System and method for manufacturing multiple pane insulated glazing units

Abstract

A method of manufacturing a glazing unit for a fenestration with a first pane and a smaller pane that is smaller than the first pane includes providing, to a processor of a control system, a first peripheral dimension, D1, for the first pane. The first peripheral dimension, D1, is measured between a first pair of opposing edges of the first pane. The method also includes providing, to the processor, a second peripheral dimension, D2, for the first pane. The second peripheral dimension, D2, is measured between a second pair of opposing edges of the first pane. Additionally, the method includes determining dimensions of the smaller pane based on the first peripheral dimension, D1, and the second peripheral dimension, D2.

Description

SYSTEM AND METHOD FOR MANU FACTU RING MU LTIPLE PAN E INSULATED GLAZI NG UN ITSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 514,489, filed July 19, 2023, the entire disclosure of which is incorporated by reference.TECH N ICAL FI ELD

[0002] The present disclosure generally relates to insulated glazing units for fenestration units and, more particularly, relates to systems and methods for manufacturing multiple-pane insulated glazing units.BACKGROUND

[0003] A fenestration unit, such as a window, sliding window, slider door, etc., may include a frame that supports one or more other components of the unit. For example, the fenestration unit may include a frame that supports a sash, which in turn supports a glazing unit. The glazing unit enables light to pass through the fenestration unit, and may also permit thermal energy to pass through the fenestration unit. As the fenestration unit may be installed in a building or other structure, it is generally undesirable for thermal energy within the building or other structure to pass freely through the glazing unit as it reduces energy efficiency of the building or other structure.

[0004] In some embodiments, the glazing unit may include a plurality of panes. The plurality of panes may increase energy efficiency. However, one or more of the panes may be difficult to support. Thus, the strength of the glazing unit may be disadvantageously limited. Moreover, manufacturing costs typically increase when plural panes are included. Additionally, it may be difficult to modify a glazing unit that is configured for one fenestration for use in another fenestration.

[0005] Accordingly, it is desirable to provide an improved glazing unit with multiple panes. It is also desirable to provide a more robust multi-pane glazing unit. It is further desirable to provide improved manufacturing methods and systems for providing multi-pane glazing units at lower costs,higher manufacturing efficiency, etc. Also, it is desirable to provide systems for modifying, adjusting, selecting, and tailoring a glazing unit for use in a particular fenestration. Furthermore, other desirable features and characteristics of the present disclosure will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background.BRI EF SU MMARY

[0006] In an example embodiment, a method of manufacturing a glazing unit for a fenestration with a first pane and a smaller pane that is smaller than the first pane is disclosed. The method includes providing, to a processor of a control system, a first peripheral dimension, Di, for the first pane. The first peripheral dimension, Di, is measured between a first pair of opposing edges of the first pane. The method also includes providing, to the processor, a second peripheral dimension, D?, for the first pane. The second peripheral dimension, D2, is measured between a second pair of opposing edges of the first pane. Additionally, the method includes determining, by the processor, a periphery reduction variable, x, according to the provided first peripheral dimension, Di, and the second peripheral dimension, D2, that satisfies:0.95 < ( - x) * (Z>2- ) / (£>! * D2) < 1 (1) andFurthermore, the method includes calculating, by the processor, a first reduced peripheral dimension, D3, of the smaller pane by reducing the first peripheral dimension, Di, by the determined periphery reduction variable (D3= Di - x). Additionally, the method includes calculating, by the processor, a second reduced peripheral dimension, D4, of the smaller pane by reducing the second peripheral dimension, D2, by the determined periphery reduction variable (D4= D2- x). Moreover, the method includes calculating, by the processor, an area, A, of the smaller pane using the calculated first reduced peripheral dimension, D3, and the calculated second reduced peripheral dimension, D4. Also, the method includes determining a thickness, T, of the smaller pane that satisfies: A / T > 180 (3)Furthermore, the method includes storing, in a computerized memory device, a dimension set for the glazing unit, which includes the first peripheral dimension, Di, and the second peripheral dimension, D2, of the first pane associated with the calculated first reduced peripheral dimension, D3, the calculated second reduced peripheral dimension, D4, and the determined thickness, T, of the smaller pane.

[0007] In another example embodiment, a manufacturing system is disclosed for manufacture of a glazing unit for a fenestration unit with a first pane and a smaller pane that is smaller than the first pane. The manufacturing system includes a control system with a processor, a memory device, and an output device. The processor is configured to receive a first peripheral dimension, Di, for the first pane, and the first peripheral dimension, Di, is measured between a first pair of opposing edges of the first pane. The processor is also configured to receive a second peripheral dimension, D2, for the first pane, and the second peripheral dimension, D2, is measured between a second pair of opposing edges of the first pane. The processor is configured to determine a periphery reduction variable, x, according to the provided first peripheral dimension, Di, and the second peripheral dimension, D2, that satisfies:Moreover, the processor is configured to calculate a first reduced peripheral dimension, D3, of the smaller pane by reducing the first peripheral dimension by the determined periphery reduction variable (D3= Di - x). Also, the processor is configured to calculate a second reduced peripheral dimension, D4, of the smaller pane by reducing the second peripheral dimension by the determined periphery reduction variable (D4= D2 - x). Also, the processor is configured to calculate an area, A, of the smaller pane using the calculated first reduced peripheral dimension, D3, and the calculated second reduced peripheral dimension, D4. The processor is configured to determine a thickness, T, of the smaller pane that satisfies: / A / T > 180 (3)Moreover, the memory device is configured to store a dimension set for the glazing unit, which includes the first peripheral dimension, Di, and the second peripheral dimension, D2, of the firstpane associated with the calculated first reduced peripheral dimension, Dj, the calculated second reduced peripheral dimension, D4, and the determined thickness, T, of the smaller pane. The output device is configured to output the dimension set to a user.BRIEF DESCRIPTION OF DRAWI NGS

[0008] The exemplary embodiments will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:

[0009] FIG. 1 is a perspective partially cross-sectional illustration of a fenestration unit, such as a vertical sliding window, which includes an exemplary multiple pane insulated glazing unit in accordance with the various teachings of the present disclosure;

[0010] FIG. 2 is a cross-sectional view of the fenestration unit of FIG. 1, taken along line 2-2 of FIG. 1;

[0011] FIG. 3 is perspective view of the multiple pane insulated glazing unit of the fenestration unit ofFIG. 1;

[0012] FIG. 4 is a cross-sectional view of the multiple pane insulated glazing unit, taken along line 4-4 of FIG. 3;

[0013] FIG. 5 is a schematic view of a manufacturing system for manufacturing the multiple pane insulated glazing unit of FIGS. 1-4; and

[0014] FIG. 6 is a flowchart illustrating a method of manufacturing the multiple pane insulated glazing units of FIGS. 1-4.DETAILED DESCRI PTION

[0015] The following detailed description is merely exemplary in nature and is not intended to limit the application and uses. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. In addition, those skilled in the art will appreciate that embodiments of the present disclosure may be practiced in conjunction with any type of fenestration unit that would benefit from a multiple pane insulated glazing unit and the use of the multiple pane insulated glazing unit with a sliding window sash described herein is merely one exemplary embodiment according to the present disclosure. Further, it should be noted that many alternative or additional functional relationships or physical connections may be present in an embodiment of the present disclosure. In addition, while the figures shown herein depict an example with certain arrangementsof elements, additional intervening elements, devices, features, or components may be present in an actual embodiment. It should also be understood that the drawings are merely illustrative and may not be drawn to scale.

[0016] Generally, the present disclosure includes a glazing unit with at least two panes, wherein at least one pane is larger than another. The larger pane may be directly connected to the frame and may be supported as a so-called "structural pane," and the other smaller pane may be indirectly connected to the frame and supported therein as a so-called "non-structural pane." The non- structural pane may be significantly thinner than the structural pane. The non-structural pane may also have smaller peripheral dimensions than the structural pane. In some embodiments, the glazing unit may include at least three panes with at least two structural panes, and the smaller non- structural pane disposed and supported therebetween. The at least three panes may be lie in parallel planes that are spaced apart from each other. In some embodiments, the panes may share a common centerline that extends through (i.e., normal to) the panes. Thus, the peripheral edges of the smaller non-structural pane may be inset (i.e., disposed closer to the centerline) relative to the peripheral edges of the larger structural panes.

[0017] Also, the present disclosure provides a method and system for determining, selecting, and providing the difference in peripheral dimension of the non-structural pane as compared to the larger structural pane(s) (i.e., a reduction of the peripheral dimension of the structural pane to be used for the non-structural pane). For example, the method and system of the present disclosure may be utilized to determine a reduction in width and height dimensions of the intermediate pane according to the height and width dimensions of the structural pane(s). In some embodiments, a manufacturing system may include a computerized tool that uses a method for selecting the dimensional difference. The size reduction of the smaller pane may be related to the width and height of the larger structural pane(s). The thickness of the smaller pane may also be determined accordingly and, thus, determined in part according to the dimensions of the larger structural panes.

[0018] As such, multiple pane glazing units may be manufactured to be robust while also being compact and lightweight. In some embodiments, the glazing unit manufactured according to the methods of the present disclosure may provide a viewable area larger than 95% of the overall glazing unit area. The methods and systems of the present disclosure may significantly reduce likelihood of damage to non-structural panes upon handling and transportation. These glazing units may be manufactured with high efficiency according to the teachings of the present disclosure.

[0019] One or more features of the present disclosure may relate to computerized systems and methods. As used herein, the term module refers to any hardware, software, firmware, electronic control component, processing logic, and / or processor device, individually or in any combination, including without limitation: application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that executes one or more software or firmware programs, a combinational logic circuit, and / or other suitable components that provide the described functionality.

[0020] Embodiments of the present disclosure may be described herein in terms of functional and / or logical block components and various processing steps. It should be appreciated that such block components may be realized by any number of hardware, software, and / or firmware components configured to perform the specified functions. For example, an embodiment of the present disclosure may employ various integrated circuit components, e.g., memory elements, digital signal processing elements, logic elements, look-up tables, or the like, which may carry out a variety of functions under the control of one or more microprocessors or other control devices.

[0021] For the sake of brevity, conventional techniques related to signal processing, data transmission, signaling, control, and other functional aspects of the systems (and the individual operating components of the systems) may not be described in detail herein. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent example functional relationships and / or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in an embodiment of the present disclosure.

[0022] With reference to FIGS. 1 and 2, a fenestration unit 10 including a multiple pane insulated glazing unit 200 is shown. The fenestration unit 10 and / or the glazing unit 200 may be configured according to the teachings of co-owned U.S. Patent Application No. 18 / 058,550, filed November 23, 2022, published as U.S. Patent Publication 2024 / 0167325 on May 23, 2024, the entire disclosure of which is incorporated by reference herein.

[0023] In this example, the fenestration unit 10 is a sliding window, such as a vertical sliding window, which includes two multiple pane insulated glazing units 200. It should be noted, however, that the present disclosure may be applicable to other types of fenestration units, including, but not limited to horizontal sliding doors, horizontal sliding windows, casement windows, awnings, skylights, etc. In this example, the fenestration unit 10 includes a fenestration frame 12, a fixed, first sash 14 and a movable, second sash 16. The fenestration frame 12 in this example is composed of a polymericmaterial, such as polyvinyl chloride, which is extruded, however, the fenestration frame 12 may be composed of other materials, including, but not limited to aluminum, wood, cladded wood, wood plastic composite, etc. The fenestration frame 12 supports the first sash 14 and the second sash 16. The first sash 14 is a fixed, non-active sash that is fixedly supported within the fenestration frame 12 and is immovable relative to the fenestration frame 12. The second sash 16 is a sliding sash that is supported within the fenestration frame 12 for sliding movement along a vertical axis 18. The vertical axis 18 is perpendicular to a lateral or horizontal axis 20 (i.e., lateral or horizontal direction), and an interior / exterior axis 22 is perpendicular to the vertical axis 18 and the horizontal axis 20. The first and second sashes 14, 16 are supported within the fenestration frame 12 and are offset along the interior / exterior axis 22 such that the second sash 16 partially overlaps the first sash 14. Generally, the second sash 16 is movable between: 1) a first position, shown in FIG. 2, in which the second sash 16 is closed; 2) a second position, in which the second sash 16 is open to enable ventilation through the fenestration unit 10; and 3) various positions in between the first position and the second position. When the fenestration unit 10 is coupled to a structure, such as a building, an exterior side 26 of the fenestration unit 10 is disposed on and faces outward from an exterior of the building, while an interior side 28 of the fenestration unit 10 is disposed on and faces inward into an interior of the building (FIG. 2).

[0024] In this example, with reference to FIG. 2, a screen 30 is coupled to the fenestration frame 12 so as to be covered by the second sash 16 in the closed, first position. In the second position, the screen 30 is exposed to enable fluids, such as air, to flow through the fenestration unit 10. The second sash 16 may include one or more seals 32, such as brush seals, which assist in inhibiting debris, fluids, etc. from entering through the movement of the second sash 16. The second sash 16 and the fenestration frame 12 may also include interlocking seals 34, which ensures debris, fluids, etc. do not enter through the fenestration frame 12 around the second sash 16. Generally, each of the multiple pane insulated glazing units 200 is removably retained within the respective sash 14, 16 via one or more glass stops 36. In this example, each of the sashes 14, 16 include two glass stops 36 on opposite sides of the respective sash 14, 16. The glass stops 36 each include a support flange 38 and a flexible leg 40. The support flange 38 is in contact with and adjacent to the respective multiple pane insulated glazing unit 200 when the glass stops 36 are coupled to the respective sash 14, 16. The flexible leg 40 releasably couples the glass stops 36 to the respective sash 14, 16. In one example, each flexible leg 40 is received within a channel 42 defined in the respective sash 14, 16 such that a rotation of the support flange 38 relative to the channel 42 of the respective sash 14, 16releases the glass stop 36 from the sash 14, 16. This enables the multiple pane insulated glazing unit 200 to be removed for cleaning or replacement, for example.

[0025] With reference to FIG. 3, one of the multiple pane insulated glazing units 200 is shown in greater detail. In some embodiments, each of the multiple pane insulated glazing units 200 is the same. For the sake of brevity, a single multiple pane insulated glazing unit 200 will be described in detail herein. Generally, the multiple pane insulated glazing unit 200 is a multiple pane glazing assembly, which assists in reducing the passage of thermal energy through the fenestration unit 10. In one example, the multiple pane insulated glazing unit 200 includes a first outer pane 202, a second outer pane 204, a third intermediate pane 206, a first spacer 208, and a second spacer 210.

[0026] In this example, the first outer pane 202 is positioned proximate the exterior side 26 of the fenestration unit 10, and the second outer pane 204 is positioned proximate the interior side 28 of the fenestration unit 10. The third intermediate pane 206 may be disposed between the first outer pane 202 and the second outer pane 204 along the interior / exterior axis 22. The first spacer 208 may be disposed between the first outer pane 202 and the third intermediate pane 206 and may support these panes 202, 206 spaced apart along the interior / exterior axis 22. The second spacer 210 may be disposed between the second outer pane 204 and the third intermediate pane 206 and may support these panes 204, 206 spaced apart along the interior / exterior axis 22. The third intermediate pane 206 may be substantially centered between the first and second outer panes 202, 204 along the interior-exterior axis 22. Also, the three panes 202, 204, 206 may be aligned along a common centerline that extends therethrough along the interior-exterior axis 22.

[0027] In one example, the first outer pane 202, the second outer pane 204, and the third intermediate pane 206 are composed of glass, and have about the same glass composition. The first outer pane 202, the second outer pane 204 and the third intermediate pane 206 may be formed using a glass float process.

[0028] In this example, the first outer pane 202, the second outer pane 204 and the third intermediate pane 206 are each composed of boron-free soda lime silicate glass. For example, each of the first outer pane 202 and the second outer pane 204 are composed of about 68 weight percent (wt%) to about 74 weight percent (wt%) of silicon dioxide (SiO2); about 12 weight percent (wt%) to about 16 weight percent (wt%) of sodium oxide (Na2O); about 0 weight percent (wt%) to about 1.1 weight percent (wt%) of potassium oxide (K2O); about 4 weight percent (wt%) to about 13 weight percent (wt%) of Calcium Oxide (CaO); about 0 weight percent (wt%) to about 4.5 weight percent (wt%) of magnesium oxide (MgO); about 0 weight percent (wt%) to about 4.8 weightpercent (wt%) of aluminum oxide (AI2O3); less than about 0.3 weight percent (wt%) of sulfur trioxide SO3; and less than about 0.6 weight percent (wt%) of total iron oxide (Fe2O3 and FeO). In certain instances, less than about 0.5 weight percent (wt%) of Cerium oxide (CeO2) and titanium dioxide (TiO2) may be added to allow for a higher iron content. The total iron oxide content assists in filtering infrared and ultraviolet light. Generally, more than 25% of the total iron oxide content is iron oxide (FeO) as a higher concentration of iron oxide (FeO) is beneficial for infrared and ultraviolet light filtering. It should be noted that the weight percent of the total iron in the first outer pane 202, the second outer pane 204 and the third intermediate pane 206 may be reduced if higher visible light transmission is desired. In addition, one or more of the first outer pane 202, the second outer pane 204, and the third intermediate pane 206 may be annealed and / or tempered. In this example, the first outer pane 202 and the second outer pane 204 are annealed.

[0029] Generally, silicon dioxide acts as a glass network former, and alkali (sodium oxides and potassium oxides) and alkaline-earth oxides (calcium and magnesium oxides) act as a glass network modifier. Aluminum oxide acts as an intermediate for the glass network, and the sulfur acts as a refining agent. Generally, the use of this glass composition enables the first outer pane 202, the second outer pane 204 and the third intermediate pane 206 to have good chemical durability, high mechanical performance, and good thermal stability. This glass composition also provides for high throughput rate in the float glass manufacturing process, and the cost of manufacturing this glass composition using the float glass manufacturing process is relatively low compared to a vertical fusion manufacturing process.

[0030] With reference to FIG. 4, the first outer pane 202 includes a first outer surface 220 and a first inner surface 222 that is opposite the first outer surface 220. In this example, the first outer pane 202 is rectangular, and includes a plurality of first edges or sides 224. It should be noted, however, that the first outer pane 202 may have any desired shape, including, but not limited to, circular, trapezoidal, square, or generally any polygonal shape that corresponds with the shape of the second outer pane 204 and the third intermediate pane 206. In one example, the first outer surface 220 is coated, and includes a hard coating or scratch resistant coating, including, but not limited to silica and other oxides or nitrides with high surface hardness. In other embodiments, the first outer surface 220 may be uncoated. The first inner surface 222 is coated, and includes soft coating such as a low emissivity coating, including, but not limited to silver (Ag), copper (Cu), platinum (Pt), rhodium (Rh), nickel (Ni), Chromium (Cr), or combinations thereof in an alloy, etc. The first outer pane 202 has a thickness T1 defined between the first outer surface 220 and the first inner surface 222 or inthe interior / exterior axis 22. In some embodiments, the thickness T1 may be about three millimeters (mm). In one example, the first outer pane 202 has a height Hl defined between opposed first sides 224 in the vertical axis 18 of about 800 millimeters (mm) and a width W1 defined between opposed first sides 224 (FIG. 3) in the horizontal axis 20 of about 700 millimeters (mm). It should be noted that the height Hl and the width W1 (FIG. 3) of the first outer pane 202 may vary based on the fenestration frame 12 associated with the multiple pane insulated glazing unit 200, and thus, the values of the height Hl and the width W1 are merely examples.

[0031] With continued reference to FIG. 4, the second outer pane 204 includes a second outer surface 230 and a second inner surface 232 that is opposite the second outer surface 230. In this example, the second outer pane 204 is rectangular, and includes a plurality of second edges or sides 234. It should be noted, however, that the second outer pane 204 may have any desired shape, including, but not limited to, circular, trapezoidal, square, or generally any polygonal shape that corresponds with the shape of the first outer pane 202 and the third intermediate pane 206. In one example, the second outer surface 230 is coated, and includes a hard coating or scratch resistant coating, including, but not limited to silica and other oxides or nitrides with high surface hardness, a tin oxide coating, or a transparent conductive oxide coating. The second inner surface 232 may be coated to include a soft coating such as a low emissivity coating, including, but not limited to silver (Ag), copper (Cu), platinum (Pt), rhodium (Rh), nickel (Ni), Chromium (Cr), or combinations thereof in an alloy, etc.

[0032] In some embodiments, the second outer pane 204 may have the same thickness T1 defined between the second outer surface 230 and the second inner surface 232 (i.e., measured along the interior / exterior axis 22) as the first outer pane 202. Thus, like the first outer pane 202, the second outer pane 204 may have a thickness T1 of about three millimeters (mm). Moreover, in some embodiments, the second outer pane 204 may have the same height defined between opposed second sides 234 in the vertical axis 18 and the same width W1 defined between opposed second sides 234 (FIG. 3) in the horizontal axis 20 as the first outer pane 202. Thus, the second outer pane 204 may have the same height Hl, the same width Wl, and the same thickness T1 as the first outer pane 202 as indicated in FIG. 4.

[0033] The third intermediate pane 206 may be positioned between the first outer pane 202 and the second outer pane 204. The third intermediate pane 206 includes a third inner surface 240 and a fourth inner surface 242 that is opposite the third inner surface 240. In this example, the third intermediate pane 206 is rectangular, and includes a plurality of third edges or sides 244. In oneexample, the third inner surface 240 is coated, and includes a hard coating or scratch resistant coating, including, but not limited to silica and other oxides or nitrides with high surface hardness, a tin oxide coating, or a transparent conductive oxide coating. The fourth inner surface 242 may also be coated with a hard coating such as a scratch resistant coating, including, but not limited to silica and other oxides or nitrides with high surface hardness. In certain embodiments, the fourth inner surface 242 may be uncoated. In addition, in certain embodiments, the third inner surface 240 and / or the fourth inner surface 242 may include a soft coating such as a low emissivity coating, including, but not limited to silver (Ag), copper (Cu), platinum (Pt), rhodium (Rh), nickel (Ni), Chromium (Cr), or combinations thereof in an alloy, etc. The low emissivity coating may have an emissivity of about 0.02 to about 0.07, and a solar transmittance of about 0.2 to about 0.7. Generally, the hard coatings, such as the scratch resistant coatings, are coated onto the surfaces of the respective panes 202, 204, 206 during the float glass manufacturing process, using a pyrolytic coating process where the temperature bonds the hard coating onto the respective surface. For the soft coatings, the metallic elements are deposited onto the surface of the respective panes 202, 204, 206 at a relatively lower temperature than that of the pyrolytic coating process using a magnetron sputtering process, for example.

[0034] In one example, the third intermediate pane 206 is a comparatively skinny pane having a thickness T3 that is different and less than the thickness T1 of the first outer pane 202 and the second outer pane 204. In some embodiments, the thickness T3 is about 0.2 millimeters (mm) to about 1.2 millimeters (mm) and in this example, is about 0.7 millimeters (mm). Also, the third intermediate pane 206 has a height H3 defined between opposed third sides 244 in the vertical axis 18 (FIG. 4) and a width W3 defined between opposed third sides 244 (FIG. 3) in the horizontal axis 20. In one example, the height H3 is different and less than the height Hl, and the width W3 is different and less than the width Wl. Stated another way, a perimeter of the third intermediate pane 206 defined by the third sides 244 may be different and less than (i.e., reduced in comparison to) a perimeter of the first outer pane 202 defined by the first sides 224. Similarly, the perimeter of the third intermediate pane 206 defined by the third sides 244 may be different and less than (i.e., reduced in comparison to) a perimeter of the second outer pane 204 defined by the second sides 234.

[0035] When assembled, the intermediate pane 206, the first outer pane 202, and the second outer pane 204 may be layered in a stack with the intermediate pane 206 between the outer panes 202, 204, and the panes 202, 204, 206 may share a centerline that extends along the axis 22. The firstand second outer panes 202, 204 may be centered on the axis 22 such that the sides 224 substantially have the same, overlapping peripheral profile (when viewed along the axis 22), and the profile of the intermediate pane 206 may be centered within the overlapping profiles of this stack such that the sides 244 are disposed inwardly along the axis 18 and the axis 20 relative to the sides 224, 234. Accordingly, the outer perimeter of the third intermediate pane 206 may be recessed, inset, and disposed inwardly relative to the respective perimeters of the first outer pane 202 and the second outer pane 204. In other words, all sides 244 of the third intermediate pane 206 may be inset and spaced inwardly toward a common centerline relative to the sides 224, 234 when viewed along interior / exterior axis 22. Additionally, it will be appreciated that an area of the third intermediate pane 206 may be different and less than an area of each of the first outer pane 202 and the second outer pane 204.

[0036] The thickness T3 of the third intermediate pane 206 may be smaller than the thickness T1 of the first and second outer panes 202, 204, and as a result, the overall thickness of the glazing unit 200 (measured along the axis 22 between the first outer surface 220 and the second outer surface 230) may be relatively small. Thus, the glazing unit 200 may be advantageously compact. Also, the smaller thickness T3 may provide significant reduction in weight for the glazing unit 200.

[0037] Additionally, a number of advantages may be provided due to the third intermediate pane 206 having a height H3 and width W3 that is different (less than) the height Hl and the width Wl, respectfully, of the first outer pane 202 and the second outer pane 204. The smaller dimensions of the third intermediate pane 206 may provide for ease of assembly of the multiple pane insulated glazing unit 200. In this regard, the third intermediate pane 206 may serve as a visual guide for the coupling of the first spacer 208 or the second spacer 210 to the third intermediate pane 206. In addition, by providing the third intermediate pane 206 with the height H3 and the width W3 that is different and less than the height Hl and the width Wl of the first outer pane 202 and the second outer pane 204, respectively, the third intermediate pane 206 may be less prone to damage during transportation and handling. For example, the sides 244 may be shielded, protected, etc. by the outwardly disposed sides 224 of the first outer pane 202 and the sides 234 of the second outer pane 204. Further, by reducing the size of the third intermediate pane 206, the first edges or sides 224 and / or second edges or sides 234 of the thicker outer panes 202, 204 may be the surfaces of the multiple pane insulated glazing unit 200 that are contacted during handling and transportation. Thus, by reducing the peripheral size of the third intermediate pane 206 within the glazing unit 200, the third edges or sides 244 of the third intermediate pane 206 may be protected from contact orexperiencing an impact when being handled or transported. Further, the reduced size (height H3 and width W3) of the third intermediate pane 206 may provide shock absorption for the multiple pane insulated glazing unit 200. The recessed sides 244 of the third intermediate pane 206 may eliminate the potential for the third edges or sides 244 of the third intermediate pane 206 to contact the first sides 224 and / or second sides 234 of the respective outer panes 202, 204 during a compression of the multiple pane insulated glazing unit 200 caused by thermal contraction of the fenestration frame 12 and / or the sashes 14, 16.

[0038] With the third intermediate pane 206 positioned between the first outer pane 202 and the second outer pane 204, a first chamber 250 and a second chamber 252 may be defined between the third intermediate pane 206 and the respective one of the first outer pane 202 and the second outer pane 204. In this example, the first chamber 250 may be defined between the first inner surface 222 and the third inner surface 240. The second chamber 252 may be defined by the fourth inner surface 242 and the second inner surface 232. The first spacer 208 may enclose the first chamber 250, and the second spacer 210 may enclose the second chamber 252 such that the first chamber 250 is fluidly isolated from the second chamber 252. In one example, each of the first chamber 250 and the second chamber 252 may have a chamber width WC, and the chamber width WC of the first chamber 250 may be equal to that of the second chamber 252. In this example, the chamber width WC may be approximately 0.7 millimeters (mm). The first chamber 250 and the second chamber 252 may provide insulation between the panes 202, 204, 206, which cooperates in reducing the transmission of thermal energy through the multiple pane insulated glazing unit 200.

[0039] Generally, the first spacer 208 and the second spacer 210 may form a seal about the perimeter of the respective one of the first outer pane 202 and the third intermediate pane 206, and the second outer pane 204 and the third intermediate pane 206.

[0040] The first and second spacers 208, 210 may be substantially similar and may respectively include a spacer base 260, a first spacer leg 262 and a second spacer leg 264 that are arranged to define a C-shaped cross-section (FIG. 4). Each of the first spacer 208 and the second spacer 210 may be hollow. The spacer base 260 may be substantially planar, and may define a spacer outer perimeter 266 of each of the first spacer 208 and the second spacer 210. The spacer outer perimeter 266 may be inset, recessed, etc. from the sides 224, 234 of the first and second outer panes 202, 204. The spacer outer perimeter 266 may also be inset, recessed, etc. from the sides 244 of the third intermediate pane 206. The spacers 208, 210 may be attached and sealed to the opposing surfacesof respective panes 202, 204, 206 with a first sealant 300 on the first spacer leg 262 and a second sealant 302 on the second spacer leg 264.

[0041] The spacer base 260 may define a fill opening, which enables a nozzle, tube or other conduit to be inserted to fill the respective one of the first chamber 250 and the second chamber 252 with a fluid F once the multiple pane insulated glazing unit 200 is assembled, if desired. In one example, the fluid F includes, but is not limited to a pressurized gas, air-argon mix, argon-krypton mix, air, etc. In this example, the fluid F is the same between the first chamber 250 and the second chamber 252, but in other embodiments, the fluid F may be different between the first chamber 250 and the second chamber 252.

[0042] Referring back to FIGS. 1 and 2, the assembled glazing unit 200 may be supported in the frame 12 of the fenestration unit 10. The first and second outer panes 202, 204 of the glazing unit 200 may be referred to as "structural panes" since they are directly connected to and in contact with the frame 12 and, therefore, provide substantial support to the overall structural integrity of the glazing unit 200. The intermediate pane 206, on the other hand, may be referred to as a "non-structural pane" since it is indirectly attached to the frame 12 (i.e., attached via the spacers 208, 210, the outer panes 202, 204, etc.) and, therefore, provides less to the overall structural integrity of the glazing unit 200.

[0043] Referring now to FIGS. 3-6, the dimensional differences of the third intermediate pane 206 from the first and second outer panes 202, 204 will be discussed further. The differences in peripheral dimensions (height and width) and the resulting differences in area may be selected and tailored according to the dimensions of the first and second outer panes 202, 204 to provide a number of advantages. The thickness of the intermediate pane 206 may also be determined according to these relationships as well.

[0044] In some embodiments represented in FIG. 5, a manufacturing system 500 of the present disclosure may be provided for manufacturing the glazing unit 200. The manufacturing system 500 may utilize a manufacturing method 1000 represented in FIG. 6. The manufacturing system 500 may comprise a computerized manufacturing tool that is used to select and determine certain parameters of the glazing unit 200.

[0045] The manufacturing system 500 may include a computerized control system 501 for controlling the tools. The control system 501 may include at least one processor 504, a memory device 506, and a user interface 508. The processor 504 and memory device 506 may be of any suitable type. The user interface 508 may include one or more input devices (e.g., keyboard, mouse, voice recognitionmodule, etc.) and / or one or more output devices (e.g., display screen, speaker, etc.). The system 500 may also include additional tooling, implements, or other features for forming, constructing, assembling, handling, or otherwise providing components of the glazing unit 200 according to the selected parameters. For example, the manufacturing system 500 may include an actuator system 510 that may selectively and automatically actuate, convey, handle, move, assemble, etc. components of the glazing unit 200. The actuator system 510 may, thus, include a conveyor belt, a vacuum-assisted handling tool, and other suitable devices. In additional embodiments, one or more of the components is conveyed, handled, moved, assembled, etc. manually. In further embodiments, the manufacturing system 500 and the method 1000 may include manual as well as automated features.

[0046] In some embodiments, the method 1000 of manufacturing the glazing unit 200 may include selecting, determining, etc. a dimensional difference, x, of the intermediate pane 206 according to corresponding dimensions of the first and second outer panes 202, 204. The dimensions of the panes 202, 204, 206 may be selected, determined, and output according to a number of relationships explained below. Using the method 1000 of the present disclosure, edge-to-edge dimensions, H3 and W3, of the third intermediate pane 206 may be determined according to the corresponding dimensions, Hl and Wl, of the first and second outer panes 202, 204. The thickness, T3, of the intermediate pane 206 may also be determined, selected, etc. according to the teachings of the present disclosure.

[0047] In the following discussion, the variable Di will represent the width, Wl, of the first and second outer panes 202, 204, and the variable D2will represent the height, Hl, of the first and second outer panes 202, 204. In some embodiments, Di is greater than five inches, and D2is greater than five inches.

[0048] In some embodiments, the first and second peripheral dimensions, Di, D2are known by a user. For example, these dimensions, Di, D2may be selected according to the dimensions of a particular rough opening of a building or structure. Accordingly, the method 1000 may begin at 1002, wherein, DI and D2 are input by the user, via the user interface 508, to the control system 501. The processor 504 may receive these dimensions of the first and second outer panes 202, 204, and subsequently at 1004, the processor 504 may communicate with the memory device 506 and determine, calculate, etc. a periphery reduction variable, x, of the intermediate pane 206. The periphery reduction variable, x, is the size reduction of the non-structural intermediate pane 206 in width and heightfrom the outer panes 202, 204. In other words, x characterizes the differences between the dimensions W1 and W3 of FIG. 3 and between the dimensions Hl and H3 of FIG. 4.

[0049] In some embodiments, at 1004 of the method 1000, the processor 504 may determine at least one value for the periphery reduction variable, x, that satisfies:0.95 < (£>! - ) * (£)2- x) / (£)1* D2) < 1 (1)Furthermore at 1004, in some embodiments, the processor 504 may determine at least one value of the periphery reduction variable, x, that also satisfies:

[0050] Then, at 1006 of the method 1000, with this determined variable, x, the processor 504 may calculate a reduced width, D3= Di - x, and a reduced height, D4= D2- x, of the intermediate pane 206, and also calculate an area thereof by multiplying D3and D4. The processor 504 may further calculate the area, A, of the third intermediate pane 206 using the calculated reduced width, D3, and height, D4 (e.g., A = D3 * D4). Subsequently, at 1006 of the method 1000, a thickness, T, of the third intermediate pane 206 may be determined using the calculated area, A, to satisfy: A / T > 180 (3)Accordingly, the control system 501 may determine a dimension dataset at 1004 and 1006 that includes the determined width, D3, height, D4, and thickness, T, dimensions of the third intermediate pane 206. This dimension dataset D3, D4, T may be associated together for a particular intermediate pane 206 that is tailored and configured according to the dimensions of the first and second outer panes 202, 204.

[0051] Next, at 1008 of the method 1000, the processor 504 may communicate with the memory device 506 and store the dataset determined at 1004 and 1006 of the method. The dataset D3, D4, T determined at 1004 and 1006 may be associated and combined with the first and second dimensions Di, Dj input at 1002 and saved as a glazing unit dataset, which includes the first peripheral dimension, Di, and the second peripheral dimension, D2, of the first pane associated with the calculated first reduced peripheral dimension, D3, the calculated second reduced peripheral dimension, D4, and the determined thickness, T, of the intermediate pane 206.

[0052] Then, at 1010 of the method 1000, the control system 501 may output the dimension dataset. For example, at 1010 of the method, the dimension dataset D3, D4, T may be output to a user via theuser interface 508. At 1010, in some embodiments, the dataset D3, D4, T saved at 1008 may be displayed, a hard copy may be provided, or may otherwise be output.

[0053] In some embodiments, the control system 501 may communicate with a glass supply 600 of the manufacturing system 500 and output the dataset Ds, D4, T thereto. For example, the glass supply 600 may include a computerized terminal that receives a glass request from the processor 504, and the glass request may include the dataset, D3, D4, T stored at 1008.

[0054] In response to the request output at 1010, the glass supply 600 may provide, at 1012, the intermediate pane 206 according to the requested dataset D3, D4, T. At 1012, the first and second outer panes 202, 204 may be provided as well with the dimensions entered at 1002. The control system 504 may send control commands to the actuator system 510, for example, for delivering one or more of the panes 202, 204, 206 to a workspace, assembly unit, etc. In some embodiments, the glass supply 600 may include a glass cutter 602 (e.g., an edged glass cutter, a laser cutter, a waterjet cutter, etc.). The control system 504 may provide control signals to the glass cutter 602, which may cut the intermediate pane to size according to the requested dimension dataset D3, D4, T. In additional embodiments, the glass supply 600 may include a sorting tool 604, which may be used to sort through a plurality of panes to locate and provide the intermediate pane 206 having the dimensions requested at 1010. The control system 504 may provide control signals to the sorting tool 604 to perform these tasks. In further embodiments, the glass supply 600 may provide the intermediate pane 206 as well as the first and second outer panes 202, 204 together for assembly. Furthermore, the spacers 208, 210 may also be provided. Then, at 1014, the glazing unit 200 may be assembled together as discussed above. Subsequently, the glazing unit 200 may be assembled into the frame 12 as discussed above. The method 1000 may then conclude as shown in FIG. 6.

[0055] Thus, the manufacturing system 500 and method 1000 of the present disclosure may be convenient and useful for selecting, determining, calculating, etc. the size reduction, x, of the intermediate pane 206 based on the relationships discussed above. The dimensions of the panes 202, 204, 206 may be selected, determined, and dimensioned together for use as an improved glazing unit 200. The control system 504 may control a manufacturing tool for making the glazing unit 200. For example, the processor 504 may be used to generate and communicate control signals to the actuator system 510, the glass cutter 602, or other components for forming the panes 202, 204, 206 to the selected dimensions, layering the panes 202, 204, 206 together with the spacers 208, 210, to form the glazing unit 200.

[0056] The table below represents a plurality of embodiments of the dimensions of the panes. Each row represents a different example for the dimensional relationship between the panes 202, 204,206 determined according to the relationships discussed above.

[0057] Accordingly, these glazing units 200 may be highly robust. These glazing units 200 may be strong, may provide high thermal efficiency, etc. Also, these glazing units 200 may be resistant to damage during handling.

[0058] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the present disclosure. It is understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the present disclosure as set forth in the appended claims.

Claims

CLAIMSWhat is claimed is:

1. A method of manufacturing a glazing unit for a fenestration with a first pane and a smaller pane that is smaller than the first pane, the method comprising: providing, to a processor of a control system, a first peripheral dimension, Di, for the first pane, the first peripheral dimension, Di, measured between a first pair of opposing edges of the first pane; providing, to the processor, a second peripheral dimension, D2, for the first pane, the second peripheral dimension, D2, measured between a second pair of opposing edges of the first pane; determining, by the processor, a periphery reduction variable, x, according to the provided first peripheral dimension, Di, and the second peripheral dimension, D2, that satisfies:0.95 < (D1- X) * (D2- X) / (D1* D2) < 1 (1) andcalculating, by the processor, a first reduced peripheral dimension, Da, of the smaller pane by reducing the first peripheral dimension by the determined periphery reduction variable (Da = Di - x); calculating, by the processor, a second reduced peripheral dimension, D4, of the smaller pane by reducing the second peripheral dimension by the determined periphery reduction variable (D4= D2- x); calculating, by the processor, an area, A, of the smaller pane using the calculated first reduced peripheral dimension, Da, and the calculated second reduced peripheral dimension, D4; determining a thickness, T, of the smaller pane with the calculated area, A, to satisfy: A / T > 180 (3) storing, in a computerized memory device, a dimension set for the glazing unit, which includes the first peripheral dimension, Di, and the second peripheral dimension, D2, of the first pane associated with the calculated first reduced peripheral dimension, D3, the calculated second reduced peripheral dimension, D4, and the determined thickness, T, of the smaller pane.

2. The method of claim 1, further comprising outputting to a user, by an output device of the control system, the dimension set.

3. The method of claim 1, further comprising assembling the glazing unit according to the dimension set.

4. The method of claim 3, wherein assembling the glazing unit includes assembling the glazing unit to include the first pane and a second pane that has the first peripheral dimension, DI, and the second peripheral dimension, D2.

5. The method of claim 4, wherein assembling the glazing unit includes disposing the smaller pane between the first pane and the second pane.

6. The method of claim 5, wherein assembling the glazing unit includes substantially aligning the first pane, the second pane, and the smaller pane along a common centerline extending therethrough.

7. The method of claim 6, wherein assembling the glazing unit includes providing a first spacer between the first pane and the smaller pane and providing a second spacer between the second pane and the smaller pane, the first spacer being separate from the second spacer.

8. The method of claim 7, further comprising: disposing the smaller pane with an intermediate periphery of the smaller pane inset from an outer periphery of the first pane and the second pane; and disposing the first spacer and the second spacer with a spacer periphery of the first spacer and the second spacer inset from the intermediate periphery of the smaller pane.

9. The method of claim 4, wherein the first pane, the second pane, and the smaller pane are each rectangular.

10. The method of claim 1, wherein the first peripheral dimension, DI, is greater than five inches and the second peripheral dimension, D2, is greater than five inches.

11. A manufacturing system for manufacture of a glazing unit for a fenestration unit with a first pane and a smaller pane that is smaller than the first pane, the manufacturing system comprising: a control system with a processor, a memory device, and an output device; the processor configured to receive a first peripheral dimension, Di, for the first pane, the first peripheral dimension, Di, measured between a first pair of opposing edges of the first pane; the processor configured to receive a second peripheral dimension, D2, for the first pane, the second peripheral dimension, D2, measured between a second pair of opposing edges of the first pane; the processor configured to determine a periphery reduction variable, x, according to the provided first peripheral dimension, Di, and the second peripheral dimension, D2, that satisfies:0.95 < (Dx- ) * (D2- x) / (D1* D2) < 1 (1) andthe processor configured to calculate a first reduced peripheral dimension, D3, of the smaller pane by reducing the first peripheral dimension by the determined periphery reduction variable (D3 = Di - x); the processor configured to calculate a second reduced peripheral dimension, D4, of the smaller pane by reducing the second peripheral dimension by the determined periphery reduction variable (D4= D2- X); the processor configured to calculate an area, A, of the smaller pane using the calculated first reduced peripheral dimension, D3, and the calculated second reduced peripheral dimension, D4; the processor configured to determine a thickness, T, of the smaller pane with the calculated area, A, to satisfy: A / T > 180 (3) the memory device configured to store a dimension set for the glazing unit, which includes the first peripheral dimension, Di, and the second peripheral dimension, D2, of the first pane associated with the calculated first reduced peripheral dimension, D3, the calculated second reduced peripheral dimension, D4, and the determined thickness, T, of the smaller pane; and the output device configured to output the dimension set to a user.

12. The system of claim 11, wherein the memory device is configured to store the dimension set to include the first peripheral dimension, DI, and the second peripheral dimension, D2, for the first pane and for a second pane of the glazing unit having the first peripheral dimension, DI, and the second peripheral dimension, D2.

13. The system of claim 12, wherein the glazing unit is configured for the smaller pane to be disposed between the first pane and the second pane.

14. The system of claim 12, wherein the first pane, the second pane, and the smaller pane are each rectangular.

15. The system of claim 11, wherein the first peripheral dimension, DI, is greater than five inches and the second peripheral dimension, D2, is greater than five inches.

Images