded onto (or adhered to) the pane and the temperature of the spacer bead exceeds 100°C. Edge warping in the third or center pane can cause detrimental effects during IGU manufacturing and in the finished IGU, including but not limited to: visual distortion; reduced manufacturing yield; loss of spacer viability; or gas leakage in the IGU; and so on.

[0006] To fabricate a thin center pane IGU (e.g., having a thickness less than about 2 mm; or less than about 1.6 mm, or less than 1 mm), it has been found that edge warping can be reduced and / or eliminated by incorporating one or more of the embodiments disclosed herein into the IGU fabrication process, which includes: preheating the third pane to a preheated temperature (e.g., in the range of 60 °C to 120 °C); mechanically constraining the third pane (to prevent edge warping / deformation when the heated adhesive is placed in contact with the edges of the third pane); and / or cooling (actively and / or passively) the heat affected zone of the third pane. For one or more of the embodiments described herein, both high CTE and low CTE center pane glasses can be used as the center pane in a thin triple-pane IGU. The resulting IGU will have little to no edge warping; thus, the resulting IGU will have improved characteristics, including: little to no visual distortion, improved seal integrity, improved / enhanced manufacturability; and improved field longevity as compared to an IGU that does not utilize such an embodiment (e.g., without utilizing such techniques described herein, such a high CTE thin center pane IGU may have experienced the detrimental effects described above during manufacture and / or use). Accordingly, in one or more of the embodiments described herein, there is provided a thin CTE center pane multi-pane IGU having a TPS spacer (or other high temperature deposited spacer) and a method of manufacturing the same.

[0007] In one aspect, there is provided a method of manufacturing an insulating glass unit (IGU), comprising: heating a third glass pane to a preheated temperature, the third glass pane having a thickness less than 2.5 mm and having a third coefficient of thermal expansion (CTE 3); applying a first heated adhesive bead to a first side of the third glass pane; contacting a second side of a first glass pane with the first heated adhesive bead, wherein the first glass pane has a thickness of at least 2.5 mm and a first coefficient of thermal expansion (CTE 1); applying a second heated adhesive bead to a second side of the third glass pane or a first side of a second glass pane; contacting a first side of the second glass pane with the second heated adhesive bead, wherein the second glass pane has a thickness of at least 2.5 mm and a second coefficient of thermal expansion (CTE 2); and wherein, via the preheating step, the IGU is configured to have no edge warping in the third pane and no visual distortion in the third pane.

[0008] In some embodiments, preheating further comprises heating the third pane to an average temperature of at least 60 °C.

[0009] In some embodiments, preheating further comprises heating the third pane to an average temperature of at least 90 °C.

[0010] In some embodiments, preheating further includes heating the third pane to an average temperature in a range between at least 60 °C and less than or equal to 120 °C.

[0011] In some embodiments, the method further includes mechanically constraining the third pane in a flattened configuration.

[0012] In some embodiments, mechanically constraining the third pane further includes evacuating across a second side of the third pane.

[0013] In some embodiments, evacuating across a second side of the third pane further includes engaging a plurality of vacuum holes having a negative pressure on a vacuum table.

[0014] In some embodiments, the negative pressure is less than 0 to less than or equal to -1 atm.

[0015] In some embodiments, the vacuum table is further configured with a heating element such that preheating of the third pane is achieved via the heated vacuum table.

[0016] In some embodiments, mechanically constraining the third pane further includes mechanically fixing at least a portion of a perimeter edge of the third pane to hold the third pane in the flattened configuration.

[0017] In some embodiments, mechanically fixing at least a portion of a perimeter edge of the third pane further includes attaching the third pane to a support surface along an edge of the third pane via at least one edge fixing device.

[0018] In some embodiments, mechanically fixing at least a portion of a perimeter edge of the third pane further includes attaching the third pane to a support surface along at least two edges of the third pane via at least two edge fixing devices.

[0019] In some embodiments, the mechanically fixed edges are adjacent.

[0020] In some embodiments, the edges are non - adjacent (both horizontal edges or both vertical edges).

[0021] In some embodiments, mechanically fixing at least a portion of a perimeter edge of the third pane further includes attaching the third pane to a support surface along at least three edges of the third pane via at least three edge fixing devices.

[0022] In some embodiments, mechanically fixing at least a portion of a perimeter edge of the third pane further includes attaching the third pane to a support surface along four edges of the third pane via at least four edge fixing devices.

[0023] In some embodiments, mechanically fixing at least a portion of the perimeter corners of the third pane further comprises attaching the third pane to a support surface along at least two corners of the third pane via at least two corner fixing devices.

[0024] In some embodiments, the mechanically fixed corners are adjacent.

[0025] In some embodiments, the corners are non - adjacent.

[0026] In some embodiments, mechanically fixing at least a portion of the perimeter corners of the third pane further comprises attaching the third pane to a support surface along at least three corners of the third pane via at least three corner fixing devices.

[0027] In some embodiments, mechanically fixing at least a portion of the perimeter corners of the third pane further comprises attaching the third pane to a support surface along four corners of the third pane via four corner fixing devices.

[0028] In some embodiments, the mechanical fixing devices further comprise brackets, weight members, clamps, frame members, and / or combinations thereof.

[0029] In some embodiments, the method further comprises cooling at least a portion of a thermally affected zone in the third pane via a heat sink disposed in the support surface for passive cooling. (For example, the heat sink is further configured as a metal support surface with a finned inner surface).

[0030] In some embodiments, the method further comprises cooling at least a portion of the thermally affected zone by actively cooling the thermally affected zone in the third pane.

[0031] In some embodiments, active cooling further comprises a support surface configured with one or more chambers, the one or more chambers being configured with a cooling medium (gas or liquid) for transfer to transfer heat from the thermally affected zone of the third pane into the support surface.

[0032] In some embodiments, the method includes, after the contacting step, cooling a first heated adhesive bead to define a first spacer seal between the first pane and the third pane.

[0033] In some embodiments, a first gas chamber is defined between the first pane, the third pane, and the first spacer seal.

[0034] In some embodiments, the method further comprises compressing the IGU by applying a compressive force to the first surface of the first pane and the second surface of the second pane.

[0035] In some embodiments, the compression further includes compressing by simultaneously bringing the second side of the IGU into contact with a support surface by engaging a plurality of rollers on the first side of the IGU.

[0036] In some embodiments, the method includes, after the contacting step, cooling the second heated adhesive bead to define a second spacer seal between the third pane and the second pane.

[0037] In some embodiments, a second gas cavity is defined between the third pane, the second pane, and the second spacer seal.

[0038] In some embodiments, CTE 3 is less than CTE 1, and wherein CTE 3 is less than CTE 2.

[0039] In some embodiments, the composition of the third pane is different from the compositions of the first pane and the second pane.

[0040] In some embodiments, the third pane is borosilicate glass.

[0041] In some embodiments, the first pane and the second pane are soda-lime glass.

[0042] In some embodiments, CTE 3 is the same as CTE 1, and wherein CTE 3 is the same as CTE 2.

[0043] In some embodiments, the composition of the third pane is the same as the compositions of the first pane and the second pane.

[0044] In some embodiments, the applying step further includes guiding a formable softened adhesive bead onto the first side of the third pane.

[0045] In some embodiments, the applying step further includes extrusion.

[0046] In some embodiments, the first heated adhesive bead and the second heated adhesive bead further include a thermoplastic spacer material.

[0047] In some embodiments, the first heated adhesive bead and the second heated adhesive bead are configured to have an average application temperature in the range of at least 100°C to less than or equal to 130°C.

[0048] In some embodiments, contacting the second pane further includes adhering an adhesive to the second side of the first pane.

[0049] In some embodiments, the thickness of the third pane is less than or equal to 1.6 mm.

[0050] In some embodiments, the second pane has a thickness of at least 3 mm.

[0051] In some embodiments, the first pane has a thickness of at least 3 mm.

[0052] In some embodiments, at least one of the first pane and the second pane is strengthened by: heat tempering, heat strengthening, or chemical strengthening.

[0053] In some embodiments, both the first pane and the second pane are strengthened.

[0054] In some embodiments, the third pane is configured with a vertical inset and a horizontal inset.

[0055] In some embodiments, the third pane is configured with a vertical edge protrusion and a horizontal edge protrusion.

[0056] In some embodiments, the contacting step is performed in an environment or chamber having a first gas therein such that the first gas is retained in a first gas chamber between the first pane and the third pane via the contacting step.

[0057] In some embodiments, the contacting step is performed in an environment or chamber having a second gas therein such that the second gas is retained in a second gas chamber between the third pane and the second pane via the contacting step.

[0058] In some embodiments, the method includes injecting a first gas into the first gas chamber.

[0059] In some embodiments, the method includes injecting a second gas into the second gas chamber.

[0060] In some embodiments, the method further includes injecting a first gas into the first gas chamber; and injecting a second gas into the second gas chamber, wherein the first gas and the second gas are the same gas or different gases.

[0061] In another aspect, a method of manufacturing an insulating glass unit (IGU) is provided, including: mechanically constraining a third pane in a planarized configuration, the third glass pane having a thickness of less than 2.5 mm and having a third coefficient of thermal expansion (CTE 3); applying a first heated adhesive bead to a first side of the third glass pane; contacting a second side of the first glass pane with the heated adhesive bead, wherein the first glass pane has a thickness of at least 2.5 mm and a first coefficient of thermal expansion (CTE 1); applying a second heated adhesive bead to a second side of the third glass pane or a first side of the second glass pane; contacting a first side of the second glass pane with the second heated adhesive bead, wherein the second glass pane has a thickness of at least 2.5 mm and a second coefficient of thermal expansion (CTE 2); and additionally wherein, via the mechanical constraining step, the IGU is configured to have no edge warping in the third pane or no visual distortion in the third pane.

[0062] In some embodiments, prior to the contacting step, the method further comprises heating a third window pane to a preheat temperature.

[0063] In some embodiments, mechanically constraining the third pane further comprises evacuating across a second side of the third pane.

[0064] In some embodiments, mechanically constraining the third pane further comprises mechanically securing at least a portion of a perimeter edge and / or corners of the third pane to hold the third pane in a flattened configuration.

[0065] In some embodiments, the method further comprises cooling at least a portion of a heat affected zone in the third pane via a heat sink configured for passive cooling in a support surface.

[0066] In some embodiments, the method further comprises cooling at least a portion of the heat affected zone by actively cooling the heat affected zone in the third pane.

[0067] In another aspect, a method of manufacturing an insulating glass unit (IGU) is provided, comprising: applying a first heated adhesive bead onto a first side of a third window pane having a thickness less than 2.5 mm and having a third coefficient of thermal expansion (CTE3); while applying the first heated adhesive bead, cooling at least a portion of the third pane defined by a heat affected zone of the third pane (e.g., an area in contact with, and / or adjacent to, the heated adhesive bead); contacting a second side of a first window pane with the heated adhesive bead, wherein the first window pane has a thickness of at least 2.5 mm and a first coefficient of thermal expansion (CTE 1); applying a second heated adhesive bead onto a second side of the third window pane or a first side of a second window pane; optionally, while applying the second heated adhesive bead onto the second side of the third pane, contacting a first side of the second window pane with the second heated adhesive bead, wherein the second window pane has a thickness of at least 2.5 mm and a second coefficient of thermal expansion (CTE 2); and further wherein, via the cooling step, the IGU is configured to have no edge warping in the third pane or no visual distortion in the third pane.

[0068] In some embodiments, the method further comprises: mechanically constraining the third pane in a flattened configuration.

[0069] In some embodiments, mechanically constraining the third pane further comprises evacuating across a second side of the third pane.

[0070] In some embodiments, mechanically constraining the third pane further comprises mechanically fixing at least a portion of the perimeter edge and / or corners of the third pane to hold the third pane in a flattened configuration.

[0071] In some embodiments, the method further comprises preheating the third glass pane to a preheat temperature prior to the first application step.

[0072] In some embodiments, the method further comprises cooling at least a portion of the thermally affected zone in the third pane via a heat sink configured in the support surface for passive cooling.

[0073] In some embodiments, the method further comprises cooling at least a portion of the thermally affected zone by actively cooling the thermally affected zone in the third pane.

[0074] In another aspect, there is provided a insulating glass unit comprising: a first glass pane having a first side and a second side, a first thickness of at least 2.5 mm and a CTE 1;

[0075] a second glass pane having a first side and a second side, a second thickness of at least 2.5 mm and a CTE 2; and a third glass pane having a first side and a second side, a third thickness of less than or equal to 2.5 mm and a CTE3; a first thermoplastic spacer positioned between the second side of the first pane and the first side of the third pane to define a first gas cavity having a first cavity depth; and a second thermoplastic spacer positioned between the second side of the third pane and the first side of the second pane to define a second gas cavity having a second cavity depth; wherein the IGU has no visually observable edge warping distortion on the third pane.

[0076] In some embodiments, the third pane has a thickness of at least 0.3 mm to less than or equal to 2.2 mm.

[0077] In some embodiments, the third pane has a thickness of at least 0.3 mm to less than or equal to 1.6 mm.

[0078] In some embodiments, the third pane has a thickness of at least 0.3 mm to less than or equal to 1.3 mm.

[0079] In some embodiments, the third pane has a thickness of at least 0.45 mm to less than or equal to 1 mm.

[0080] In some embodiments, CTE 3 is less than either of CTE1 and CTE 2.

[0081] In some embodiments, the third pane is aluminosilicate glass.

[0082] In some embodiments, at least one of the first pane and the second pane is soda-lime glass.

[0083] In some embodiments, both the first pane and the second pane are soda-lime glass.

[0084] In some embodiments, CTE 3 is the same as CTE1 and CTE 2.

[0085] In some embodiments, the third pane, the second pane, and the first pane are each made of soda-lime glass.

[0086] In some embodiments, the first gas cavity is configured with a gas selected from the group consisting of air, krypton, argon, and a mixture of at least two of the foregoing gases.

[0087] In some embodiments, the second gas cavity is configured with a gas selected from the group consisting of air, krypton, argon, and a mixture of at least two of the foregoing gases.

[0088] In some embodiments, the third pane has a vertical inward taper compared to the first pane and the second pane.

[0089] In some embodiments, the third pane has a horizontal inward taper compared to the first pane and the second pane. As will be explained in more detail below, these aspects of the present disclosure, either individually or in various combinations thereof, can provide a three-pane IGU that can employ a thin glass sheet as the second sheet of the laminated pane without causing excessive deformation of the laminated pane.

[0090] Additional features and advantages of the present disclosure will be set forth in the detailed description below, and will in part be readily apparent to those skilled in the art from the description or recognized by practicing the methods as described herein, which include the detailed description below, the claims, and the drawings.

[0091] It should be understood that the foregoing general description and the following detailed description present various embodiments of the present disclosure and are intended to provide an overview or framework for understanding the nature and characteristics of the claims. The drawings are included to provide a further understanding of the present disclosure, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the present disclosure and, together with the description, are used to explain the principles and operations of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0092] The following detailed description can be further understood when read in conjunction with the following drawings, in which:

[0093] Figure 1 A schematic cross-sectional side view of an embodiment of a insulating glass unit (IGU) in accordance with one aspect of the present disclosure is depicted;

[0094] Figure 2depicts, according to one or more aspects of the present disclosure, Figure 1 a schematic plan side view; and

[0095] Figure 3 a schematic side view depicting an example of edge warping that may be caused by high-temperature spacers positioned adjacent to the edges of a glass substrate, according to aspects of the present disclosure. DETAILED DESCRIPTION

[0096] Aspects of the present disclosure will now be described with reference to Figures 1-3 the figures, which illustrate aspects of the claimed embodiments and their components, features, or properties. The following general description is intended to provide an overview of the claimed apparatus, and the various aspects will be described more specifically throughout the disclosure with reference to the depicted non-limiting aspects, which are generally interchangeable within the context of the present disclosure.

[0097] As Figure 1 shown, a cross-sectional side view of a three-pane IGU 10 is depicted. Figure 2 A front view of Figure 1 is depicted. Referring to Figure 1 and 2 , the IGU 10 includes three panes: a first pane 20, a second pane 30, and a third pane 40, where the third pane 40 is positioned between the first pane 20 and the second pane 30. The panes 20, 40, and 30 are spaced apart to define two predetermined distances: a gap between the first pane 20 and the third pane 40 and a gap between the third pane 40 and the second pane 30.

[0098] The first pane 20 is configured with a cross-sectional thickness and two major surfaces: a first side 22 of the first pane and a second side 24 of the second pane.

[0099] The second pane 30 is configured with a cross-sectional thickness and two major surfaces: a first side 32 of the second pane and a second side 34 of the second pane.

[0100] The third pane 40 is configured with a cross-sectional thickness and two surfaces: a first side 42 of the third pane and a second side 44 of the third pane.

[0101] A predetermined gap between the second side 24 of the first pane and the first side 42 of the third pane and the first spacer 52 defines a first gas cavity 16. More specifically, a first side 54 of the first spacer is connected to the second side 24 of the first pane, and a second side 56 of the first spacer is connected to the first side 42 of the third pane. A predetermined gap between the second side 44 of the third pane and the first side 32 of the second pane and the second spacer 60 defines a second gas cavity 18. More specifically, a first side 62 of the second spacer is connected to the second side 44 of the third pane, and a second side 64 of the second spacer is connected to the first side 32 of the third pane.

[0102] In some embodiments, compared with the first pane 20 or the second pane 30, the third pane 40 is configured with an amount of inward convergence (occupying a smaller area or cross-sectional area). Figure 1 The first amount of inward convergence 14 is depicted, where the upper and lower edges of the third pane 40 are set inward from the corresponding edges of the upper and lower edges of the first pane 20 and the second pane 30. Refer to Figure 2 , both the first amount of inward convergence 14 (in a vertical manner) and the second amount of inward convergence 12 (in a horizontal manner) are depicted.

[0103] In some embodiments, the IGU 10 is configured such that the first spacer 52 and the second spacer 60 are positioned at a predetermined distance from the edges of the third pane 40 to enhance sealing integrity, facilitate forming, and increase manufacturing yield. In Figure 1 , the amount of outward extension of the third pane is represented by a first edge outward extension 48 (the upper and lower edges of the third pane 40) in a vertical manner and a second edge outward extension 46 (the side edges of the third pane 40, as Figure 2 shown).

[0104] In some embodiments, the gas in the gas cavity (the first gas cavity or the second gas cavity) is: argon, krypton, or air, or a mixture of at least two gases (e.g., argon and krypton).

[0105] In some embodiments, the first amount of inward convergence is: 0.5 mm to 5 mm.

[0106] In some embodiments, the second amount of inward convergence is: 0.5 mm to 5 mm.

[0107] In some embodiments, the first pane is: soda-lime silicate glass.

[0108] In some embodiments, the second pane is: soda-lime silicate glass.

[0109] In some embodiments, the third pane is: inorganic glass. In some embodiments, the third pane is EAGLE commercially available from Corning Incorporated

[0110] In some embodiments, the spacer is: a thermoplastic spacer (TPS).

[0111] In some embodiments, the thickness of the first spacer is configured to extend along the first gas cavity such that the cross-sectional thickness of the first spacer is the same as the cross-sectional thickness of the first gas cavity. In some embodiments, the thickness of the second spacer is configured to extend along the second gas cavity such that the cross-sectional thickness of the second spacer is the same as the cross-sectional thickness of the second gas cavity.

[0112] In some embodiments, the first edge protrusion amount is from at least 0.5 mm to less than or equal to 2.5 mm. In some embodiments, the first edge protrusion amount is configured in the vertical dimension such that the third pane slightly extends from the spacer.

[0113] In some embodiments, the second edge protrusion amount is from at least 0.5 mm to less than or equal to 2.5 mm. In some embodiments, the second edge protrusion amount is configured in the horizontal dimension such that the third pane slightly extends from the spacer.

[0114] In some embodiments, the cross-sectional thickness of the first pane is from at least 2.2 to less than or equal to 10 mm. In some embodiments, the cross-sectional thickness of the first pane is at least 2.5 mm; at least 3 mm; at least 3.5 mm; at least 4 mm; at least 4.5 mm; at least 5 mm; at least 5.5 mm; at least 6 mm; at least 6.5 mm; at least 7 mm; at least 7.5 mm; at least 8 mm; at least 8.5 mm; at least 9 mm; or at least 9.5 mm. In some embodiments, the cross-sectional thickness of the first pane is less than or equal to 3 mm; less than or equal to 3.5 mm; less than or equal to 4 mm; less than or equal to 4.5 mm; less than or equal to 5 mm; less than or equal to 5.5 mm; less than or equal to 6 mm; less than or equal to 6.5 mm; less than or equal to 7 mm; less than or equal to 7.5 mm; less than or equal to 8 mm; less than or equal to 8.5 mm; less than or equal to 9 mm; or less than or equal to 9.5 mm.

[0115] In some embodiments, the cross-sectional thickness of the second pane is from at least 2.2 to less than or equal to 10 mm.

[0116] In some embodiments, the cross-sectional thickness of the first pane is at least 2.5 mm; at least 3 mm; at least 3.5 mm; at least 4 mm; at least 4.5 mm; at least 5 mm; at least 5.5 mm; at least 6 mm; at least 6.5 mm; at least 7 mm; at least 7.5 mm; at least 8 mm; at least 8.5 mm; at least 9 mm; or at least 9.5 mm. In some embodiments, the cross-sectional thickness of the second pane is less than or equal to 3 mm; less than or equal to 3.5 mm; less than or equal to 4 mm; less than or equal to 4.5 mm; less than or equal to 5 mm; less than or equal to 5.5 mm; less than or equal to 6 mm; less than or equal to 6.5 mm; less than or equal to 7 mm; less than or equal to 7.5 mm; less than or equal to 8 mm; less than or equal to 8.5 mm; less than or equal to 9 mm; or less than or equal to 9.5 mm.

[0117] In some embodiments, the cross-sectional thickness of the third pane is from 0.3 mm to less than or equal to 3 mm thick.

[0118] In some embodiments, the cross-sectional thickness of the third pane is less than or equal to 3 mm; less than or equal to 2.5 mm; less than or equal to 2 mm; less than or equal to 1.5 mm; less than or equal to 1 mm; less than or equal to 0.5 mm; less than or equal to 0.3 mm; or less than or equal to 0.1 mm. In some embodiments, the cross-sectional thickness of the third pane is: less than or equal to 2 mm; less than or equal to 1.7 mm; less than or equal to 1.5 mm; less than or equal to 1.3 mm; less than or equal to 1 mm; less than or equal to 0.7 mm; less than or equal to 0.5 mm; less than or equal to 0.3 mm; or less than or equal to 0.1 mm.

[0119] In some embodiments, the cross-sectional thickness of the third pane is at least 2.5 mm, at least 2 mm, at least 1.5 mm, at least 1 mm, at least 0.5 mm, at least 0.3 mm or at least 0.1 mm. In some embodiments, the cross-sectional thickness of the third pane is at least 1.6 mm, at least 1.3 mm, at least 1 mm, at least 0.8 mm, at least 0.7 mm, at least 0.5 mm or at least 0.3 mm.

[0120] In some embodiments, the cross-sectional thickness of the third pane is: 0.3 mm to less than or equal to 2 mm thick.

[0121] In some embodiments, the cross-sectional thickness of the first gas cavity is: 4 mm thick to less than or equal to 20 mm thick. In some embodiments, the cross-sectional thickness of the first gas cavity is: at least 5 mm; at least 7 mm; at least 10 mm; at least 12 mm; at least 14 mm; at least 16 mm; at least 18 mm; or at least 20 mm. In some embodiments, the cross-sectional thickness of the first gas cavity is: less than or equal to 7 mm; less than or equal to 10 mm; less than or equal to 12 mm; less than or equal to 14 mm; less than or equal to 16 mm; less than or equal to 18 mm; or less than or equal to 20 mm.

[0122] In some embodiments, the cross-sectional thickness of the second gas cavity is: 4 mm to less than or equal to 20 mm thick.

[0123] In some embodiments, the cross-sectional thickness of the first gas cavity is: at least 5 mm; at least 7 mm; at least 10 mm; at least 12 mm; at least 14 mm; at least 16 mm; at least 18 mm; or at least 20 mm. In some embodiments, the cross-sectional thickness of the second gas cavity is: less than or equal to 7 mm; less than or equal to 10 mm; less than or equal to 12 mm; less than or equal to 14 mm; less than or equal to 16 mm; less than or equal to 18 mm; or less than or equal to 20 mm.

[0124] In some embodiments, the spacer is configured as a bead, and the bead is an extrudate (extruded in a hot-softened form) such that it can be dispensed / positioned from a nozzle onto one of the first pane, the second pane, or the third pane.

[0125] In some embodiments, one or more panes are configured with a coating. In some embodiments, the coating is selected from a low emissivity coating, an anti-reflective coating, or a combination thereof. In some embodiments, the low emissivity coating may be disposed on surface 22, 24, 32, 34, 42, or 44, or a combination thereof.

[0126] In some embodiments, the IGU is incorporated into a window with a frame having a seal. The seal is configured to fit around the IGU perimeter when assembled into the frame such that the seal fixedly engages the IGU into the frame.

[0127] The coefficient of linear thermal expansion (CTE) cited herein is measured using ASTM standard E831, "Standard Test Method for Linear Thermal Expansion of Solid Materials by Thermomechanical Analysis," ASTM E228, "Test Method for Linear Thermal Expansion of Solid Materials With a Push-Rod Dilatometer," or an equivalent. As cited herein, the coefficient of thermal expansion described herein is quantified as the coefficient of thermal expansion (CTE) measured in the temperature range of 0 - 300 °C.

[0128] As measured in the range from 0 °C to about 300 °C, the CTE of the third pane is less than 70×10 -7 / °C and greater than zero. In some embodiments, as measured in the range from 0 °C to about 300 °C, the CTE of the third pane is less than 50×10 -7 / °C and greater than zero. In some embodiments, as measured in the range from 0 °C to about 300 °C, the CTE of the third pane is less than about 35×10 -7 / °C and greater than zero.

[0129] The first and second panes are selected from soda-lime glass, borosilicate glass, alkaline earth borosilicate glass, or alkali-free borosilicate glass. The third pane is selected from soda-lime glass, borosilicate glass, alkaline earth borosilicate glass, or alkali-free borosilicate glass. Exemplary commercially available glass products include, but are not limited to EAGLE and Lotus TM NXT glass. In some embodiments, the first or second pane is a float product or a fusion draw product. The CTE of soda-lime glass is approximately 90×10-7 / °C. In comparison, as measured in the range of 0°C to about 300°C, the CTE of Corning EAGLE XG glass is approximately 32×10 -7 / °C, which is approximately one-third (1 / 3) of the CTE of soda-lime glass.

[0130] In some embodiments, the feature of edge warping can be a non-planar substrate visually observed to have an upwardly curled edge. In some embodiments, the feature of edge warping can be a visual distortion when attempting to view through the edge planar region, because the refractive index of the deformed / edge-warped portion of the substrate (i.e., the feature can be a non-planar substrate visually observed to have an upwardly curled edge) is different from the refractive index of the remaining portion (non-curled portion) of the substrate. In some embodiments, edge warping is distinguishable from bending because edge warping is a local deformation adjacent to the substrate edge (e.g., and can be manifested as an upward curl in response to contact with a locally hot material near the edge), while bending can act on the entire substrate or a portion thereof (not just related to the edge), and can cause end-to-end displacement (presented in a convex or concave manner), or cause a portion or the entire substrate to appear kinked or bent (completely different from the local region near the edge).

[0131] Although there is no standard test for edge lift / warping, there are some standards related to edge lift within a defined region near the edge with a defined limit (applicable to tempered glass). For example, one way to quantify edge warping can be the EU standard DIN EN 12150-1, which defines the edge lift / edge warping of tempered glass as the deformation within 100 mm of the edge, and for 3 mm tempered glass, the deformation does not exceed 0.5 mm. For thinner non-tempered glass, edge lift may be more pronounced but is still near the edge region. As another example, another way to quantify edge lift via visual distortion can be ASTM C1036 (for flat glass), which uses an angle-dependent visual inspection with a zebra board, but this standard has some perception limitations because building products (such as thin center-pane triple IGUs) may not exhibit / display measurable deformation at viewing angles ≤ 35°.

[0132] In some embodiments, the third pane is an architecturally sized substrate. The cross-sectional area (area size) of the IGU incorporating the third pane is at least 2'×5'; at least 3'×7'; or at least 4'×10', or larger.

[0133] In some embodiments, the edge warp is from zero to less than or equal to 3 mm; or from zero to less than or equal to 2 mm; or from zero to less than or equal to 1.5 mm; or from zero to less than or equal to 1 mm; or from zero to less than or equal to 0.7 mm; or from zero to less than or equal to 0.5 mm; or from zero to less than or equal to 0.3 mm. In some embodiments, the edge warp is from 0.05 mm to less than or equal to 3 mm; or from 0.1 mm to less than or equal to 2 mm; or from 0.25 mm to less than or equal to 1.5 mm.

[0134] In some embodiments, the edge warp in a substrate (e.g., the third substrate) in the IGU is: less than or equal to 3 mm; less than or equal to 2.5 mm; less than or equal to 2 mm; less than or equal to 1.5 mm; less than or equal to 1 mm; less than or equal to 0.5 mm; or less than or equal to 0.1 mm. In some embodiments, the edge warp in a substrate (e.g., the third substrate) in the IGU is: less than or equal to 2 mm; less than or equal to 1.7 mm; less than or equal to 1.5 mm; less than or equal to 1.3 mm; less than or equal to 1 mm; less than or equal to 0.7 mm; less than or equal to 0.5 mm; less than or equal to 0.3 mm; less than or equal to 0.1 mm; less than or equal to 0.07 mm; less than or equal to 0.05 mm; less than or equal to 0.03 mm; or less than or equal to 0.01 mm.

[0135] In some embodiments, the edge warp in a substrate (e.g., the third substrate) in the IGU is: at least 2.5 mm; at least 2 mm; at least 1.5 mm; at least 1 mm; at least 0.5 mm; or at least 0.1 mm.

[0136] In some embodiments, the edge warp in a substrate (e.g., the third substrate) in the IGU is: at least 2 mm; at least 1.7 mm; at least 1.5 mm; at least 1.3 mm; at least 1 mm; at least 0.7 mm; at least 0.5 mm; at least 0.3 mm; at least 0.1 mm; at least 0.07 mm; at least 0.05 mm; at least 0.03 mm; or at least 0.01 mm.

[0137] It should be understood that the various disclosed embodiments may relate to specific features, elements, or steps described in connection with the specific embodiments. It should also be understood that although a specific feature, element, or step is described in connection with one particular embodiment, it may be interchanged or combined with alternative embodiments in various combinations or arrangements not shown.

[0138] It should also be understood that, as used herein, the terms "the", "a", or "an" mean "at least one", and unless explicitly indicated to the contrary, should not be limited to "only one". Thus, for example, a reference to "a component" includes examples having one such "component" or two or more such "components" unless the context clearly indicates otherwise. Similarly, "a plurality" or "an array" is intended to mean two or more, such that an "array of components" or "a plurality of components" means two or more such components.

[0139] In this document, ranges can be expressed as from "about" a particular value and / or to "about" another particular value. When expressing such ranges, examples include from one particular value and / or to another particular value. Similarly, when a value is expressed as an approximation by use of the antecedent "about", it should be understood that the particular value forms another aspect. It should be further understood that each endpoint of a range is significant relative to the other endpoint and independent of the other endpoint.

[0140] Unless otherwise explicitly indicated, all numerical values expressed herein should be understood to include "about", whether or not so stated. However, it should be further understood that each recited numerical value is also considered with rigor, whether or not it is expressed as "about" that value. Thus, both "a size less than 100 nm" and "a size less than about 100 nm" include embodiments of "a size less than about 100 nm" as well as "a size less than 100 nm".

[0141] Unless otherwise explicitly stated, no method set forth herein is intended to be construed as requiring that its steps be performed in a particular order. Thus, where a method claim does not actually recite an order of its steps or where the steps are not otherwise specifically limited to a particular order in the claims or the specification, no particular order is intended to be inferred.

[0142] Although the transitional phrase "comprising" may be used to disclose various features, elements, or steps of a particular embodiment, it should be understood that alternative embodiments are implied, including those that may be described using the transitional phrases "consisting of" or "consisting essentially of". Thus, for example, the implied alternative embodiments of a device comprising A + B + C include embodiments in which the device consists of A + B + C and embodiments in which the device consists essentially of A + B + C.

[0143] It will be apparent to those skilled in the art that various modifications and alterations can be made to the present disclosure without departing from the spirit and scope thereof. Since those skilled in the art can conceive of modifications, combinations, sub - combinations, and alterations of the disclosed embodiments that incorporate the spirit and gist of the present disclosure, the present disclosure should be construed to cover all things falling within the scope of the appended claims and their equivalents.

[0144] Example: Proxy experiment for evaluating edge warping in thin glass:

[0145] Figure 3 Depicts the glass warpage produced by a high - temperature extruded TPS spacer applied to soda - lime glass. The edge warpage exhibited by soda - lime glass is undesirable and can result in visible optical distortion in the final IGU or window product and / or a higher incidence of on - site edge seal failure.

[0146] In IGU manufacturing, the extruded TPS is applied to the glass substrate at a high temperature above 100 °C (the TPS temperature during application can range from 110 °C to 130 °C). To better understand and quantify the edge warpage of thin glass substrates in contact with high - temperature extrudates at different CTEs, a surrogate experiment was conducted.

[0147] Since the effect of edge warpage on thinner glass is greater than that on thicker substrates, the experiment focused on thin glass (thickness < 1 mm) with two different CTEs, high CTE and low CTE.

[0148] For the high - CTE (soda - lime glass) samples, 11 samples were completed. For the low - CTE (aluminosilicate glass) samples, 10 samples were evaluated.

[0149] All samples were specimens measuring 12" × 12" and having a thickness of 0.7 mm. Edge warpage was measured at the same location along each sample edge (at approximately 6" (or the mid - position) along the sample edge). Although visually observed that the edges (especially the edges of SLG samples) had different degrees of edge warpage, measurements were taken at only 1 location along the sample. Edge warpage was measured by measuring the displacement of the pane edge relative to a flat surface when the pane was placed on a flat surface. Measurements were taken at the same location (mid - position between the edges) for each sample. Thus, as stated in the table below, although each of the high - CTE and low - CTE samples used the same measurement tool and method, the standard deviation of the SLG samples was larger. Without being bound by any mechanism or theory, the higher standard deviation of the high - CTE samples may be attributed to the qualitative data noted by the experimenter, i.e., compared to each low - CTE sample, the high - CTE samples exhibited a higher variation in edge warpage within each sample.

[0150] Although this experiment used metrics such as edge warping that are easy to determine and quantify, based on the specimen size and experimental design, edge warping or edge deformation in thin soda-lime glass can be quantified by the following: edge kinking, discontinuous seals in the resulting IGU and / or gas cavities, or other visual deformation issues based on visual observation when observing the cross-section of an IGU with edge warping through the center pane, as well as other ways to quantify the problems present in the thin high-CTE glass and thin low-CTE glass described herein.

[0151] Experimental data obtained using hot melt adhesive (at approximately 130 °C, the same manual extrusion process) for small sample sizes showed that for glass of the same thickness (0.7 mm), under the same extrusion conditions, the degree of warping of high-CTE glass (soda-lime glass) was three times greater than that of low-CTE glass. Some measurable edge warping occurred in all samples, as shown in the table below.

[0152] Sample number High CTE Low CTE 1 -0.66 -0.33 2 -0.34 -0.14 3 -0.83 -0.05 4 -0.86 -0.11 5 -0.44 -0.26 6 -1.11 -0.24 7 -0.95 -0.2 8 -0.46 -0.16 9 -0.91 -0.06 10 -0.6 -0.08 11 -0.48 --- Average value -0.69 -0.16 Standard deviation 0.24 0.09

[0153] The high-CTE glass exhibited edge warping up to 1.11 mm, while, in sharp contrast, the highest edge warping measured in the low-CTE samples was 0.33 mm. The highest edge warping measured in the low-CTE samples was still far lower than the average edge warping of 0.69 mm in the high-CTE samples. It should be noted that the average edge warping in the low-CTE samples was 0.16 mm, far lower than all the edge warping values measured in the high-CTE samples.

[0154] Although this was a bench-top experiment with manual deposition of the extrudate, it is expected that larger-scale building-size substrate manufacturing and higher TPS deposition rates (compared to the manual experiment) will retain these trends, and SLG exhibits increased edge warping, even higher than that of the low-CTE substrates. Without being bound by any specific mechanism or theory, it is believed that applying a heated adhesive (e.g., an extruded TPS spacer with an average deposition temperature in the range of at least 110 °C to less than or equal to 130 °C) causes locally high, non-uniform temperatures at the edges, which can lead to edge warping on soda-lime glass compositions with a higher CTE (e.g., CTE in the range of 85 - 95 × 10-7 / °C) when the glass thickness is less than 3 mm. It is believed that edge warping becomes more severe as the thickness decreases. On the other hand, in sharp contrast, the edge warping on the borosilicate glass evaluated herein (e.g., with a low CTE of approximately 32 × 10-7 / °C) shows significantly less edge warping even in the case of thin cross-sectional thicknesses.

[0155] Reference Numerals

[0156] IGU 10

[0157] First Gas Cavity 16

[0158] First gas chamber 18

[0159] First adduction amount 12

[0160] Second adduction amount 14

[0161] First pane 20

[0162] First side of the first pane 22

[0163] Second side of the first pane 24

[0164] Second pane 30

[0165] First side of the second pane 32

[0166] Second side of the second pane 34

[0167] Third pane 40

[0168] First side of the third pane 42

[0169] Second side of the third pane 44

[0170] First edge extension amount 46

[0171] Second edge extension amount 48

[0172] Spacer bead (extrusion) 50

[0173] First spacer 52

[0174] First side of the first spacer 54

[0175] Second side of the first spacer 56

[0176] Second spacer 60

[0177] First side of the second spacer 62

[0178] Second side of the second spacer 64

[0179] Coating (optionally: second side of the first pane and / or first side of the second pane)

Claims

1. A method of manufacturing an insulating glass unit (IGU), comprising: a. heating a third window pane to a preheat temperature, the third window pane having a thickness less than 2.5 mm and having a third coefficient of thermal expansion (CTE 3), b. applying a first heated adhesive bead to a first side of the third window pane, c. bringing a second side of a first window pane into contact with the heated adhesive bead, wherein the first window pane has a thickness of at least 2.5 mm and a first coefficient of thermal expansion (CTE 1), d. applying a second heated adhesive bead to a second side of the third window pane or a first side of a second window pane, e. bringing a first side of the second window pane into contact with the second heated adhesive bead, wherein the second window pane has a thickness of at least 2.5 mm and a second coefficient of thermal expansion (CTE 2), Additionally, wherein via the preheating step, the IGU is configured to have no edge warping in the third pane.

2. The method according to claim 1, wherein preheating further comprises heating the third pane to an average temperature of at least 60°C.

3. The method according to claim 1, wherein preheating further comprises heating the third pane to an average temperature of at least 90°C.

4. The method according to claim 1, wherein preheating further comprises heating the third pane to an average temperature in the range of at least 60°C to less than or equal to 120°C.

5. The method according to any one of claims 1 to 4, wherein the method further comprises mechanically constraining the third pane in a flattened configuration.

6. The method according to claim 5, wherein mechanically constraining the third pane further comprises evacuating across the second side of the third pane.

7. The method according to claim 6, wherein evacuating across the second side of the third pane further comprises engaging a plurality of vacuum holes having a negative pressure on a vacuum table.

8. The method according to claim 7, wherein the negative pressure is less than 0 to less than or equal to -1 atm.

9. The method according to any one of claims 6 to 8, wherein the vacuum table is further configured with a heating element such that preheating of the third pane is achieved via the heated vacuum table.

10. The method according to any one of claims 5 to 9, wherein mechanically constraining the third pane further comprises mechanically fixing at least a portion of the perimeter edge of the third pane to hold the third pane in a flattened configuration.

11. The method according to any one of claims 5 to 9, wherein mechanically fixing at least a portion of the perimeter edge of the third pane further comprises attaching the third pane to a support surface along the edge of the third pane via at least one edge fixing device.

12. The method according to claim 11, wherein mechanically fixing at least a portion of the perimeter edge of the third pane further comprises attaching the third pane to a support surface along at least two edges of the third pane via at least two edge fixing devices.

13. The method according to claim 12, wherein the edges are adjacent.

14. The method according to claim 12, wherein the edges are non - adjacent.

15. The method according to claim 10, wherein mechanically fixing at least a portion of the perimeter edge of the third pane further comprises attaching the third pane to a support surface along at least three edges of the third pane via at least three edge fixing means.

16. The method according to claim 10, wherein mechanically fixing at least a portion of the perimeter edge of the third pane further comprises attaching the third pane to a support surface along four edges of the third pane via at least four edge fixing means.

17. The method according to claim 10, wherein mechanically fixing at least a portion of the perimeter corner of the third pane further comprises attaching the third pane to a support surface along at least two corners of the third pane via at least two corner fixing means.

18. The method according to claim 17, wherein the corners are adjacent.

19. The method according to claim 17, wherein the corners are non - adjacent.

20. The method according to claim 10, wherein mechanically fixing at least a portion of the perimeter corner of the third pane further comprises attaching the third pane to a support surface along at least three corners of the third pane via at least three corner fixing means.

21. The method according to claim 10, wherein mechanically fixing at least a portion of the perimeter corner of the third pane further comprises attaching the third pane to a support surface along four corners of the third pane via four corner fixing means.

22. The method according to any one of claims 5 to 21, wherein the mechanical fixing means further comprises a bracket, a weight member, a clamp, a frame member, and / or a combination thereof.

23. The method according to any one of claims 1 to 22, wherein the method further comprises cooling at least a portion of the heat - affected zone in the third pane via a heat sink disposed in the support surface for passive cooling.

24. The method according to any one of claims 1 to 23, wherein the method further comprises cooling at least a portion of the heat - affected zone by actively cooling the heat - affected zone in the third pane.

25. The method according to claim 24, wherein the active cooling further comprises a support surface configured with one or more chambers, the one or more chambers being configured with a cooling medium for transfer so as to transfer heat from the heat - affected zone of the third pane to the support surface.

26. The method according to any one of claims 1 to 25, wherein the method comprises, after the contacting step, cooling the first heated adhesive bead to define a first spacer seal between the first pane and the third pane.

27. The method according to claim 26, wherein a first gas chamber is defined between the first pane, the third pane, and the first spacer seal.

28. The method according to any one of claims 1 to 27, wherein the method further comprises compressing the IGU by applying a compressive force on a first surface of the first pane and a second surface of the second pane.

29. The method according to claim 28, wherein the compressing further comprises compressing by engaging a plurality of rollers on a first side of the IGU while simultaneously bringing a second side of the IGU into contact with a support surface.

30. The method according to any one of claims 1 to 29, wherein the method comprises, after the contacting step, cooling the second heated adhesive bead to define a second spacer seal between the third pane and the second pane.

31. The method according to claim 30, wherein a second gas chamber is defined between the third pane, the second pane, and the second spacer seal.

32. The method according to any one of claims 1 to 31, wherein CTE 3 is less than CTE 1, and wherein CTE 3 is less than CTE 2.

33. The method according to any one of claims 1 to 32, wherein the composition of the third pane is different from the compositions of the first pane and the second pane.

34. The method according to any one of claims 1 to 33, wherein the third pane is borosilicate glass.

35. The method according to any one of claims 1 to 34, wherein the first pane and the second pane are soda-lime glass.

36. The method according to any one of claims 1 to 30, wherein CTE 3 is the same as CTE 1, and wherein CTE 3 is the same as CTE 2.

37. The method according to any one of claims 1 to 30, wherein the composition of the third pane is the same as the composition of the first pane and the composition of the second pane.

38. The method according to any one of claims 1 to 30, wherein the first pane, the second pane, and the third pane are made of soda-lime glass.

39. The method according to any one of claims 1 to 38, wherein the applying step further comprises guiding a formable softened adhesive bead onto the first side of the third pane.

40. The method according to claim 39, wherein the applying step further comprises extrusion.

41. The method according to any one of claims 1 to 40, wherein the first heated adhesive bead and the second heated adhesive bead further comprise a thermoplastic spacer material.

42. The method according to any one of claims 1 to 41, wherein the first heated adhesive bead and the second heated adhesive bead are configured with an average application temperature in the range of at least 100 °C to less than or equal to 130 °C.

43. The method according to any one of claims 1 to 42, wherein contacting the second pane further comprises adhering the adhesive to the second side of the first pane.

44. The method according to any one of claims 1 to 42, wherein the thickness of the third pane is less than or equal to 1.6 mm.

45. The method according to any one of claims 1 to 43, wherein the second pane has a thickness of at least 3 mm.

46. The method according to any one of claims 1 to 44, wherein the first pane has a thickness of at least 3 mm.

47. The method according to any one of claims 1 to 46, wherein at least one of the first pane and the second pane is strengthened by: tempering, heat strengthening or chemical strengthening.

48. The method according to claim 47, wherein both the first pane and the second pane are strengthened.

49. The method according to any one of claims 1 to 48, wherein the third pane is configured with a vertical inward amount and a horizontal inward amount.

50. The method according to any one of claims 1 to 48, wherein the third pane is configured with a vertical edge protrusion amount and a horizontal edge protrusion amount.

51. The method according to any one of claims 1 to 50, wherein the contacting step is completed in an environment or chamber having a first gas therein, such that the first gas is retained in the first gas chamber between the first pane and the third pane via the contacting step.

52. The method according to any one of claims 1 to 50, wherein the contacting step (d) is completed in an environment or chamber having a second gas therein, such that the second gas is retained in the second gas chamber between the third pane and the second pane via the contacting step.

53. The method according to claim 27, further comprising injecting a first gas into the first gas chamber.

54. The method according to claim 31, further comprising injecting a second gas into the second gas chamber.

55. The method according to any one of claims 28 or 31, further comprising injecting a first gas into the first gas chamber; and injecting a second gas into the second gas chamber, wherein the first gas and the second gas are the same gas or different gases.

56. A method of manufacturing an insulating glass unit (IGU), comprising: a. mechanically constraining a third pane in a flattened configuration, the third glass pane having a thickness less than 2.5 mm and having a third coefficient of thermal expansion (CTE3), b. applying a first heated adhesive bead to a first side of the third glass pane, c. bringing a second side of a first glass pane into contact with the heated adhesive bead, wherein the first glass pane has a thickness of at least 2.5 mm and a first coefficient of thermal expansion (CTE 1), d. applying a second heated adhesive bead to a second side of the third glass pane or a first side of a second glass pane, e. bringing a first side of a second glass pane into contact with the second heated adhesive bead, wherein the second glass pane has a thickness of at least 2.5 mm and a second coefficient of thermal expansion (CTE 2), a. Additionally, wherein, via a mechanical restraint step, the IGU is configured to have no edge warping or no visual distortion in the third pane.

57. The method according to claim 56, wherein prior to the contacting step, the method further comprises heating a third glass pane to a preheat temperature.

58. The method according to claim 56 or 57, wherein mechanically restraining the third pane further comprises evacuating across the second side of the third pane.

59. The method according to any one of claims 56 to 58, wherein mechanically restraining the third pane further comprises mechanically fixing at least a portion of the perimeter edge and / or corners of the third pane to hold the third pane in a flattened configuration.

60. The method according to any one of claims 56 to 59, wherein the method further comprises cooling at least a portion of the heat - affected zone in the third pane via a heat sink configured for passive cooling in the support surface.

61. The method according to any one of claims 56 to 60, wherein the method further comprises cooling at least a portion of the heat - affected zone by actively cooling the heat - affected zone in the third pane.

62. A method of manufacturing an insulating glass unit (IGU), comprising: a. Applying a first heated adhesive bead to a first side of a third glass pane, the third glass pane having a thickness of less than 2.5 mm and a third coefficient of thermal expansion (CTE3), b. While applying the first heated adhesive bead, cooling at least a portion of the third pane defined by the heat - affected zone of the third pane (e.g., the area in contact with and / or adjacent to the heated adhesive bead), c. Contacting a second side of a first glass pane with the heated adhesive bead, wherein the first glass pane has a thickness of at least 2.5 mm and a first coefficient of thermal expansion (CTE1), d. Applying a second heated adhesive bead to the second side of the third glass pane or the first side of a second glass pane, e. Optionally, while applying the second heated adhesive bead to the second side of the third pane, f. Contacting a first side of a second glass pane with the second heated adhesive bead, wherein the second glass pane has a thickness of at least 2.5 mm and a second coefficient of thermal expansion (CTE2), Additionally, wherein, via the cooling step, the IGU is configured to have no edge warping or no visual distortion in the third pane.

63. The method according to claim 62, wherein the method further comprises: Mechanically restrain the third pane in a flattened configuration.

64. The method according to claim 63, wherein mechanically restraining the third pane further comprises evacuating across the second side of the third pane.

65. The method according to claim 62 or 63, wherein mechanically constraining the third pane further comprises mechanically fixing at least a portion of the perimeter edge and / or corners of the third pane to hold the third pane in a flattened configuration.

66. The method according to any one of claims 62 to 65, further comprising preheating the third glass pane to a preheating temperature before the applying step.

67. The method according to any one of claims 62 to 66, wherein the method further comprises cooling at least a portion of the heat-affected zone in the third pane via a heat sink configured in the support surface for passive cooling.

68. The method according to any one of claims 62 to 67, wherein the method further comprises cooling at least a portion of the heat-affected zone by actively cooling the heat-affected zone in the third pane.

69. An insulating glass unit, comprising: a. A first glass pane having a first side and a second side, a first thickness of at least 2.5 mm, and CTE 1; b. A second glass pane having a first side and a second side, a second thickness of at least 2.5 mm, and CTE 2; and c. A third glass pane having a first side and a second side, a third thickness less than or equal to 2.5 mm, and CTE3; d. A first thermoplastic spacer positioned between the second side of the first pane and the first side of the third pane to define a first gas cavity having a first cavity depth; and e. A second thermoplastic spacer positioned between the second side of the third pane and the first side of the second pane to define a second gas cavity having a second cavity depth; wherein the IGU has no visually observable edge warping distortion on the third pane.

70. The IGU according to claim 69, wherein the third pane has a thickness of at least 0.3 mm to less than or equal to 2.2 mm.

71. The IGU according to claim 69, wherein the third pane has a thickness of at least 0.3 mm to less than or equal to 1.6 mm.

72. The IGU according to claim 69, wherein the third pane has a thickness of at least 0.3 mm to less than or equal to 1.3 mm.

73. The IGU according to claim 69, wherein the third pane has a thickness of at least 0.45 mm to less than or equal to 1 mm.

74. The IGU according to any one of claims 69 to 73, wherein CTE 3 is less than either CTE1 or CTE 2.

75. The IGU according to any one of claims 69 to 74, wherein the third pane is aluminosilicate glass.

76. The IGU according to any one of claims 69 to 75, wherein at least one of the first pane and the second pane is soda-lime glass.

77. The IGU according to any one of claims 69 to 75, wherein both the first pane and the second pane are soda-lime glass.

78. The IGU according to any one of claims 69 to 73, wherein CTE 3 is the same as any one of CTE1 and CTE 2.

79. The IGU according to any one of claims 69 to 73, wherein the third pane, the second pane, and the first pane are each made of soda-lime glass.

80. The IGU according to any one of claims 69 to 79, wherein the first gas cavity is configured with a gas selected from the following: air, krypton, argon, and a mixture of at least two of the foregoing gases.

81. The IGU according to any one of claims 69 to 80, wherein the second gas cavity is configured with a gas selected from the following: air, krypton, argon, and a mixture of at least two of the foregoing gases.

82. The IGU according to any one of claims 69 to 81, wherein the third pane has a vertical inward convergence compared to the first pane and the second pane.

83. The IGU according to any one of claims 69 to 82, wherein the third pane has a horizontal inward convergence compared to the first pane and the second pane.

Images