Spacer for multiple pane insulated glazing units

Abstract

A spacer for a glazing unit includes a spacer support member with a spacer base, a first spacer leg, and a second spacer leg. The first spacer leg is spaced apart from the second spacer leg with the spacer base extending therebetween. The spacer base, the first spacer leg, and the second spacer leg cooperatively define a channel of the spacer support member. The channel extends along a longitudinal axis of the spacer support member. The spacer also includes a thermal insert member that is received in the channel, that extends longitudinally along the longitudinal axis, and that spans across the channel between the first spacer leg and the second spacer leg. The thermal insert member has a first side facing into the channel and a second side facing out of the channel. The second side has a plurality of pockets.

Description

PATENT APPLICATIONATTORNEY DOCKET NO. 123950 (380.0959PC)SPACER FOR MU LTI PLE PANE INSULATED GLAZING UN ITSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 63 / 514,477, 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 a spacer for a multiple pane insulated glazing unit.BACKGROUN D

[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 an 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 be separated by at least one spacer within the glazing unit. However, conventional spacers may be deficient for some glazing units. They may not exhibit sufficient thermal properties. Furthermore, the spacer may not provide a suitable attachment to the pane and / or frame.

[0005] Accordingly, it is desirable to provide an improved spacer for a glazing unit with multiple panes. It is also desirable to provide a spacer that provides improved thermal performance. Furthermore, it is desirable to provide a strong and robust spacer that is convenient to attach within a glazing unit. Furthermore, other desirable features and characteristics of the present disclosure will becomeapparent 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 thermal edge spacer is disclosed for a glazing unit having a first pane and a second pane. The thermal edge spacer includes a spacer support member with a spacer base, a first spacer leg, and a second spacer leg. The first spacer leg is spaced apart from the second spacer leg with the spacer base extending therebetween. The spacer base, the first spacer leg, and the second spacer leg cooperatively define a channel of the spacer support member. The channel extends along a longitudinal axis of the spacer support member. The first spacer leg is configured to support the first pane, and the second spacer leg is configured to support the second pane. The spacer also includes a thermal insert member that is received in the channel, that extends longitudinally along the longitudinal axis, and that spans across the channel between the first spacer leg and the second spacer leg. The thermal insert member has a first side facing into the channel and a second side facing out of the channel. The second side has a plurality of pockets.

[0007] In another example embodiment, a glazing unit for a fenestration unit is disclosed that includes a first pane, a second pane, and a third pane disposed between the first pane and the second pane. The glazing unit further includes a first spacer disposed between the first pane and the third pane to support the first pane and the third pane separated at a distance and to define a first chamber therebetween. The first spacer defines a first outer boundary of the first chamber. The glazing further includes a second spacer disposed between the second pane and the third pane to support the second pane and the third pane separated at a distance and to define a second chamber therebetween. The second spacer defines a second outer boundary of the second chamber. The first spacer and the second spacer respectively include a spacer support member with a spacer base, a first spacer leg, and a second spacer leg. The first spacer leg is spaced apart from the second spacer leg with the spacer base extending therebetween. The spacer base, the first spacer leg, and the second spacer leg cooperatively define a channel of the spacer support member. The channel extends along a longitudinal axis of the spacer support member. Moreover, the first spacer and the second spacer respectively include a thermal insert member that is received in the channel, that extends longitudinally along the longitudinal axis, and that spans across the channel between the first spacerleg and the second spacer leg, the thermal insert member has a first side facing into the channel and a second side facing out of the channel. The second side has a plurality of pockets.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 cross-sectional view of a spacer configured for the glazing unit of FIGS. 1-4;

[0014] FIG. 6 is a plan view of a thermal insert member of the spacer of FIGS. 1-4 according to additional embodiments; and

[0015] FIG. 7 is a cross-sectional view of the thermal insert member taken along the line 7-7 of FIG. 6.DETAILED DESCRI PTION

[0016] 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 functionalrelationships 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 arrangements of 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.

[0017] Generally, the present disclosure relates to a glazing unit for a fenestration unit, such as a window, wherein the glazing unit includes at least two panes, which are separated and spaced apart by a spacer. The spacer may include an insert member that provides thermal benefits for the glazing unit. In some embodiments, the insert member may include surface variations that define thermal pockets within the spacer that are open to the interior chamber of the glazing unit between the panes. The thermal pockets may be arranged, in some embodiments, side-by-side along a thermal path direction (e.g., along an interior-exterior axis of the fenestration unit) within the spacer. In some embodiments, the insert member may be a thin strip of material that is folded, dimpled, or otherwise provided with undulations, waves, etc., and spaces between these undulations, waves, etc. may define the thermal pockets for the spacer. When installed in the glazing unit, the thermal pockets may increase fluid volume along the longitudinal length of the spacer, which can advantageously improve thermal insulation for the glazing unit.

[0018] In some embodiments, the glazing unit may include a first pane, a second pane, and an intermediate pane disposed therebetween. A first spacer may be included between the first pane and the intermediate pane, and a second spacer may be included between the second pane and the intermediate pane. Both the first spacer and the second spacer may include thermal pockets. Thus, the multiple pane glazing unit of the present disclosure may provide significant thermal benefits. Also, the glazing unit of the present disclosure may be manufactured with high efficiency.

[0019] The spacer may include textured members, materials, etc. that define multiple convection chambers (i.e., pockets) along the path of heat transfer through the glazing unit. The spacer may include integrated glue that can be pressure sensitive and that can be applied onto the glass panes. The spacer may include a built-in moisture barrier element (e.g., desiccant) to enhance the performance of glazing unit and fenestration unit over an extended time.

[0020] 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.

[0021] 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 polymeric material, 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 an interior of the building (FIG. 2).

[0022] 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 insulatedglazing 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, 16 releases 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.

[0023] 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. The first spacer 208 and the second spacer 210 may be referred to as "warm edge spacers."

[0024] 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.

[0025] 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 pane202, the second outer pane 204 and the third intermediate pane 206 may be formed using a glass float process.

[0026] 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 weight percent (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.

[0027] 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.

[0028] 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 in the 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.

[0029] 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.

[0030] 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.

[0031] 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 one example, 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.

[0032] 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 1.2millimeters (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 and a width W3 defined between opposed third sides 244 (FIG. 3) in the horizontal axis 20.

[0033] In some embodiments, 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 a perimeter of the first outer pane 202 defined by the first sides 224 and different and less than a perimeter of the second outer pane 204 defined by the second sides 234 such that the third intermediate pane 206 is recessed relative to the first outer pane 202 and the second outer pane 204. Thus, generally, an area of the third intermediate pane 206 is different and less than an area of each of the first outer pane 202 and the second outer pane 204.

[0034] 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, the third intermediate pane 206 provides 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. For example, the side 244 may establish a convenient reference point for the position of an outer peripheral side 266 of the spacers 208, 210. More specifically, both spacers 208, 210 may include a respective outer peripheral side 266 that faces outwardly from a centerline of the panes 202, 204, 206 extending along the axis 22, and the outer peripheral side 266 may be disposed inwardly at a distance 280 from the side 244 of the intermediate pane 206. Likewise, the outer peripheral side 266 may be disposed inwardly at a distance 282 from the sides 224, 234 of the first and second pane 202, 204. This may increase manufacturing convenience during assembly of the glazing unit, during quality control of an assembled glazing unit 200, or otherwise.

[0035] 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, the third intermediate pane 206 may be less prone to damage during transportation and handling. 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 more prone to contact during handling and transportation. Thus, by reducing a size of the third intermediate pane 206, the third edges or sides244 of the third intermediate pane 206 may be protected from contact or experiencing an impact when being handled or transported. Further, the reduced size (height H3 and width W3) of the third intermediate pane 206 may act as a shock absorber for the multiple pane insulated glazing unit 200, because the recessed edges 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 contraction of the fenestration frame 12 and / or the sashes 14, 16 due to changes in temperature.

[0036] With the third intermediate pane 206 positioned between the first outer pane 202 and the second outer pane 204, and with the spacers 208, 210 included proximate the peripheries of these panes 202, 204, 206, 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 is defined between the first inner surface 222 and the third inner surface 240. The second chamber 252 is defined between the fourth inner surface 242 and the second inner surface 232. The first spacer 208 encloses the first chamber 250 and the second spacer 210 encloses 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 have a chamber width WC, which is the same. In some embodiments, the chamber width WC is about 0.7 millimeters (mm). The first chamber 250 and the second chamber 252 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.

[0037] Referring now to FIGS. 4 and 5, the first spacer 208 and the second spacer 210 will be discussed in greater detail according to example embodiments of the present disclosure. Generally, the first spacer 208 and the second spacer 210 may be provided to support the panes 202, 204, 206 spaced apart at a distance and to form a seal for the chambers 250, 252 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.

[0038] The first spacer 208 will be discussed in detail with reference to FIG. 5, and it will be appreciated that the second spacer 210 may be substantially similar. The first spacer 208 may include a spacer support member 211 that is elongate. The spacer support member 211 may have a spacer base 260, a first spacer leg 262, and a second spacer leg 264 that may be integrally attached (i.e., unitary, one-piece). The first spacer leg 262 may be spaced apart from the second spacer leg 264 with the spacer base 260 extending therebetween along the interior / exterior axis 22. The first spacer leg 262 and the second spacer leg 264 may project from opposite sides of the spacer base 260 to define a hollow U- shaped or C-shaped cross-section taken through a longitudinal axis of the spacer 208. Accordingly, the spacer base 260, the first spacer leg 262, and the second spacer leg 264 may cooperatively define a channel 265 extending along the longitudinal axis of the spacer 208. The cross-section of the spacer support member 211 (e.g., the cross-section shown in FIG. 5) may be substantially constant along a majority of the longitudinal axis of the spacer 208. The spacer 208 may be elongated along the longitudinal axis. It will be appreciated that the longitudinal axis may extend along the peripheries of the panes 202, 206 and to define the outer boundary of the chamber 250.

[0039] The spacer base 260 may be substantially planar, and may define the outer peripheral side 266 of the spacer 208. An inner side 268 of the spacer base 260 may be planar as well and may face in an opposite direction from the outer peripheral side 266 (i.e., toward an interior of the chamber 250 of the glazing unit 200). The first spacer leg 262 and the second spacer leg 264 may project perpendicularly from the spacer base 260. The first spacer leg 262 may terminate at a first interior edge 270, and the second spacer leg 264 may terminate at a second interior edge 1 . The first and second spacer legs 262, 264 may be spaced apart along the interior / exterior axis 22.

[0040] In some embodiments, the spacer support member 211 may be substantially rigid. For example, the spacer support member 211 may be formed of a strong polymeric material, such as polycarbonate material or other rigid plastics. Furthermore, in some embodiments, the spacer support member 211 may be manufactured via an extrusion process.

[0041] In some embodiments, the glazing unit 200 may include a fill opening extending through the spacer base 260, enabling a nozzle, tube or other conduit to be inserted to fill the chamber 250 (FIG. 4) 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] The spacer 208 may also include a thermal insert member 274 that is received in the open portion of the rigid spacer support member 211. The thermal insert member 274 may be strip of material (e.g., a polymeric strip, a textile, a wood-fiber based material, paper, etc.) with an inner side276 and an opposite outer side 278. The thermal insert member 274 may have a substantially constant thickness measured between the inner side 276 and the outer side 278. Also, the thermal insert member 274 may be textured, contoured, folded, or otherwise disposed in a non-planar arrangement. The thermal insert member 274 may be dimpled, may be folded, may include a plurality of folds, may undulate such that the inner side 276 and / or the outer side 278 are non-planar. Accordingly, as will be discussed, the thermal insert member 274 may include and define a plurality of thermal pockets 284 on the inner side 276 thereof.[00431 The thermal insert member 274 may undulate, may be dimpled, may be folded, may be contoured, etc. In some embodiments represented in FIG. 5, the thermal insert member 274 may define a plurality of inner contours or folds 290 and a plurality of outer contours or folds 292. The thermal insert member 274 may be contained substantially (e.g., entirely) within the hollow interior of the spacer support member 211 with the outer folds 292 disposed proximate the spacer base 260 and the inner folds 290 proximate the interior edges 270, 272. The insert member 274 may also include a first edge il , which may be proximate and attached to the first spacer leg 262, and a second edge 279, which may be proximate and attached to the second spacer leg 264.

[0044] As shown in the illustrated embodiments, the thin, sheet-like insert member 274 may be uneven and non-planar on the inner side 276 as well as uneven and non-planar on the outer side 278 so as to enable a high degree of contouring, curvature, folding, etc. of the insert member 274. Thus, surface area of the inner side 276 (and that of the outer side 278) may be substantially larger, for example, than the surface area of the planar inner side 268 of the spacer base 260.

[0045] The insert member 274 may be contoured, textured, patterned, or otherwise disposed in a variety of arrangements without departing from the scope of the present disclosure. The insert member 274 may undulate, fold, contour, ripple, may be arranged in a waveform to define a plurality of alternating peaks and valleys.

[0046] The arrangement may extend in a number of directions, including the interior / exterior direction (i.e., along the axis 22) as shown in FIGS. 4 and 5. In some embodiments, the uneven, non-planar, wavy inner side 276 may be arranged along the axis 22 such that the inner folds 290 are spaced apart along the axis 22 at a distance 294. The distance 294 may vary between neighboring pairs of the plurality of inner folds 290. The outer folds 292 may be spaced apart as well.

[0047] In some embodiments, the spacer 208 may also include a side adhesive layer 296 on one or more outer surfaces. For example, the spacer 208 may include an adhesive layer 296 on the outer side of the first spacer leg 262 and an additional adhesive layer 296 on the outer side of the second spacer leg 264. The adhesive layers 296 may be used for adhesively attaching to the respective one of the panes 202, 204, 206. The side adhesive layer 296 may be and / or include acrylic-based materials or other polymers with tackifiers, such as styrene block copolymer with tackifiers.

[0048] Moreover, the spacer 208 may include a moisture barrier element 298. The moisture barrier element 298 may be or comprise a desiccant material that acts as a drying agent for the spacer 208 within the glazing unit 200. The moisture barrier element 298 may be disposed in the channel 265, between the spacer base 260 and the thermal insert member 274.

[0049] FIGS. 6 and 7 show the insert member 1274 according to additional embodiments of the present disclosure. The insert member 1274 may be substantially similar to the insert member 274 of FIGS. 4 and 5. Corresponding features are identified with corresponding reference numbers increased by 1000.

[0050] The insert member 1274 may be dimpled. Stated differently, the insert member 1274 may include a plurality of dimples 1275 that are arranged in an evenly spaced array. The pockets 1284 of the dimples 1275 may be defined on the inner side 1276 and the outer side 1278 of the insert member 1274. The pockets 1284 of the dimples 1275 may be hollow spaces on the inner side 1276 and may be hemispherical. The dimples 1275 may have corresponding convex, hemispherical contour on the outer side 1278.

[0051] As shown in FIGS. 6 and 7, the dimples 1275 may be arranged along the axis 22 and such that the pockets 1284 are spaced apart along the axis 22 at a distance 1294. Also, as shown in FIG. 6, the dimples 1275 may be arranged along the longitudinal axis of the insert member 1274 (e.g., along the vertical axis 18 or the horizontal axis 20 of the glazing unit 200) such that the pockets 1284 are spaced apart at a distance 1295. In some embodiments, the distance 1294 and the distance 1295 are substantially equal between the dimples 1275; however, it will be appreciated that the spacing of the dimples may be irregular. The shapes, arrangement, folding, undulations, waveforms, wrinkles, pattern of peaks and valleys, etc. of the thermal insert member 1274 may vary without departing from the scope of the present disclosure.

[0052] The thermal insert member 1274 may be disposed in the spacer 208 and / or the second spacer 210 of FIG. 4 with the first edge 1277 attached to the first spacer leg 262 and the second edge 1279 attached to the second spacer leg 264. In some embodiments, the first edge 1277 and the second edge 1279 may be sealed to the legs 262, 264, respectively, via a sealant.

[0053] In some embodiments represented in FIG. 7, the thermal insert member 1274 may be deformable. A neutral position of the thermal insert member 1274 is shown in solid lines, and a deformed position is shown in broken lines. One or more of the dimples 1275 may deform as the thermal insert member 1274 moves between neutral and deformed positions, thus changing the volume of the respective pocket 1284. In some embodiments, the thermal insert member 1274 may deform elastically. Thus, for example, when filling the chamber 250 with fluid, F, the fluid pressure may, for example, as represented in FIG. 7, in which the dimple 1275 collapses to a degree along the axis 22 and the air pocket 128 moves in an outward direction transverse to the axis 22. In some embodiments, thermal changes (e.g., thermal expansion) may cause the insert member 1274 to deform, for example, as shown in FIG. 7. The insert member 1274 may be resiliently deformable for elastic deformation from the neutral position toward the deformed position, and the insert member 1274 may resiliently recover back toward the neutral position as loads on the insert member 1274 change.

[0054] It will be appreciated that the insert member 274 of FIGS. 4 and 5 may be deformable as well. For example, the inner folds 290 and / or the outer folds 292 may move in a radial direction relative to the axis 22, for example, during assembly of the glazing unit 200, due to filling the chamber 250, because of thermal conditions of the glazing unit 200, etc. During assembly, the insert member 274, 1274 may deform and seal against the surrounding features (e.g., against the spacer legs 262, 264, against the moisture barrier element 298, etc.). Also, air pockets, such as the pockets 284, 1284 may be created and defined within the assembled glazing unit 200. These pockets 284, 1284 (e.g., air pockets) may substantially improve thermal performance of the glazing unit 200.

[0055] The insert member 274, 1274 may be made of a number of materials without departing from the scope of the present disclosure. In some embodiments, the insert member 274, 1274 may be made from or include a polymeric material, such as a strip of polycarbonate. In additional embodiments, the inset member 274, 1274 may be made from or include metallic material, such as aluminum, tin-coated steel, stainless steel, etc. The insert member 274, 1274 may be extruded, pressed, stamped, or otherwise formed.

[0056] The spacer 208 may be manufactured using composite laminating technology. Accordingly, a plurality of the features discussed above may be formed simultaneously. For example, in some embodiments represented in FIG. 5, multiple features of the spacer 208 may be formed substantially simultaneously in a single manufacturing process. Specifically, the adhesive 296, the moisture barrier element 298 (including the desiccant), and the insert member 274 may be provided in a laminating process on the spacer support member 211.

[0057] In some embodiments, there may be several design choices (different part colors, different textures for the insert member 274, 1274, and different configurations may be tailored for optimal design appearance and performance of the glazing unit 200. The insert member 274, 1274 creates and defines multiple convection chambers or pockets 284, 1284 across the path of heat transfer and therefore increases the energy efficiency of the glazing unit 200.

[0058] Also, it will be appreciated that the embodiments of FIGS. 1-4, in which the glazing unit 200 includes three panes with one relatively thin layered between the other two, the spacers 208, 210 may be useful for substantially enhancing thermal performance of the glazing unit 200. The pockets 284, 1284 in the spacers 208, 210 may advantageously improve the thermal performance, and the glazing unit 200 nay have a reduced overall thickness measured along the interior / exterior axis 22.

[0059] While at least one exemplary embodiment has been presented in the foregoing detailed description of the disclosure, 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 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 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 disclosure as set forth in the appended claims.

Claims

CLAIMSWhat is claimed is:

1. A thermal edge spacer for a glazing unit having a first pane and a second pane comprising: a spacer support member with a spacer base, a first spacer leg, and a second spacer leg, the first spacer leg spaced apart from the second spacer leg with the spacer base extending therebetween, the spacer base, the first spacer leg, and the second spacer leg cooperatively defining a channel of the spacer support member, the channel extending along a longitudinal axis of the spacer support member, the first spacer leg configured to support the first pane, the second spacer leg configured to support the second pane; and a thermal insert member that is received in the channel, that extends longitudinally along the longitudinal axis, and that spans across the channel between the first spacer leg and the second spacer leg, the thermal insert member having a first side facing into the channel and a second side facing out of the channel, the second side having a plurality of pockets.

2. The thermal edge spacer of claim 1, wherein the first side and the second side are non- planar.

3. The thermal edge spacer of claim 2, wherein the thermal insert member has a plurality of folds, the plurality of pockets defined between neighboring pairs of the plurality of folds.

4. The thermal edge spacer of claim 2, wherein the thermal insert member includes a plurality of dimples, the plurality of pockets defined by respective ones of the plurality of dimples.

5. The thermal edge spacer of claim 1, wherein the plurality of pockets are spaced apart across the channel between the first spacer leg and the second spacer leg.

6. The thermal edge spacer of claim 1, wherein the plurality of pockets are spaced apart along the longitudinal axis.

7. The thermal edge spacer of claim 1, wherein thermal insert member is deformable to vary a volume of the plurality of pockets.

8. The thermal edge spacer of claim 1, wherein the thermal insert member is disposed entirely within the channel.

9. The thermal edge spacer of claim 1, wherein the thermal insert member undulates across the channel between the first spacer leg and the second spacer leg.

10. The thermal edge spacer of claim 1, wherein the thermal insert member is formed of a thermoplastic polymer material.

11. The thermal edge spacer of claim 10, wherein the thermal insert member is formed of a polycarbonate material.

12. The thermal edge spacer of claim 1, further comprising an adhesive layer that is included on the first spacer leg for adhesively attaching the first spacer leg to the first pane.

13. The thermal edge spacer of claim 1, further comprising a moisture barrier member disposed in the channel between the spacer base and the thermal insert member.

14. The thermal edge spacer of claim 13, wherein the moisture barrier member comprises a desiccant.

15. A glazing unit for a fenestration unit comprising: a first pane; a second pane; a third pane disposed between the first pane and the second pane; a first spacer disposed between the first pane and the third pane to support the first pane and the third pane separated at a distance and to define a first chamber therebetween, the first spacer defining a first outer boundary of the first chamber; a second spacer disposed between the second pane and the third pane to support the secondpane and the third pane separated at a distance and to define a second chamber therebetween, the second spacer defining a second outer boundary of the second chamber; the first spacer and the second spacer respectively comprising: a spacer support member with a spacer base, a first spacer leg, and a second spacer leg, the first spacer leg spaced apart from the second spacer leg with the spacer base extending therebetween, the spacer base, the first spacer leg, and the second spacer leg cooperatively defining a channel of the spacer support member, the channel extending along a longitudinal axis of the spacer support member; and a thermal insert member that is received in the channel, that extends longitudinally along the longitudinal axis, and that spans across the channel between the first spacer leg and the second spacer leg, the thermal insert member having a first side facing into the channel and a second side facing out of the channel, the second side having a plurality of pockets.

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