Compression Fit Grooved Spacers

Abstract

The spacer supports the first and second panes of the insulating unit and also compressively supports the third, inner pane between the first and second panes. The spacer defines a channel that receives the peripheral edge of the third pane. When the third pane is inserted into the channel, the spacer on either side of the channel neck deforms. Due to the resilience of the spacer material, the spacer material on either side of the channel neck compressively engages the third pane of glass. Thus, the spacer retains the inner spacer without the need for adhesive disposed within the channel. This configuration closes the channel against the pane, preventing the inner surface of the channel from being visible. This provides a desirable appearance to the interior of the insulating glass unit.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to and the benefit of U.S. Provisional Patent Application No. 62 / 901,120, filed September 16, 2019, the disclosure of which is incorporated herein by reference. [Background technology]

[0002] The present disclosure relates to insulating glass units, spacers for triple-sheet insulating glass units, methods for manufacturing spacers, and methods for manufacturing triple-sheet insulating glass units. internal The present invention relates to a spacer that compressively holds the third pane of the vehicle.

[0003] To increase the energy efficiency of homes and other buildings, multiple-pane insulating units are used. A multiple-pane insulating unit includes a pair of outer glazing panes separated by a spacer placed around or just inside the perimeter of the panes. The two panes cooperate with the spacer to form an insulating, sealed cavity filled with either air or an inert gas. One or more internal The pane may be held in a substantially parallel relationship to the outer glazing pane by a spacer assembly. internal The inner pane can be a separate pane of glass of the same thickness as the outer pane, a separate pane of glass thinner than the outer pane, or an inner film of thin flexible plastic, typically made of polyethylene terephthalate (PET). In triple units, internalThe panes divide a cavity into a pair of cavities, adding an additional layer of insulation between the outer and inner spaces. One method of forming a triple-pane insulating unit is to use two spacers between the three panes to form side-by-side, individually sealed insulating cavities. An example of this configuration is shown in Figures 4-7 of U.S. Patent 4,831,799. Another method of forming a triple-pane insulating unit is disclosed in U.S. Patent 6,295,788, which internal The panes are received in open slots defined by inserts held by rigid spacers. The use of such slots in thin inner panels presents manufacturing problems. A further method is disclosed in U.S. Pat. No. 8,534,019, which internal The panes are received by flexible fingers that project into the inwardly facing channels. Summary of the Invention [Problem to be solved by the invention]

[0004] The present disclosure provides a spacer for supporting first and second panes of an insulating glass unit, wherein the spacer also supports a third pane between the first and second panes. internalThe spacer compressively supports the third pane of glass. The spacer defines a channel that receives the peripheral edge of the third pane. The defined channel has a neck that connects the channel base to the interior surface of the spacer. In one configuration, the channel base has a maximum width greater than the thickness of the third pane, and the neck has a width less than the thickness of the third pane. This configuration requires spacer material on either side of the channel neck that can be deformed to allow the third pane to be inserted into the channel. The spacer is resilient. The resilience of the spacer material causes the spacer material on both sides of the channel neck to compressively engage the third pane of glass. Thus, the spacer retains the spacer on the interior side without the need for adhesive disposed within the channel. This arrangement confines the channel against the pane and obscures the interior surface of the channel, providing a desirable appearance for the interior portion of the insulating glass unit.

[0005] The present disclosure provides a thin, multi-pane unit that allows the triple pane unit to have the same overall thickness while having the same weight as a two pane unit. internal To provide an insulating glass unit having a pane.

[0006] The present disclosure provides a method for manufacturing a spacer comprising: internal A spacer configuration is provided with multiple channels that can receive panes to create an insulating glazing unit having three or more panes.

[0007] In one configuration, the spacer defines a channel offset inwardly from the center of the spacer, wherein the spacer material disposed along the channel neck is thinner than the spacer material disposed between the channel base and the outer surface of the spacer.

[0008] The present disclosure also provides an option where a material is placed within the channel and the edge of the third pane engages the material. The material can be an adhesive, sealant, or desiccant matrix. The channel configuration helps prevent this material from leaking out of the channel neck both before and after the third pane is inserted.

[0009] The present disclosure provides a method for forming a spacer having a channel capable of receiving the edge of a third pane of glass. The method includes extruding or otherwise forming an elongated spacer with a longitudinal opening that forms a channel base. The longitudinal opening has a width greater than the thickness of the pane to be inserted into the channel. The spacer is then slit from its inner surface into the channel to form a neck having a width less than the thickness of the pane to be inserted into the neck of the channel.

[0010] Individual features described herein can be combined in different combinations than those specifically described below to form different configurations of the devices of the present disclosure. The foregoing non-limiting aspects of the present disclosure, as well as other aspects, are described in more detail below. A more complete understanding of the devices, assemblies, and methods can be obtained by reference to the accompanying drawings, which are not intended to illustrate the relative sizes and dimensions of the assemblies. In these drawings and the following description, like numerical designations refer to components of like function. Specific terminology used in the description is intended to refer only to the specific structure of the embodiments selected for illustration in the drawings and is not intended to define or limit the scope of the present disclosure. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a cross-sectional view of a triple pane insulating glass unit with the center section cut away. [Figure 2] FIG. 2 is a cross-sectional view of an exemplary spacer body. DETAILED DESCRIPTION OF THE INVENTION

[0012] Detailed Description of Disclosure An exemplary insulating unit is generally designated in the accompanying drawings by the reference numeral 2. The insulating unit 2 includes first and second outer panes, designated 4 and 6, and is supported by a perimeter spacer assembly 10. internal and a third pane 8. Panes 4, 6, and 8 can be glass or other materials such as transparent or translucent polymer panes. The combination of outer panes 4 and 6 and spacer assembly 10 can be filled with air or an inert gas. internal An insulating chamber is defined. internal The third pane of internal The insulating chamber is divided into a first and a second portion, and the first and second portions are internal are in fluid communication around the edge of the third pane 8. In some embodiments, openings can be formed in the third pane 8 to provide fluid communication between different portions of the internal insulating chamber. internal The third pane 8 can be provided substantially thinner (0.5 mm to 2.0 mm, e.g., 0.7 mm) than panes 4 and 6, so that the thickness and weight of unit 2 is the same as or not significantly greater than a conventional double unit. The first and second panes 4 and 6 can be provided in thicknesses of 2 mm to 10 mm, with exemplary thicknesses being 3 mm to 4 mm and 9 mm to 10 mm. These dimensions are provided by way of example. Other thicknesses are also possible for the outer panes. internal Similar proportions can be used between the panes.

[0013] The spacer assembly 10 includes a spacer body 20 made from a dense or foamed elastic material. For example, the material can be primarily made of rubber, silicone, or EPDM. The spacer body 20 can have the composition of a spacer sold under the trademark SUPERSPACE. The material can be permeable to water vapor or impermeable. If the material is permeable, a desiccant can be disposed throughout the spacer body 20. Depending on the moisture and gas permeability of the material used behind the spacer assembly 10, the spacer assembly 10 can include a vapor and gas barrier 22 applied to the outer surface 24 of the spacer body. This barrier 22 can be a coating applied directly to the spacer body 20 or a separate sheet 22 adhered to the spacer body 20. The vapor barrier 22 can be a metal foil, a plastic sheet, or a metalized plastic film.

[0014] The flexible or semi-rigid foam spacer body 20 can be manufactured from thermoplastic or thermosetting plastics. Suitable thermosetting plastics include silicone and polyurethane. Suitable thermoplastic materials include thermoplastic elastomers such as Santoprene. Foamed silicone can also be used. Advantages of silicone foam include excellent durability, minimal outgassing, low compression set, excellent resilience, high temperature stability, and low temperature flexibility. An additional advantage of silicone foam is that the material is moisture permeable, allowing water vapor to easily reach the desiccant material within the foam.

[0015] During foam production, desiccants are added as fillers. The type of desiccants used is typically 3A molecular sieve zeolite to remove water vapor, with smaller amounts of 13X molecular sieve, silica gel, or activated carbon being used to remove organic vapors. Overall, the amount of desiccants used should match the amount typically incorporated into conventional sealed glazing units.

[0016] The interior surface 34 of the spacer body 20 must be UV resistant to prevent the material from powdering or flaking after prolonged exposure to sunlight. Depending on the material used, various special measures can be taken to provide the required long-term durability, such as adding UV stabilizers to the material or covering or coating the interior surface 34 of the spacer body 20. Durable materials such as silicone have excellent UV resistance and do not require special coatings or coverings of the interior surface.

[0017] An adhesive 26 connects the spacer body 20 to the interior surfaces of the panes 4 and 6. The adhesive can be a pressure-sensitive acrylic adhesive. The pressure-sensitive adhesive 26 is pre-applied to both sides of the spacer body 20. There are five primary criteria when selecting an appropriate adhesive: high tack, shear strength, heat resistance, UV resistance, and non-outgassing. While a variety of adhesives can be used with the silicone foam spacer body, the adhesive can be a UV-resistant pressure-sensitive acrylic adhesive.

[0018] The spacer assembly 10 is lined with a sealant 28. The sealant 28 may be a polyisobutene-based sealant. The sealant 28 is disposed within a channel defined on the exterior of the spacer assembly 10 between the first and second panes 4 and 6.

[0019] The spacer body 20 is internal A channel is defined that resiliently retains an outer edge portion of the third pane 8. The channel includes an open channel base 30 with a channel neck 32 connecting the channel base 30 to an interior surface 34 of the spacer body 20. The center of the channel base 30 is offset inwardly within the spacer body 20 from the centerline of the spacer body 20 (see dimension 40 in FIG. 2 ). internal Before the third pane 8 is placed within the channel base 30, the channel neck 32 is internal a spacer body (20) having a width less than the thickness of the pane (8) and defining a channel neck (32); Shoulder part 36 is internalThe shoulder portions 36 are disposed on the inside of the channel base 30, the outside of the channel neck 32, and the outside of the inner surface 34. internal The third pane of When sealed, the shoulder part 36 provides a closed, smooth appearance to the inner surface 34. Since the inner surface 34 is visible, a closed, smooth appearance is a desirable appearance for the spacer body 20.

[0020] The channel base 30 can be provided in different cross-sectional shapes, such as circular, triangular, or rectangular. In an exemplary configuration, the channel base 30 is oval, with the length dimension aligned with the height of the spacer body 20. This allows the outer edge of the panel 8 to be positioned directly at the narrow end (or seat) of the oval along the channel neck 32. Channel bases 30 of other shapes can have seats aligned with the neck 32, and recesses, such as triangular corners or otherwise, can be defined in the walls defining the channel base. The channel base can be centered across the width of the spacer body 20, but offset inwardly such that the center of the oval is offset toward the inner surface 34 such that the distance between the inner surface 34 and the inner portion of the oval is about half or less than half the distance between the outer surface 24 and the outer portion of the oval (see dimension 40). The width of the channel base 30 can be internal the thickness of the third pane 8 is greater than that of the

[0021] In some alternative configurations, a material can be placed within the channel base 30. The material can be an adhesive or a desiccant matrix. Shoulder part 36 serves to retain material within the channel base 30.

[0022] In another exemplary configuration, the spacer body 20 may include a plurality of internal A plurality of spaced apart channels are defined for holding the panes.

[0023] Die designs are provided to form dense or foamed IG spacers with voids of any shape within the spacer body in one or more locations. In the first application, the voids are oval in the top / inner half (eyesight side) of the spacer, located left and right of center.

[0024] To form the spacer, the desired profile designed to define the spacer body 20 with openings defining the channel bases 30 is extruded / pumped and cured. The profile is processed and laminated as needed for the application. The spacer body 20 is then slit from the inner surface 34 to the openings 30, internal The slitting defines a channel for receiving the third pane 8 of the die. This slitting creates a groove of the desired width in the spacer at the center of the opening 30 formed by the die and spacer profile. The groove becomes a channel neck 32, which can be much thinner than the thickness of the pane 8. By sliding it into the open channel base 30, internal The third pane 8 of glass may define a narrow groove that compressively engages the third pane 8 of glass. The pane of glass is inserted into the groove and held in place by a compression fit via the final spacer structure.

[0025] In the foregoing description, specific terms have been used for brevity, clarity, and understanding. Such terms are used for descriptive purposes and are intended to be broadly interpreted, so that no unnecessary limitations should be implied therefrom beyond the requirements of the prior art. Furthermore, the above description and accompanying illustrations are merely exemplary. The invention is not limited to the exact details shown or described. Throughout the description and claims of this specification, the words "comprise" and "comprises," as well as variations of the word "comprises," are not intended to exclude additives, components, integers, or steps.

Claims

1. Assembly (2) comprising: a first pane (4) and a second pane (6) held by a peripheral spacer assembly (10) that define an internal insulating chamber, the first pane (4) having a thickness and the second pane (6) also having a thickness; a third inner pane (8) held by a spacer assembly (10) within an inner insulating chamber, the third inner pane (8) having a thickness that is less than the thicknesses of the first pane (4) and the second pane (6); The peripheral spacer assembly (10) includes a resilient spacer body (20) made from a foamed resilient material that is permeable to water vapor, a desiccant material disposed throughout the resilient spacer body (20), the resilient spacer body (20) having an inner surface (34) facing the interior insulating chamber, first and second side surfaces, and an outer surface (24); The inner surface of the first pane (4) is adhered to the first side of the elastic spacer body (20) by an adhesive (26); The inner surface of the second pane (6) is adhered to the second side of the elastic spacer body (20) by an adhesive (26); The resilient spacer body (20) defines a channel for receiving an edge portion of the third inner pane (8), the channel being defined by a channel base (30) and a channel neck (32) connecting an inner surface (34) of the resilient spacer body (20) to the channel base (30); and The resilient spacer body (20) includes a shoulder portion (36) bounded by the inner surface (34), the channel neck (32), and the channel base (30) that compressively engages the third inner pane (8).

2. The assembly of claim 1, wherein said resilient spacer body (20) has a width and said channel neck (32) is centered relative to the width of said resilient spacer body (20).

3. 2. The assembly of claim 1, wherein the elastic spacer body (20) has a height and a center, and the channel base (30) has a center offset inside the center of the height of the elastic spacer body (20).

4. 2. The assembly of claim 1, wherein the channel base has a width greater than a thickness of the third inner pane (8).

5. 5. The assembly of claim 4, wherein the channel base (30) defines a seat for the third inner pane (8), the seat being along a channel neck (32).

6. 2. The assembly of claim 1, wherein the third inner pane (8) divides the inner insulating chamber into a first portion and a second portion, the first and second portions of the inner insulating chamber having fluid communication around an edge of the third inner pane (8).

7. 2. The assembly of claim 1, wherein the third inner pane (8) divides the inner insulating chamber into a first portion and a second portion, the first and second portions of the inner insulating chamber having fluid communication through an opening defined by the third inner pane (8).

8. An assembly as described in claim 1, further comprising a sealant disposed within a channel defined between an outer surface of the spacer assembly (10) and the first pane (4) and the second pane (6).

9. The assembly of claim 1 , wherein the adhesive is an acrylic adhesive.

10. The assembly of claim 1 further comprising a water vapor barrier connected to an outer surface of the resilient spacer body (20).

11. A perimeter spacer assembly (10) for use in forming a triple pane insulating glass unit, comprising: The triple pane insulating glass unit includes a first pane (4) and a second pane (6) having a thickness, which define an interior insulating chamber and are held together by a perimeter spacer assembly (10); a third inner pane (8) having a thickness, and the peripheral spacer assembly (10) includes: a resilient spacer body (20) made from a foamed resilient material that is permeable to water vapor, with a desiccant disposed throughout the resilient spacer body (20), the resilient spacer body (20) having an inner surface (34) facing an interior insulating chamber, first and second sides, and an outer surface (24); The inner surface of the first pane (4) is adhered to the first side of the elastic spacer body (20) by an adhesive (26); The inner surface of the second pane (6) is adhered to the second side of the elastic spacer body (20) by an adhesive (26); The resilient spacer body (20) defines a channel adapted to receive an edge portion of the third inner pane (8), the channel being defined by a channel base (30) and a channel neck (32) connecting an inner surface of the resilient spacer body (20) to the channel base; and The resilient spacer body (20) includes a shoulder portion (36) bounded by the inner surface (34), the channel neck (32), and the channel base (30) that compressively engages the third inner pane (8).

12. 12. The assembly of claim 11, wherein the resilient spacer body (20) has a width and the channel neck is centered relative to the width of the resilient spacer body (20).

13. 12. The assembly of claim 11, wherein the elastic spacer body (20) has a height and a center, and the channel base (30) has a center offset inside the center of the height of the elastic spacer body (20).

14. The assembly of claim 11, wherein the channel base (30) has a width greater than the channel neck (32).

15. 15. The assembly of claim 14, wherein the channel base (30) defines a seat for a third inner pane (8), the seat being along a channel neck (32).

16. The assembly of claim 11 , wherein the adhesive is an acrylic adhesive.

17. The assembly of claim 11, further comprising a water vapor barrier connected to an outer surface of the resilient spacer body (20).

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