Electrical connections and / or related methods for providing power inside an insulating glass unit

Abstract

Certain exemplary embodiments relate to an insulating glass (IG) unit. A spacer is interposed between a first substrate and a second substrate. The spacer serves to maintain the substrates in a substantially parallel, spaced-apart relationship and define a gap between the substrates. A first exterior surface and a second exterior surface of the spacer face the interior surfaces of the first substrate and the second substrate, respectively. A third exterior surface and a fourth exterior surface of the spacer face toward and away from the cavity, respectively. A membrane is provided on at least a portion of the fourth exterior surface of the spacer. Pins protrude through the membrane through holes in the third and fourth exterior surfaces of the spacer. The pins are formed from a conductive material. A structural seal for the IG unit is provided on the exterior of the spacer and at least partially surrounds the portions of the pins protruding through the membrane.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Patent Application No. 16 / 947,006, filed July 15, 2021, the entire contents of which are incorporated herein by reference.

[0002] FIELD OF THE INVENTION Certain exemplary embodiments of the present invention relate to techniques and / or related methods for providing electrical power to the interior cavity of an insulating glass unit (IG unit or IGU). For example, certain exemplary embodiments of the present invention relate to powering electrically potential-driven shades and / or LED lights that may be used with an IG unit, IG units including such shades, and / or methods of manufacturing the same. Background Art and Summary of the Invention

[0003] The building sector is known for its high energy consumption, which has been shown to represent 30-40% of global primary energy consumption. Operational costs such as heating, cooling, ventilation, and lighting account for a large portion of this consumption, especially in older structures built to less rigorous building codes for energy efficiency.

[0004] Windows, for example, provide natural light, fresh air, access, and connection to the outside world. However, they often represent a significant source of wasted energy. With the growing trend toward increased use of architectural windows, balancing the conflicting interests of energy efficiency and human comfort is becoming increasingly important. Furthermore, concerns about global warming and carbon dioxide emissions are driving the development of new energy-efficient glazing systems.

[0005] In this regard, windows are typically the "weak link" in a building's insulation, and when one considers modern building designs that often include entire glass facades, it becomes clear that having better insulating windows would be advantageous in terms of controlling and reducing energy waste. The development of highly insulating windows therefore has significant environmental and economic benefits.

[0006] Insulating glass units (IG units or IGUs) have been developed to improve the insulation of buildings and other structures. FIG. 1 is a cross-sectional schematic diagram of an exemplary IG unit. In the exemplary IG unit of FIG. 1, a first substrate 102 and a second substrate 104 are substantially parallel and spaced apart from one another. A spacer system 106 is provided around the periphery of the first substrate 102 and the second substrate 104 to help maintain the substrates in a substantially parallel, spaced apart relationship and define a gap or space 108 between the substrates. The gap 108 may optionally be at least partially filled with an inert gas (e.g., Ar, Kr, Xe, etc.), for example, to improve the insulating properties of the overall IG unit. In some cases, an optional outer seal may be provided in addition to the spacer system 106.

[0007] Windows are an inherent element in most buildings in that they have the ability to "energize" a building in the form of winter solar gain and year-round daylight. However, current window technology often leads to excessive heating costs in the winter, excessive cooling in the summer, and often fails to capture the benefits of daylight, allowing the light to be dimmed or turned off in many commercially available light sources.

[0008] Thin film technology is one promising way to improve window performance. Thin films can be applied, for example, directly to glass during manufacturing or onto polymer webs, which can be retrofitted to existing windows at correspondingly lower costs. Progress has been made over the past two decades, primarily by lowering the U-value of windows through the use of static or "passive" low-emissivity (low-E) coatings, as well as by reducing the solar heat gain coefficient (SHGC) through the use of spectrally selective low-E coatings. Low-E coatings can be used in conjunction with IG units, such as those shown in and described with reference to Figure 1. However, further enhancements are possible.

[0009] For example, it will be appreciated that it would be desirable to provide more dynamic IG unit options that take into account the desire to provide improved insulation to buildings, etc., take advantage of the ability of the sun to "energize" the interior of a building, and also provide privacy on a more "on-demand" basis. It will be appreciated that such products would also be desirable to have a pleasing aesthetic appearance.

[0010] Certain exemplary embodiments address these and / or other concerns. For example, certain exemplary embodiments of the present invention relate to potential-driven shades that may be used with IG units, IG units that include such shades, and / or methods of making the same.

[0011] In certain exemplary embodiments, an insulating glass (IG) unit is provided. A first substrate and a second substrate are provided. A spacer is interposed between the first substrate and the second substrate, maintaining the first substrate and the second substrate in a substantially parallel, spaced-apart relationship and serving to define a cavity between the first substrate and the second substrate. A first outer surface of the spacer faces an inner surface of the first substrate, a second outer surface of the spacer faces an inner surface of the second substrate, a third outer surface of the spacer faces the cavity, and a fourth outer surface of the spacer faces away from the cavity. A membrane is provided on at least a portion of the fourth outer surface of the spacer. Pins pass through holes in the third and fourth outer surfaces of the spacer and protrude through the membrane, the pins being formed from a conductive material. A structural seal for the IG unit is provided on the exterior of the spacer and at least partially surrounds a portion of the pin protruding through the membrane.

[0012] In certain exemplary embodiments, a method for manufacturing an insulating glass (IG) unit is provided, the method including: having a spacer, the spacer including a first exterior surface, a second exterior surface, a third exterior surface, and a fourth exterior surface; applying a film to the fourth exterior surface of the spacer; inserting a pin through the third exterior surface and the fourth exterior surface of the spacer and through the film applied to the fourth exterior surface of the spacer, the pin including a conductive material; and, in manufacturing the IG unit, sealing the first substrate and the second substrate together with the spacer provided therebetween, the first exterior surface of the spacer facing an inner surface of the first substrate, the second exterior surface of the spacer facing an inner surface of the second substrate, the third exterior surface of the spacer facing a cavity of the IG unit, and the fourth exterior surface of the spacer facing away from the cavity of the IG unit; and forming an outer structural seal for the IG unit using a structural sealant provided around an exterior of the spacer.

[0013] In certain exemplary embodiments, an insulating glass (IG) unit is provided. A first substrate and a second substrate each have an inner major surface and an outer major surface, with the inner major surface of the first substrate facing the inner major surface of the second substrate. A spacer system serves to maintain the first substrate and the second substrate in a substantially parallel, spaced-apart relationship relative to one another and define a gap therebetween. One or more lighting elements are provided within the gap. A dynamically controllable shade is interposed between the first substrate and the second substrate, the shade including a first conductive layer provided directly or indirectly on the inner major surface of the first substrate, and a shutter including at least one polymer substrate, first and second conductive coatings, and first and second dielectric layers. The at least one polymer substrate is extendable to a shutter-closed position and retractable to a shutter-open position. The first conductive coating and / or the second conductive coating can be electrically connected to a power source that is controllable to set a potential difference to create a first electrostatic force that drives the at least one polymer substrate to a shutter-closed position.

[0014] Methods of producing IG units according to the previous paragraph and techniques described herein are also contemplated.

[0015] In certain exemplary embodiments, a method for operating an electronic device located within an IG unit is provided.

[0016] In certain exemplary embodiments, a method of operating a dynamic shade in an insulating glass (IG) unit is provided, the method including having an IG unit made in accordance with the techniques disclosed herein and selectively activating a power source to move a polymer substrate between a shutter-open position and a shutter-closed position.

[0017] The features, aspects, advantages, and example embodiments described herein may be combined to realize further embodiments.

[0018] These and other features and advantages may be better and more completely understood by reference to the following detailed description of illustrative embodiments taken in conjunction with the drawings. [Brief explanation of the drawings]

[0019] [Figure 1] 1 is a cross-sectional schematic diagram of an exemplary insulating glass unit (IG unit or IGU).

[0020] [Figure 2] 1 is a cross-sectional schematic diagram of an exemplary IGU incorporating a voltage-driven shade that may be used in connection with certain exemplary embodiments.

[0021] [Figure 3] 3 is a cross-sectional view illustrating exemplary on-glass components of the example IGU of FIG. 2 that enable shuttering, according to certain exemplary embodiments.

[0022] [Figure 4] 3 is a cross-sectional view of an example shutter from the example IGU of FIG. 2, in accordance with certain example embodiments.

[0023] [Figure 5] FIG. 10 is a flow diagram with an example process for forming electrical connections to provide power to the interior of an IG unit cavity, according to certain example embodiments.

[0024] [Figure 6] 10A-10C are schematic cross-sectional views illustrating how electrical connections can be used to provide power to the interior of an IG unit cavity, according to certain exemplary embodiments.

[0025] [Figure 7] 1 is a schematic diagram of a dynamic shade provided within a window frame, in accordance with certain example embodiments;

[0026] [Figure 8]8 is a schematic diagram of an LED or other lighting element being used to illuminate the extended dynamic shade from the example of FIG. 7, in accordance with certain exemplary embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0027] Certain exemplary embodiments of the present invention relate to potential-driven shades that may be used with IG units, IG units including such shades, and / or methods of manufacturing the same. Referring now more particularly to the drawings, FIG. 2 is a cross-sectional schematic diagram of an exemplary insulated glass unit (IG unit or IGU) incorporating a potential-driven shade that may be used in connection with certain exemplary embodiments. More specifically, FIG. 2 is similar to FIG. 1 in that substantially parallel, spaced-apart first and second glass substrates 102 and 104 are separated from one another using a spacer system 106, with a gap 108 defined therebetween. A first potential-driven shade 202a and a second potential-driven shade 202b are provided within the gap 108 adjacent inner major surfaces of the first and second substrates 102 and 104, respectively. As will become clear from the description provided below, the shades 202a and 202b are controlled by the creation of a potential difference between the shades 202a and 202b and conductive coatings formed on the inner surfaces of the substrates 102 and 104. Also, as will become clear from the description provided below, each shade 202a and 202b may be fabricated using a polymer film coated with a conductive coating (e.g., a coating including a layer including Al, Cr, ITO, etc.) Aluminum-coated shades may provide partial to complete reflection of visible light and up to a significant amount of total solar energy.

[0028] The shades 202a and 202b are normally retracted (e.g., rolled up) but rapidly extend (e.g., unfold) when an appropriate voltage is applied to cover at least a portion of the substrates 102 and 104, e.g., like "traditional" blinds. The rolled-up shades may have a very small diameter, typically much smaller than the width of the gap 108 between the first substrate 102 and the second substrate 104, allowing them to function therebetween and be essentially hidden from view when rolled up. The unfolded shades 202a and 202b strongly adhere to the adjacent substrates 102 and 104.

[0029] The shades 202a and 202b extend from a recessed configuration to an extended configuration along all or a portion of the vertical length of the visible or "frame" region of the substrates 102 and 104. In the recessed configuration, the shades 202a and 202b have a first surface area that substantially allows radiation transmission through the frame region. In the extended configuration, the shades 202a and 202b have a second surface area that substantially controls radiation transmission through the frame region. The shades 202a and 202b may have a width that extends across all or a portion of the horizontal width of the frame region of the substrates 102 and 104 to which they are attached.

[0030] Each shade 202a and 202b is disposed between the first substrate 102 and the second substrate 104, and preferably each is attached at one end to the inner surface of the substrate (or to a dielectric or other layer disposed on the substrate), near the top of the substrate. An adhesive layer may be used in this regard. In FIG. 2, the shades 202 and 204 are shown partially deployed (partially extended). The shades 202a and 202b, and any adhesive layer or other attachment structure, are preferably hidden from view, such that they are only visible when the shades 202a and 202b are at least partially deployed.

[0031] The diameter of the fully wound-up shade is preferably about 1 to 5 mm, but in certain exemplary embodiments it may be greater than 5 mm. Preferably, the diameter of the wound-up shade is less than or equal to the width of the gap 108, which is typically about 10 to 15 mm, in order to facilitate rapid and repeated deployment and winding-up operations. In the embodiment of FIG. 2, two shades 202a and 202b are shown, but it will be understood that in certain exemplary embodiments only one shade may be provided, and that one shade may be provided on the inner surface of either the inner or outer substrate 102 or 104. In an exemplary embodiment with two shades, the combined diameter is preferably less than or equal to the width of the gap 108, for example, to facilitate the deployment and winding-up operations of both shades.

[0032] An electronic controller may be provided to assist in driving the shades 202a and 202b. The electronic controller may be electrically connected to the shades 202a and 202b and the substrates 102 and 104, for example, via suitable lead wires. The lead wires can be made invisible through the assembled IG unit. The electronic controller is configured to provide an output voltage to the shades 202a and 202b. An output voltage in the range of about 100 to 800 V DC (for example, 100 to 500 V DC or 300 to 800 V DC) can be used to drive the shades 202a and 202b in certain exemplary embodiments. In this regard, an external AC or DC power source, a DC battery, etc. may be used. It will be understood that higher or lower output voltages may be provided depending on manufacturing parameters and materials, including those of the shades 202a and 202b, the layers on the substrates 102 and 104, etc.

[0033] The controller may be coupled to a manual switch, a remote (e.g., wireless) control, or other input device, for example, to indicate whether the shades 202a and 202b should be retracted or extended. In certain exemplary embodiments, the electronic controller may include a processor operably coupled to a memory that stores instructions for receiving and decoding control signals, which selectively apply voltages to control the extension and / or retraction of the shades 202a and 202b. Additional instructions may be provided that enable other functions to be realized. For example, timers may be provided so that the shades 202a and 202b can be programmed to extend and retract at user-specified or other times, temperature sensors may be provided so that the shades 202a and 202b can be programmed to extend and retract when user-specified indoor and / or outdoor temperatures are reached, and light sensors may be provided so that the shades 202a and 202b can be programmed to extend and retract based on the amount of light outside the structure.

[0034] As mentioned above, although two shades 202a and 202b are shown in FIG. 2, certain exemplary embodiments may incorporate only a single shade. Additionally, as noted above, such shades may be designed to extend vertically and horizontally along and substantially throughout the entire IG unit, and different exemplary embodiments may include shades that cover only the portion of the IG unit in which they are located. In such cases, multiple shades may be provided to allow for more selectable ranges for simulating a flat shutter, taking into account internal or external structures such as manifolds.

[0035] In certain exemplary embodiments, a locking restraint may be disposed at the bottom of the IGU, for example, along the width of the IGU, to help prevent the shade from deploying its entire length. The locking restraint may be made from a conductive material, such as metal. The locking restraint may also be coated with a low-dissipation polymer, such as, for example, polypropylene, fluorinated ethylene propylene (FEP), or polytetrafluoroethylene (PTFE).

[0036] Exemplary details of the operation of shades 202a and 202b are provided in connection with FIGS. 3-4. More specifically, FIG. 3 is a cross-sectional view illustrating exemplary "on-glass" components of the example IGU of FIG. 2 that enable shutter operation, according to certain example embodiments, and FIG. 4 is a cross-sectional view of an exemplary shutter of the example IGU of FIG. 2, according to certain example embodiments. FIG. 3 illustrates a glass substrate 302 that may be used for either or both of substrates 102 and 104 of FIG. 2. Glass substrate 302 supports on-glass components 304 and shutter 312. In certain example embodiments, conductors 404 may be closer to substrate 302 than ink layer 406 when unwound. In other example embodiments, this configuration may be reversed, such that conductors 404 may be farther from substrate 302 than ink layer 406 when unwound, for example.

[0037] The on-glass component 304 includes a transparent conductor 306 along with a dielectric material 308, which may be adhered to the substrate 302 via a transparent, low-haze adhesive 310 or the like. These materials are preferably substantially transparent. In certain exemplary embodiments, the transparent conductor 306 is electrically connected to leads to a controller via terminals. In certain exemplary embodiments, the transparent conductor 306 functions as a fixed electrode of a capacitor, and the dielectric material 308 functions as a dielectric for the capacitor. In such cases, a dielectric or insulator film is provided directly or indirectly on the first conductive layer, and the dielectric or insulator film is separate from the shutter.

[0038] It will be appreciated that in certain exemplary embodiments, it is possible to place all of the dielectric layers on the shade, thereby exposing a bare conductive (flat) substrate, such as a glass substrate supporting the conductive coating. For example, in certain exemplary embodiments, the polymer film insulator 308 may be provided / integrated as part of the shutter 312, rather than being provided / integrated as part of the substrate 302. That is, the shutter 312 further supports the dielectric or insulator film 308 thereon, such that when the at least one polymer substrate is in the shutter-closed position and the shutter is extended, the dielectric or insulating film is in direct physical contact with the first conductive layer with no other layers between them.

[0039] The transparent conductor 306 may be formed from any suitable material, such as, for example, ITO, tin oxide (e.g., SnO2, or other suitable stoichiometry). The transparent conductor 306 may have a thickness of 10-500 nm in certain exemplary embodiments. The dielectric material 308 may be a low-dissipation polymer in certain exemplary embodiments. Suitable materials include, for example, polypropylene, FEP, PTFE, polyethylene terephthalate (PET), polyimide (PI), and polyethylene napthalate (PEN). The dielectric material 308 may have a thickness of 4-25 micrometers in certain exemplary embodiments. The thickness of the dielectric material 308 may be selected to balance the reliability of the shade (e.g., because a thinner dielectric layer typically reduces reliability, while a thicker dielectric layer typically requires a higher applied voltage for operation).

[0040] As is known, many low emissivity (low-E) coatings are electrically conductive. Thus, in certain exemplary embodiments, a low-E coating may be used in place of the transparent conductor 306. The low-E coating may be a silver-based low-E coating, for example, one, two, three, or more layers comprising Ag may be sandwiched between dielectric layers. In such cases, the need for adhesive 310 may be reduced or eliminated entirely.

[0041] The shutter 312 may include an elastic layer 402. In certain exemplary embodiments, a conductor 404 may be used on one side of the elastic layer 402, and optionally, a decorative ink 406 may be applied to the other side. In certain exemplary embodiments, the conductor 404 may be transparent, and as shown, the decorative ink 406 is optional. In certain exemplary embodiments, the conductor 404 and / or the decorative ink 406 may be translucent or otherwise impart color or aesthetic features to the shutter 312. In certain exemplary embodiments, the elastic layer 402 may be formed from a contractile polymer, such as, for example, PEN, PET, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), or the like. The elastic layer 402 may be 1 to 25 micrometers thick in certain exemplary embodiments. The conductor 404 may be formed from the same or a different material as that used for the conductor 306 in different exemplary embodiments. For example, metal or metal oxide materials may be used. In certain exemplary embodiments, materials having thicknesses of 10-50 nm may be used, including layers containing, for example, ITO, Al, Ni, NiCr, tin oxide, etc. In certain exemplary embodiments, the resistance of conductor 404 may be in the range of 40-200 ohms / square.

[0042] Decorative ink 406 may include pigments, particles, and / or other materials that selectively reflect and / or absorb desired visible colors and / or infrared radiation.

[0043] 2, shades 202a and 202b are typically wound as spiral rolls, with the outer ends of the spirals affixed to substrates 102 and 104 (e.g., a dielectric on the substrate) by an adhesive. Conductor 404 may be electrically connected to a lead or the like via a terminal and may function as a variable electrode of a capacitor, with conductor 306 as the fixed electrode of the capacitor and dielectric 308 as the dielectric of the capacitor.

[0044] When an electrical drive is provided between the variable electrode and the fixed electrode, for example, when a voltage or current electrical drive is applied between the conductor 404 of the shutter 312 and the conductor 306 on the substrate 302, the shutter 312 is pulled toward the substrate 302 by an electrostatic force resulting from the potential difference between the two electrodes. Pulling the variable electrode deploys the coiled shade. The electrostatic force on the variable electrode holds the shutter 312 securely against the fixed electrode on the substrate 302. As a result, the ink coating layer 406 of the shade selectively reflects or absorbs certain visible colors and / or infrared radiation. In this manner, the deployed shade controls radiation transmission by selectively blocking and / or reflecting certain light or other radiation, thereby changing the overall function of the IG unit to be transparent, partially or selectively transparent, or even opaque.

[0045] When the electrical drive between the movable electrode and the fixed electrode is removed, the electrostatic force on the movable electrode is similarly removed. The spring constant present in the elastic layer 402 and the conductor 404 causes the shade to return to its original, tightly wound position. Because the movement of the shade is controlled primarily by a capacitive circuit, current essentially flows only while the shade is either unfolding or retracting. As a result, the average power consumption of the shade is very low. In this way, at least in some instances, a few standard AA batteries can be used to operate the shade for several years.

[0046] In one example, the substrate 302 may be 3 mm thick clear glass commercially available from the assignee. An acrylic adhesive with low haze may be used for the adhesive layer 310. Sputtered ITO with a resistance of 100-300 ohms / square may be used for the conductor 306. The polymer film may be a low-haze (e.g., <1% haze) PET material 12 micrometers thick. A PVC-based ink available from Sun Chemical Inc. may be applied as the decorative ink 406, with a thickness of 3-8 micrometers. A PEN material available from DuPont with a thickness of 6, 12, or 25 micrometers may be used as the elastic layer 402. Evaporated Al with a nominal thickness of 375 nm may be used for the opaque conductor 406. For a transparent option, sputtered ITO may be used. In both cases, the resistance may be 100-400 ohms / square. In certain exemplary embodiments, ITO or other conductive materials may be sputtered or otherwise formed onto their respective polymeric carrier layers. Of course, these exemplary materials, thicknesses, electrical properties, and various combinations and subcombinations thereof, etc., should not be considered limiting unless specifically claimed.

[0047] As can be seen from the above description, the dynamic shade mechanism uses a coiled polymer having a conductive layer. In certain exemplary embodiments, the conductor 402 may be formed integrally with the polymer 402 or may be an external coating applied, deposited, or otherwise formed on the polymer 402. As also noted above, the decorative ink 406 may be used with a transparent conductor material (e.g., based on ITO) and / or a partially transparent or opaque conductive layer. An opaque or partially transparent conductive layer may eliminate the need for ink in certain exemplary embodiments. In this regard, in certain exemplary embodiments, a metallic or substantially metallic material may be used. Aluminum is one example of a material that may be used with or without a decorative ink.

[0048] One or more overcoat layers may be provided over the conductors to reduce visible light reflection and / or change the color of the shade to provide a more aesthetically pleasing product, and / or by "breaking" the conductors so that a phase shifter layer appears between them. Thus, overcoats may be included to improve the overall aesthetic appearance of the shade. Thus, the shutter 312 may include a reflection-reducing overcoat, a dielectric specular overcoat, or the like. Such reflection-reducing overcoats and dielectric specular overcoats may be provided on the major surface of the shade polymer 402, including (for example) PEN, over the conductors 404 and opposite the decorative ink 406. However, it will be understood that, for example, if the conductors 404 are not transparent, the ink 406 need not be provided. For example, a specular coating such as Al may eliminate the need for the decorative ink 406. It will also be appreciated that a reflection-reducing overcoat and a dielectric specular overcoat may be provided on a major surface of the shade polymer 402, including (for example) PEN, opposite the conductor 404 in certain exemplary embodiments.

[0049] In addition to or instead of using optical interference techniques to reduce reflections, it is also possible to add a textured surface to the base polymer, chemically or physically modify the conductive layer, and / or add an ink layer to achieve further reduction in unwanted reflections, for example, to achieve the same or similar edges.

[0050] Considering that the membranes and / or other materials comprising the shutter must withstand multiple roll-up and deployment operations in accordance with the overall shade function, it will be understood that materials may be selected, and the resulting overall layer stack, to have mechanical and / or other properties that facilitate this. For example, excessive stress in the membrane layer stack is typically viewed as detrimental. However, in some cases, excessive stress may lead to cracking, "delamination" / removal, and / or other damage to the conductors 404 and / or the overcoat layer or layers formed thereon. Thus, in certain example embodiments, low stress (especially low tensile stress) may be particularly desirable in connection with layers formed on the polymer substrate of the shutter.

[0051] In this regard, the adhesion of sputtered thin films depends, among other things, on the stress in the deposited film. One way to tune the stress is through the deposition pressure. Stress versus sputter pressure does not follow a monotonic curve; instead, it is imbued with a transition pressure that is specific to each material and a function of the ratio of the material's melting temperature to the substrate temperature. Stress engineering can be achieved through gas pressure optimization, keeping these guidelines in mind.

[0052] Other physical and mechanical properties of the shade that can be taken into consideration include the modulus of elasticity of the polymer and the layer formed on the polymer, the density ratio of the layer (which can affect stress / strain), etc. These properties can be balanced with their effect on internal reflection, conductivity, etc.

[0053] As is known, temperatures inside IG units can become very high. For example, it has been observed that an IG unit containing a black pigment, such as the embodiment of FIG. 2, can reach temperatures of 87°C when the black portion of the shade faces the sun in a hot, high-sun radiation climate (e.g., a region of the southwestern United States, such as Arizona). Using a PEN material for a rollable / unrollable polymer can be advantageous because PEN has a higher glass transition temperature (~120°C) compared to other common polymers such as PET (Tg = 67-81°C), polypropylene, or PP (Tg = ~32°C). Furthermore, when PEN is exposed to temperatures approaching its glass transition temperature, the performance of the material's otherwise advantageous mechanical properties (including the material's modulus of elasticity, yield strength, tensile strength, stress relaxation modulus, etc.) can deteriorate over time, especially at high temperatures. If these mechanical properties deteriorate significantly, the shade will no longer function (e.g., the shade will not retract).

[0054] To help the shade better withstand high temperature environments, it may be advantageous to replace PEN with a polymer with higher temperature resistance. Two potential polymers include PEEK and polyimide (PI or Kapton). PEEK has a Tg of approximately -142°C, and Kapton HN has a Tg of approximately -380°C. Both of these materials have better mechanical properties in high temperature environments compared to PEN. This is especially true at temperatures above 100°C. The following chart references the mechanical properties of PEN (Teonex), PEEK, and PI (Kapton HN). UTS stands for ultimate tensile strength in the chart. [Table 1]

[0055] It will be appreciated that changing the shade substrate from its current material (PEN) to an alternative polymer with increased high temperature mechanical properties (e.g., PEEK or PI / Kapton) may be advantageous in that it may allow the shade to better withstand internal IG temperatures, particularly if the shade is installed in a hot climate. It will be appreciated that in certain example embodiments, the use of an alternative polymer may be used in conjunction with a layer on the shutter and / or glass.

[0056] Additionally or alternatively, certain exemplary embodiments may use dyed polymeric materials. For example, dyed PEN, PEEK, PI / Kapton, or other polymers may be used to create a variety of color and / or aesthetic shades. For example, dyed polymers may be advantageous for transparent / semi-transparent application embodiments, such as when the transparent conductive layer is a transparent conductive coating.

[0057] Alternative coiled shades may be used to beneficially modify the spring force, allowing them to be used for various lengths. In this regard, conductive layer properties that increase coil strength include an increased modulus of elasticity, an increased difference in the coefficient of thermal expansion (CTE) between the polymer substrate and the conductive layer, and an increased modulus-to-density ratio. Some pure metals that can be used to increase coil strength compared to Al or Cr include Ni, W, Mo, Ti, and Ta. The moduli of elasticity of the metal layers studied ranged from 70 GPa for Al to 330 GPa for Mo. The CTE of the metal layers studied ranged from 23.5×10 for Al to 10×10 for Mo. -6 / k to Mo 4.8 x 10 -6 / k. In general, the higher the modulus of elasticity, the greater the CTE mismatch between PEN or other polymers and metals, the lower the density, etc., the better the material selection for coil formation. It has been found that incorporating Mo- and Ti-based conductive layers into the shade has resulted in significantly higher coil spring forces than those achievable with Al. For example, a polymer substrate based on PEN, PEEK, PI, etc. may be advantageously included, supporting (in order from the substrate away) a layer containing Al, followed by a layer containing Mo. Thin film layers within the conductive coating and / or the conductive coating itself may be provided with a higher modulus of elasticity and a lower CTE than Al.

[0058] A PEN, PI, or other polymer substrate used as a shutter may support a thin layer containing Al for stress engineering purposes, and may support a conductive layer on top of the thin layer directly or indirectly containing Mo, Ti, etc. The conductive layer may support a corrosion resistant layer containing Al, Ti, stainless steel, etc. The side of the substrate opposite these layers may optionally support decorative inks, etc.

[0059] Certain exemplary embodiments may include micro-perforations or perforations that allow light to pass through the shade and provide a graduated amount of solar transmittance based on the angle of the sun.

[0060] Additional manufacturing, operational, and / or other details and alternatives may be implemented. See, for example, U.S. Patent Nos. 8,982,441, 8,736,938, 8,134,112, 8,035,075, 7,705,826, and 7,645,977, and U.S. Patent Application Publication No. 2020 / 0011120, the entire contents of each of which are incorporated herein by reference. Among other things, perforation configurations, polymer materials, conductive coating designs, stress engineering concepts, building-integrated photovoltaic (BIPV), and other details are disclosed therein, at least the teachings of which may be incorporated into certain exemplary embodiments.

[0061] Those skilled in the art of IG units will understand that one issue associated with dynamic shade designs relates to providing power to the internal cavity of the IG unit. For example, an electrical potential-driven dynamic shade needs to be powered to operate. To do so, power must be transmitted from outside the IG unit to inside the IG unit. While passing under or over a spacer is possible, doing so can present challenges. For example, processes involving frits can be complicated because spacers are typically conductive. The application of conductive and / or insulating frits can also be complicated because, if spacers are pre-applied, the spacers must reliably seal the IG unit together, reduce the risk of outgassing, and the like. Current inductive power transfer technologies are not suitable due to, for example, the relative cost and complexity of such systems. Also, simply drilling holes in the spacer and threading wires through it presents numerous leak points that can significantly shorten the life of the IG unit, for example, because the leak points can promote outgassing of inert gases (typically Ar, Kr, Xe, and / or other noble gases alone or mixed with air in a predetermined ratio, e.g., 80% Ar and 20% oxygen), moisture ingress, etc.

[0062] Certain illustrative embodiments help address these and / or other concerns. For example, certain illustrative embodiments relate to techniques and / or related methods for providing electrical power inside an IG unit cavity. The techniques provided herein advantageously reduce the likelihood of leak points developing and / or forming over time, and the connection techniques reduce the risk of outgassing, moisture ingress, and the like, thereby extending the lifespan of the IG unit compared to other techniques. Advantageously, the techniques described herein can be used to provide electrical power inside an IG unit cavity for use in a variety of applications, including, for example, applications in which electrical power is used to drive dynamic shades, operate lights, power sensors, extract power from photovoltaic (PV) cells, and / or the like.

[0063] As will become apparent from the following description, certain exemplary embodiments use dedicated pins to pierce the spacer and provide electrical connections. Prior to insertion, the spacer is prepared by placing a pad at the puncture site. The pad may be, for example, a polyisobutylene (PIB) or otherwise backed rubber pad that is placed at the puncture site. A first portion (the PIB material) provides a gas seal, and a second portion (the rubber) acts as a septum. Nori , and for pins seal This two-part seal is desirable because it allows for a barrel or other connector to be placed on the end of the pin to provide power.

[0064] 5 is a flow diagram of an exemplary process for forming electrical connections to provide power to the interior of an IG unit cavity, according to certain exemplary embodiments. In step S502, a temporary cap / plug is loaded into a jig. A two-part seal is placed in the jig. This may include, for example, fabricating the two-part seal by fastening a PIB to rubber and cutting the PIB-lined rubber to size, as described in step S504. The PIB / rubber piece may then be placed in the jig, as in step S506. In step S508, a spacer is placed in the jig. The spacer may be formed before being placed in the jig or while held in the jig. For example, in certain exemplary embodiments, the spacer may be cut to length, filled with desiccant, its ends plugged with corner keys, and then placed in the jig. Optionally, a metal rod to facilitate internal electrical connections is placed on the spacer in the fixture to correspond to the interior region of the IG unit cavity. In step S510, the pin is driven into the temporary cap / plug through the assembly with optional metal rods and spacers.

[0065] The IG unit is constructed conventionally in step S512. This involves placing the first and second substrates in a substantially parallel, spaced-apart relationship to one another, sealing them together using spacers (e.g., using PIB or other sealant provided between the spacers and the respective substrates), and applying a structural sealant (e.g., of or including silicone). The structural sealant, in certain exemplary embodiments, is applied over a temporary cap / plug. The IG unit cavity may be conventionally filled with an inert gas or inert gas mixture. In step S514, the temporary cap / plug is removed, leaving a small cavity. In step S516, a barrel or other connector is placed over the pin to provide electrical connection and a means for supplying power to the interior of the IG unit cavity. Note that the timing of the removal of the temporary cap / plug and / or the attachment of the barrel or other connector may be important. For example, this may be accomplished when the structural sealant has not yet fully cured to allow for temporary cap / plug removal and subsequent connector insertion while still allowing a good seal to be formed. Likewise, this may be accomplished in certain exemplary embodiments to reduce the likelihood of outgassing of the backfilled inert gas / insertive gas mixture.

[0066] FIG. 6 is a schematic cross-sectional view illustrating how electrical connections can be used to provide power to the interior of an IG unit cavity, according to certain exemplary embodiments. The exemplary schematic of FIG. 6 can be manufactured using the exemplary technique of FIG. 5. As shown in FIG. 6, the first and second substrates 102 and 104 are separated by a spacer 106. A sealant 602a serves to seal the spacer 106 to the first substrate 102, and a sealant 602b serves to seal the spacer 106 to the second substrate 104. The spacer 106 is provided around the periphery of the first substrate 102 and the second substrate 104, and these substrates may have the same or different sizes. In certain exemplary embodiments, PIB can be used for the sealants 602a and 602b. A desiccant 604 is located within the body of the spacer 106, which helps to mitigate issues associated with potential moisture ingress into the cavity 108. Generally, the spacer 106 is a sealed, solid structure within which beads of desiccant 604 or the like can be "stored." The spacer 106 may have any suitable shape, including, for example, a generally rectangular cross-sectional shape, a generally rectangular cross-sectional shape with chamfered corners adjacent the exterior of the IG unit as shown in FIG. 6, and / or the like. Any suitable spacer system can be used, including, for example, the SWISSPACER spacer system, IET spacers, and / or the like. In certain exemplary embodiments, the spacer 106 itself may be non-conductive. Metal (e.g., aluminum), plastic, or other materials may be used for the spacer 106 in different exemplary embodiments.

[0067] The optional conductive plate 606 may be formed from metal or another conductive material. Having a conductive plate 606 inside at least a portion of the spacer 106 may be useful for easily forming an electrical connection with a powered component. That is, the conductive plate 606 may provide a large surface area for making electrical contact, which may be significantly larger than the nails or pins 608 that provide power through the spacer 106 itself. (For purposes of this disclosure, no distinction is understood between nails or pins.) Because the inside of the IG unit may be more difficult to service or connect than the outside, the heads of the nails or pins 608 may be provided on the interior surface of the spacer 106 adjacent to the cavity 108. The conductive plate 606 in this sense may function as a bus bar or the like. The nails or pins 608 may be coated or clad along their length and around the portion of their heads that contact the bus bar to prevent electrical connection with the spacer 106 itself. Electrically insulating material may be provided around the nails in areas that would otherwise contact the spacer 106. This may be desirable when the spacer 106 is formed from a conductive material. Thus, in certain exemplary embodiments, the portion of the pin that contacts the spacer may be insulated to avoid electrical contact between the pin and the spacer.

[0068] In a dynamic shade, the conductive plates 606 may be provided at end stops, top stops, and / or the like. If other electrical components are provided within the cavity 108, a single conductive plate 606 may be used, or multiple plates may be provided. The latter may be advantageous when different components are powered using connections at different locations. For example, a dynamic shade may be powered at a top stop or end stop near the top or bottom of the shade, while LED lights provided at the bottom or top of the shade may benefit from separate plates provided in closer proximity.

[0069] As described above, the head of the nail or pin 608 is provided inside the IG unit within the cavity 108. The end of the nail extends through the spacer 106 and protrudes outward therefrom. In FIG. 6 , for example, the end of the nail or pin 608 protrudes through a two-part seal including a first portion 610 and a second portion 612. This may include an inner PIB liner (first portion 610) for an outer rubber piece (second portion 612). The nail or pin 608 is at least temporarily protected by a cap or plug 614. This cap or plug 614 may serve to protect the nail or pin 608 during IG unit manufacturing operations, storage, and / or transportation, etc. For example, the cap or plug 614 may protect the nail or pin 608 during the formation of a structural seal, which may be formed from silicone or the like.

[0070] In certain exemplary embodiments, the cap or plug 614 may be formed from a flexible silicone or Teflon material. In certain exemplary embodiments, the cap or plug 614 may be more permanent and may be hollow so that a barrel or other connector 618 may provide connection to external wires 620 that may provide power or the like to the interior of the IG unit. In the example of FIG. 6, the barrel or other connector 618 is shown disconnected from the nail or pin 608, resulting in no electrical contact between the wires 620. However, this is done for illustrative purposes only, and a functional / installed embodiment involves electrical contact and connection. In certain exemplary embodiments, the connector is located within the IG unit and is at least partially surrounded by a structural seal.

[0071] Wire could also be used instead of nails or pins 608. However, using nails or pins 608 can be advantageous for several reasons. For example, the rubber / PIB pieces provide a seal for the nails or pins 608, making it easier to seal the rigid components in place compared to more flexible wire. Additionally, the nails or pins 608 are a rigid structure and help secure the components in place. That is, the nails or pins 608 help secure the optional plate 606, inner PIB backing (first portion 610), and outer rubber piece (second portion 612) to the spacer 106. Because of this secure attachment, there is less chance of the wire breaking, for example, from transportation, storage, installation, and / or other procedures.

[0072] The advantages of this system are related to the easy manufacturing process, which accommodates existing spacer systems aside from power transmission. The two-part seal PIB / rubber acts as a membrane and can be manually placed at any time, or its placement can be automated using a robot. The pins can be inserted manually or via a robot using a dedicated fixture and pneumatic actuator at any time (e.g., before the IG unit is sealed). The temporary rubber, which also penetrates the pins, allows for normal silicone application without contaminating the wires. The temporary rubber can be removed for easy and clean access to the pins. Thus, in certain exemplary embodiments, an impermeable barrier is created, providing protection against moisture ingress into the cavity and inert gas egress from the cavity, while still providing a safe and reliable method for supplying power to the interior of the cavity.

[0073] Although certain exemplary embodiments have been described as providing a way to power the interior of the IG unit cavity, it will be appreciated that certain exemplary embodiments may use conductive nails or pins to transmit data into and out of the IG unit cavity.

[0074] FIG. 7 is a schematic diagram of dynamic shades 702a-702b provided within a window frame 704, in accordance with certain exemplary embodiments. Small LEDs or other lighting elements are provided within a portion of the frame from the view of the frame 704. When activated, the LEDs or other lighting elements provide an interesting aesthetic effect to the extended dynamic shades 702a-702b. In this regard, FIG. 8 is a schematic diagram of LEDs or other lighting elements being used to illuminate the extended dynamic shades 702a-702b from the example of FIG. 7, in accordance with certain exemplary embodiments. In certain exemplary embodiments, the LEDs or other lighting elements may be powered and / or controlled by the circuitry used to power and / or control the dynamic shades 702a-702b. For example, in certain exemplary embodiments, the small LEDs or other lighting elements may be attached to a stop bar or an interior glass surface.

[0075] In certain exemplary embodiments, this approach can be used to enhance the blackout features of dynamic shading and / or create a more interesting visual appearance. Illuminating windows can provide an aspect of privacy while still signaling "someone's home" or "someone's inside" through an illuminated background. As shown in FIG. 8 , for example, small LEDs or other lighting elements can be used to "cast" a dim light upward onto the surface of a downward-moving shade. From the inside, it may appear as a night light or accent light. From the outside, it can provide a soft white light. The light, in certain exemplary embodiments, can be controlled via a shade controller. Various use cases can be developed around when the light is turned on or off, e.g., in connection with a programmable controller. For example, the light can be turned on "after dark" or after a business closes for the day, when ambient light exceeds a threshold to prevent people from seeing into the building, when integrated with an office automation system to indicate that a conference room has been booked and privacy is desired, etc. In certain exemplary embodiments, one or more lighting elements may be actuable only when the polymer substrate is extended to a shutter-closed position.

[0076] While the example of FIG. 8 shows a point light source provided on one periphery of the unit, it will be understood that different embodiments may include different arrangements. For example, a diffuser may be provided to create a more diffused (non-point light) visual effect, light sources may be provided around two or more edges, and / or the like. In this sense, a diffuser may be provided between one or more lighting elements and a central region of the light source. As another example, in an IG unit including first and second opposing sides, one or more lighting elements may be provided on the first side, and the shutter-open position may be on the second side. In certain exemplary embodiments, multiple lighting elements are located at least on different peripheries of the IG unit.

[0077] The light may receive power from an internal or external power source, such as, for example, a battery, a dedicated power source, a PV module, and / or the like. When an external power source is used, power may be delivered to the cavity interior using the exemplary techniques disclosed herein. It will be understood that the internal or external battery may be rechargeable and may be used independently in conjunction with the PV module or dedicated power source, such as a charger. The PV module may be internal to the IG unit in certain exemplary embodiments.

[0078] Illuminated dynamic shade applications may be useful for residential or commercial windows for indoor and / or outdoor applications, in vehicles (sunroofs, side windows, front or rear windshields, etc.), merchandisers, and / or the like. In certain exemplary embodiments, the light may be provided without a dynamic shade.

[0079] Although certain exemplary embodiments have been described as powering electrostatically powered dynamic shades and / or lights, it will be appreciated that a variety of different devices may be powered, including, for example, Internet-of-Things (IoT) enabled devices (e.g., light sensors, temperature sensors, cameras, etc.), displays integrated into IG units, dynamically switchable coatings (e.g., electrochromic, polymer dispersed liquid crystal (PDLC), polymer assembled liquid crystal, and / or other coatings, etc.), photovoltaic (PV) modules, and / or the like.

[0080] The IG units described herein may incorporate a low-E coating on any one or more of surfaces 1, 2, 3, and 4. As discussed above, for example, such a low-E coating may function as a conductive layer for the shade. In other exemplary embodiments, a low-E coating may be provided on another interior surface in addition to or separate from serving as a shade and a conductive layer for the shade. For example, a low-E coating may be provided on surface 2, and a shade may be provided on surface 3. In another example, the positions of the shade and low-E coating may be reversed. In either case, a separate low-E coating may or may not be used to assist in manipulating the shade provided on surface 3. In certain exemplary embodiments, the low-E coating provided on surfaces 2 and 3 may be a silver-based low-E coating. Examples of low-E coatings are set forth in U.S. Patent Nos. 9,802,860, 8,557,391, 7,998,320, 7,771,830, 7,198,851, 7,189,458, 7,056,588, and 6,887,575, the entire contents of each of which are incorporated herein by reference. Low-E coatings based on ITO or the like may be used on the interior and / or exterior surfaces. See, for example, U.S. Patent Nos. 9,695,085 and 9,670,092, the entire contents of each of which are incorporated herein by reference. These low-E coatings may be used in connection with certain exemplary embodiments.

[0081] An anti-reflection coating may be provided on the major surfaces of the IG unit. In certain exemplary embodiments, an AR coating may be provided on each major surface that is not provided with a low-E coating and a shade. Exemplary AR coatings are described, for example, in U.S. Pat. Nos. 9,796,619 and 8,668,990, and U.S. Patent Application Publication No. 2014 / 0272314, the entire contents of each of which are incorporated herein by reference. See also U.S. Pat. No. 9,556,066, the entire contents of which are incorporated herein by reference. These AR coatings may be used in connection with certain exemplary embodiments.

[0082] The exemplary embodiments described herein can be incorporated into a wide variety of applications, including, for example, interior and exterior windows in commercial and / or residential applications, skylights, doors, display shelving for refrigerators / freezers and the like (e.g., for their doors and / or "walls"), vehicle applications, and the like.

[0083] While certain exemplary embodiments are described in the context of an IG unit including two substrates, it will be understood that the technology described herein may also be applied in the context of so-called triple IG units, in which substantially parallel, spaced-apart first, second, and third substrates are separated by first and second spacer systems, and a shade may be provided adjacent any one or more of the inner surfaces of the innermost and outermost substrates and / or adjacent one or both surfaces of the intermediate substrate.

[0084] While certain exemplary embodiments are described as incorporating glass substrates (e.g., for use in the inner and outer panes of the IG units described herein), it will be understood that other exemplary embodiments may incorporate non-glass substrates for one or both of such panes. For example, plastics, composite materials, etc. may be used. When glass substrates are used, such substrates may be heat treated (e.g., heat strengthened and / or heat tempered), chemically heat tempered, left in the annealed state, etc. In certain exemplary embodiments, the inner or outer substrate may be laminated to another substrate of the same or different material.

[0085] As used herein, terms such as "on" and "supported by" should not be construed to mean that two elements are directly adjacent to one another unless expressly stated. In other words, a first layer may be "on" or "supported by" a second layer even if there are one or more layers between them.

[0086] In certain exemplary embodiments, an insulating glass (IG) unit is provided. A first glass substrate and a second glass substrate are provided. A spacer is interposed between the first substrate and the second substrate, maintaining the first substrate and the second substrate in a substantially parallel, spaced-apart relationship and serving to define a cavity between the first substrate and the second substrate. A first outer surface of the spacer faces an inner surface of the first substrate, a second outer surface of the spacer faces an inner surface of the second substrate, a third outer surface of the spacer faces the cavity, and a fourth outer surface of the spacer faces away from the cavity. A membrane is provided on at least a portion of the fourth outer surface of the spacer. Pins protrude through the membrane through holes in the third and fourth outer surfaces of the spacer, and the pins are formed of a conductive material. A structural seal for the IG unit is provided on the exterior of the spacer and at least partially surrounds a portion of the pin protruding through the membrane.

[0087] In addition to the features of the previous paragraph, in certain exemplary embodiments, a conductive plate may be provided on a third exterior surface of the spacer, e.g., the conductive plate is in electrical contact with the pin.

[0088] In addition to the features of the previous paragraph, in certain exemplary embodiments, the pins may protrude through the conductive plate.

[0089] In addition to the features of either of the previous two paragraphs, in certain exemplary embodiments, the head of the pin may contact the conductive plate on the side of the head adjacent to the cavity.

[0090] In addition to the features of any of the previous four paragraphs, in certain exemplary embodiments, the membrane may include a polyisobutylene (PIB) reinforced rubber member.

[0091] In addition to the features of any of the previous five paragraphs, in certain exemplary embodiments, the membrane may comprise a two-part structure, e.g., having a first part that acts as a gas seal for gas within the cavity of the IG unit and a second part that acts as a septum and further seals against the pin.

[0092] In addition to the features of any of the previous six paragraphs, in certain exemplary embodiments, a plug may be provided over a portion of the pin that passes through the spacer and projects away from the spacer.

[0093] In addition to the features of any of the previous seven paragraphs, in certain exemplary embodiments, the pin may provide a location for electrical contact with a connector to a power source external to the IG unit.

[0094] In addition to the features of the previous paragraph, in certain exemplary embodiments, the connector may be a barrel connector attached to a wire, e.g., the connector is located within the IG unit and is at least partially surrounded by a structural seal.

[0095] In addition to the features of any of the previous nine paragraphs, in certain exemplary embodiments, the spacer may be sealed to the first substrate and the second substrate with a sealant, and the membrane may include the same sealant used to seal the spacer to the first and second substrates.

[0096] In addition to the features of any of the previous ten paragraphs, in certain exemplary embodiments, the portion of the pin that contacts the spacer may be insulated to avoid electrical contact between the pin and the spacer.

[0097] In addition to the features of any of the previous 11 paragraphs, in certain exemplary embodiments, an electrically powered element may be located inside the cavity, e.g., the electrically powered element may be powered from a power source external to the cavity through an electrical connection provided by a pin.

[0098] In addition to the features of the previous paragraph, in certain exemplary embodiments, the electrically powered element may be a light source, an electrostatically actuated dynamic shade, an Internet of Things device, and / or the like.

[0099] In certain exemplary embodiments, a method for manufacturing an insulating glass (IG) unit is provided, the method including: having a spacer, the spacer including a first exterior surface, a second exterior surface, a third exterior surface, and a fourth exterior surface; applying a film to the fourth exterior surface of the spacer; inserting a pin through the third exterior surface and the fourth exterior surface of the spacer and through the film applied to the fourth exterior surface of the spacer, the pin including a conductive material; and, in manufacturing the IG unit, sealing the first substrate and the second substrate together with the spacer provided therebetween, the first exterior surface of the spacer facing an inner surface of the first substrate, the second exterior surface of the spacer facing an inner surface of the second substrate, the third exterior surface of the spacer facing a cavity of the IG unit, and the fourth exterior surface of the spacer facing away from the cavity of the IG unit; and forming an outer structural seal for the IG unit using a structural sealant provided around an exterior of the spacer.

[0100] In addition to the features of the previous paragraph, in certain exemplary embodiments, a conductive plate may be connected to the third exterior surface of the spacer, e.g., the pin is in electrical contact with a conductive plate in the IG unit.

[0101] In addition to the features of the previous paragraph, in certain exemplary embodiments, the pins may be inserted so as to protrude through the conductive plate.

[0102] In addition to the features of any of the previous three paragraphs, in certain exemplary embodiments, the membrane may comprise a two-part structure, for example, having a first part that acts as a gas seal for gas within the cavity of the IG unit, and a second part that acts as a septum and further seals against the pin.

[0103] In addition to the features of any of the previous four paragraphs, in certain exemplary embodiments, a plug may be provided over a portion of the pin that passes through the spacer and projects away from the spacer.

[0104] In addition to the features of the previous paragraph, in certain exemplary embodiments, the plug may be removed before or during formation of the outer structural seal.

[0105] In addition to the features of any of the previous six paragraphs, in certain exemplary embodiments, an electrically powered element may be provided in the IG unit such that the electrically powered element is disposed inside the cavity, e.g., the electrically powered element is powerable from a power source external to the cavity through an electrical connection provided by a pin.

[0106] In certain exemplary embodiments, an insulating glass (IG) unit is provided. A first substrate and a second substrate each have an inner major surface and an outer major surface, with the inner major surface of the first substrate facing the inner major surface of the second substrate. A spacer system serves to maintain the first substrate and the second substrate in a substantially parallel, spaced-apart relationship relative to one another and define a gap therebetween. One or more lighting elements are provided within the gap. A dynamically controllable shade is interposed between the first substrate and the second substrate, the shade including a first conductive layer provided directly or indirectly on the inner major surface of the first substrate, at least one polymer substrate, first and second conductive coatings, and first and second dielectric layers. The at least one polymer substrate is extendable to a shutter-closed position and retractable to a shutter-open position. The first conductive coating and / or the second conductive coating can be electrically connected to a power source that is controllable to set a potential difference to create a first electrostatic force that drives the at least one polymer substrate to a shutter-closed position.

[0107] In addition to the features of the previous paragraph, in certain exemplary embodiments, the IG unit may have a first side and a second side opposite each other, with one or more lighting elements provided on the first side and the shutter open position being on the second side.

[0108] In addition to the features of either of the previous two paragraphs, in certain exemplary embodiments, one or more lighting elements may be actuable only when the polymer substrate is extended to the shutter closed position or is extended.

[0109] In addition to the features of any of the previous three paragraphs, in certain exemplary embodiments, one or more lighting elements and dynamically controllable shades may share control circuitry.

[0110] In addition to the features of any of the previous four paragraphs, in certain exemplary embodiments, one or more lighting elements and dynamically controllable shades may share a power source.

[0111] In addition to the features of the previous paragraph, in certain exemplary embodiments, the power source may be external to the gap.

[0112] In addition to the features of any one of the previous six paragraphs, in certain exemplary embodiments, each of the one or more lighting elements may be an LED light.

[0113] In addition to the features of any one of the previous seven paragraphs, in certain exemplary embodiments, a diffuser may be provided between one or more lighting elements and a central region of the gap.

[0114] In addition to the features of any of the previous eight paragraphs, in certain exemplary embodiments, the multiple lighting elements may be located at least on different peripheries of the IG unit.

[0115] In certain exemplary embodiments, methods of making and / or using an IG unit as described in any of the preceding nine paragraphs are provided.

[0116] While the present invention has been described in connection with what are presently considered to be practical and preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments and / or deposition techniques, but rather is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. An insulating glass (IG) unit comprising: a first substrate and a second substrate; a spacer interposed between the first substrate and the second substrate, the spacer maintaining the first substrate and the second substrate in a substantially parallel spaced apart relationship and serving to define a cavity between the first substrate and the second substrate, a first outer surface of the spacer facing an inner surface of the first substrate, a second outer surface of the spacer facing an inner surface of the second substrate, a third outer surface of the spacer facing the cavity, and a fourth outer surface of the spacer facing away from the cavity; a membrane provided on at least a portion of the fourth exterior surface of the spacer; a pin that passes through holes in the third and fourth outer surfaces of the spacer and protrudes through the membrane, the pin being formed from a conductive material; and a structural seal for the IG unit provided on an exterior of the spacer and at least partially surrounding a portion of the pin protruding through the membrane; and an electrically powered element located within the cavity; Equipped with An IG unit wherein the electrically powered element is powerable from a power source external to the cavity through an electrical connection provided by the pin.

2. The IG unit of claim 1 , further comprising a conductive plate provided on the third exterior surface of the spacer, the conductive plate being in electrical contact with the pin.

3. The IG unit of claim 2 wherein the pin protrudes through the conductive plate.

4. 4. The IG unit of claim 2 or 3, wherein the head of the pin contacts the conductive plate on a side of the head adjacent to the cavity.

5. The IG unit of any one of claims 1 to 4, wherein the membrane comprises a polyisobutylene (PIB) reinforced rubber member.

6. 6. The IG unit of claim 1, wherein the membrane comprises a two-part structure including a first part and a second part, the first part acting as a gas seal for gas within the cavity of the IG unit, and the second part acting as a septum and further sealing against the pin.

7. 7. An IG unit as claimed in any preceding claim, further comprising a plug provided over a portion of the pin that passes through the spacer and projects away from the spacer.

8. An IG unit as claimed in any preceding claim, wherein the pin provides a location for electrical contact with a connector to a power source external to the IG unit.

9. 10. The IG unit of claim 8, wherein the connector is a barrel connector attached to a wire, the connector being located within the IG unit and at least partially surrounded by the structural seal.

10. 10. The IG unit of claim 1, wherein the spacer is sealed to the first and second substrates with a sealant, and the membrane comprises the same sealant used to seal the spacer to the first and second substrates.

11. 11. An IG unit according to any preceding claim, wherein the portion of the pin that contacts the spacer is insulated to avoid electrical contact between the pin and the spacer.

12. The IG unit according to any one of claims 1 to 11, wherein the electrically-powered element is a light source.

13. The IG unit of any one of claims 1 to 11, wherein the electrically powered element is an electrostatically actuated dynamic shade.

14. The IG unit according to any one of claims 1 to 11, wherein the electrically powered element is an IoT device.

15. 1. A method of manufacturing an insulating glass (IG) unit, the method comprising: having a spacer, the spacer including a first exterior surface, a second exterior surface, a third exterior surface, and a fourth exterior surface; applying a film to the fourth exterior surface of the spacer; and inserting a pin through the third exterior surface and the fourth exterior surface of the spacer and through the film applied to the fourth exterior surface of the spacer, the pin comprising a conductive material; manufacturing the IG unit by sealing the first substrate and the second substrate together with the spacer provided therebetween, the first outer surface of the spacer facing the inner surface of the first substrate, the second outer surface of the spacer facing the inner surface of the second substrate, the third outer surface of the spacer facing the cavity of the IG unit, and the fourth outer surface of the spacer facing away from the cavity of the IG unit; forming an outer structural seal for the IG unit using a structural sealant provided around an exterior of the spacer; providing an electrically powered element and positioning the electrically powered element within the cavity in the IG unit, the electrically powered element being powerable from a power source external to the cavity through an electrical connection provided by the pin.

16. 16. The method of claim 15, further comprising connecting a conductive plate to the third exterior surface of the spacer, the pin being in electrical contact with the conductive plate in the IG unit.

17. The method of claim 16 , wherein the pin is inserted so as to protrude through the conductive plate.

18. 18. The method of any one of claims 15 to 17, wherein the membrane comprises a two-part structure, the first part acting as a gas seal for gas within the cavity of the IG unit, and the second part acting as a septum and further sealing against the pin.

19. A method according to any one of claims 15 to 18, further comprising providing a plug over a portion of the pin that passes through the spacer and projects away from the spacer.

20. 20. The method of claim 19, wherein the plug is removed before or during formation of the outer structural seal.

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