IGU having suspended thin center pane and related methods and systems

Abstract

Various aspects for an insulating glass unit (IGU) are provided herein which include a suspension assembly for retaining an inner pane in spaced relation from two outer panes, where the IGU has a seal is separate from the suspension assembly, including related methods and systems for making an IGU.

Description

IGU HAVING SUSPENDED THIN CENTER PANE AND RELATED METHODS AND SYSTEMSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application No. 63 / 602,947 filed November 27, 2023, the content of which is incorporated herein by reference in its entirety.FIELD OF THE DISCLOSURE

[0002] Generally, the present disclosure is directed towards embodiments of insulated glazing units (IGUs) that include tailored triple pane window configurations with desirable characteristics. More specifically, the present disclosure is directed towards embodiments of IGUs that include triple pane window systems having a third pane (center pane) that is a thin suspended pane, with related assembly.BACKGROUND

[0003] Traditional triple pane windows provide improved performance in areas including: solar heat gain coefficient (SHGC) and insulation (U-values), to name a few. However, the third pane adds weight to the assembly, adds difficulty in handling / installation, and increases thickness of the glazing assembly (i.e. requiring new tooling and / or thicker frame / sash materials), among other complications.SUMMARY OF THE DISCLOSURE

[0004] Generally, the present disclosure is directed towards embodiments of IGU assemblies that include tailored triple pane windows configurations with desirable characteristics. More specifically, the present disclosure is directed towards embodiments of a IGU assembly that include insulating glass units, configured as triple pane window systems having a third pane (e.g. center pane) that is a suspended thin pane with related suspension members, configured as an suspended assembly, where the assembly is configured between two outer panes (a first and second pane), such that efficiencies during manufacturing are realized as compared to manufacturing conventional thick triple pane windows.

[0005] Triple-pane insulating glass units (IGUs) are designed with three panes of glass separated by cavities filled with gas, typically one sealing spacer between each pair of panes, to define two gas cavities. With increased seal deposition, the manufacturing rate for a triple pane IGU is longer than with a double pane IGU (longer seal deposition and multiple gas press operations to retain an insulating gas in each cavity). Also, with two seals, there is increased glass-spacer interfaces and increased risk for IGU leakage. Also, certain applications or end use locations require pressure equalizing tubes or technologies to be used between the two independent cavities, driving up complexity and time to manufacture and potentially driving down manufacturing yield rates. While some specialized spacer technologies have been identified, where a polymeric member is configured with a groove, and the center / inner pane is retained in the groove, this technology is problematic for thin glass (e.g. glass having a thickness of less than 2.2 mm, or less than 1.6mm, or less than 1 mm, or around 0.5 mm). The complexity of engaging thin glass in a groove around the entire perimetrical edge of the thin glass makes these pocket-type spacer technologies impractical and / or impossible at retaining thin glass in a thin triple IGU with a single spacer.

[0006] In some embodiments, the suspension assembly is configured to enable communication between the first zone of the gas cavity and the second zone of the gas cavity to promote dissipation / normalization of pressure differentials; to reduce, prevent, and / or eliminate bowing in the IGU assembly; to dissipate moisture so as to reduce, prevent, and / or eliminate moisture / fog in the first defined gap and / or second defined gap, among other drivers). Thin glass is advantaged as the second pane, as having a thin, lightweight pane is easier to retain with suspension members (lighter weight, will not deform seal during seal deposition or pressing step). Moreover, utilizing a thin center pane results in suspension members that are tailored to retain / hold the lightweight substrate in place - less material is needed to retain the thin glass in place, so the suspension members can be configured to be lighter weight, plastic or polymeric materials that provide improved thermal performance as compared to metal spacers. Moreover, when utilizing thin glass that is a fusion-formed material, an improved optical performance is provided.

[0007] In one aspect of the present disclosure, an insulating glass unit (IGU) is provided, comprising: a first pane comprising a transparent material; a suspension assembly comprising: a second pane and at least one suspension member, wherein the second pane comprises a thin glass substrate having a thickness of not greater than 2.2 mm, wherein the suspension assembly is configured to retain the second pane in spaced relation from the firstpane; a third pane comprising a transparent material, wherein the third pane is configured in spaced relation from the first pane; and a spacer positioned adjacent an outer edge and connecting the first pane and the third pane to define a gas cavity therebetween.

[0008] In some embodiments, the suspension member is configured with: a retaining region to retain the second pane; and an attachment portion to engage with a second major surface of the first pane.

[0009] In some embodiments, the second pane does not contact the spacer.

[0010] In some embodiments, the second pane is retained in spaced relation from the third pane via attachment to the first pane.

[0011] In some embodiments, the second pane is inset from the first pane (and the third pane). In some embodiments, the second pane is at least 1 mm to not greater than 15 mm dimensionally inset from at least one of the first pane and the third pane.

[0012] In some embodiments, the inset is at least 0.5 mm to not greater than 6 mm. In some embodiments, the inset is at least 1.5 mm to not greater than 7 mm. In some embodiments, the inset is at least 1 mm to not greater than 3 mm. In some embodiments, the inset is at least 2 mm to not greater than 6 mm. In some embodiments, the inset is at least 2 mm to not greater than 10 mm. In some embodiments, the inset is at least 7 mm to not greater than 12 mm.

[0013] In some embodiments, the suspension member is configured to attach to the second pane via an adhesive component, a mechanical attachment component, a compressive retention between the first pane and the third pane, and / or combinations thereof.

[0014] In some embodiments, the suspension member is a thermoplastic spacer portion; a super spacer portion, a foam configured with adhesive, a grid, a post configured with glue, a member configured with a groove or second pane retaining region.

[0015] In some embodiments, via the second pane, the sealed gas cavity is configured in a first zone (between the first pane and the second pane) and a second zone (between the second pane and the third pane).

[0016] In some embodiments, the second pane is unstrengthened or annealed.

[0017] In some embodiments, the second pane is chemically strengthened or heat strengthened.

[0018] In some embodiments, the second pane is configured as a safety pane, such that the second pane is configured with a safety film adhered thereon; a glass - glass laminate or a glass-polymer laminate or such that the second pane is strengthened (e.g. chemically strengthened or heat strengthened).

[0019] In some embodiments, the suspension member is configured to engage (e.g. contact) the first pane and the third pane.

[0020] In some embodiments, the suspension member is configured to contact one of the first pane and the third pane.

[0021] In some embodiments, via the suspension assembly, the first zone of the gas cavity is in communication with the second zone of the gas cavity.

[0022] In some embodiments, the suspension member is configured to perimetrically surround 95% of the second pane.

[0023] In some embodiments, the suspension member is configured to perimetrically surround not greater than 10 % of the second pane.

[0024] In some embodiments, the spacer is selected from at least one of a polymer material, a thermoplastic material, a metal spacer bar material, super spacer, and / or combinations thereof.

[0025] In some embodiments, the IGU further comprises: a secondary seal configured to extend between the region outside of the spacer and the outer edges of the first pane and the third pane. (e.g. around the outer perimeter of the second pane and cross-sectionally between the first pane and the third pane).

[0026] In some embodiments, the second pane comprises a thickness in the range of at least 0.4 mm to not greater than 1.6 mm.

[0027] In some embodiments, the thin glass comprises a thickness in the range of 0.4 mm to not greater than 1 mm. In some embodiments, the second pane has a thickness of not greater than 2 mm. In some embodiments, the second pane has a thickness of not greater than 1.5 mm. In some embodiments, the second pane has a thickness of not greater than 1 mm.

[0028] In some embodiments, the second pane has a thickness of not greater than 0.9 mm. In some embodiments, the second pane has a thickness of not greater than 0.7 mm. In some embodiments, the second pane comprises film having a thickness of not greater than 0.4 mm, or not greater than 0.36 mm. In some embodiments, the second pane has a thickness of not greater than 2.6 mm, or not greater than 2.4mm, or not greater than 1.6 mm.

[0029] In some embodiments, at least one of the first pane, the second pane, or the third pane is further configured with a color, a tint, a reflective layer, an acoustic dampening layer, or combinations thereof.

[0030] In some embodiments, wherein the IGU comprises a low emissivity coating on at least one of: a first major surface of the first glass layer, a second major surface of the second glass layer, and combinations thereof.

[0031] In some embodiments, the first pane and the third pane are glass or a polymer.

[0032] In some embodiments, the first pane and the third pane are each of a glass material.

[0033] In some embodiments, the first pane and the third pane are strengthened (e.g. tempered, heat strengthened, chemically strengthened, ion exchanged).

[0034] In some embodiments, the first pane has a thickness of at least 2 mm to not greater than 10 mm, or at least 2 mm to not greater than 6 mm, or at least 3 mm to not greater than 5 mm. In some embodiments, the first pane has a thickness of: at least 2.5 mm; at least 3 mm; at least 3.5 mm; at least 4 mm; at least 4.5 mm; at least 5 mm; at least 5.5 mm; at least 6 mm; at least 6.5 mm; at least 7 mm; at least 7.5 mm; at least 8 mm; at least 8.5 mm; at least 9 mm; at least 9.5 mm; or at least 10 mm. In some embodiments, the first pane has a thickness of: not greater than 3 mm; not greater than 3.5 mm; not greater than 4 mm; not greater than 4.5 mm; not greater than 5 mm; not greater than 5.5 mm; not greater than 6 mm; not greater than6.5 mm; not greater than 7 mm; not greater than 7.5 mm; not greater than 8 mm; not greater than 8.5 mm; not greater than 9 mm; not greater than 9.5 mm; or not greater than 10 mm.

[0035] In some embodiments, the third pane have a thickness of at least 2 mm to not greater than 10 mm, or at least 2 mm to not greater than 6 mm, or at least 3 mm to not greater than 5 mm. In some embodiments, the first pane has a thickness of: at least 2.5 mm; at least 3 mm; at least 3.5 mm; at least 4 mm; at least 4.5 mm; at least 5 mm; at least 5.5 mm; at least 6 mm; at least 6.5 mm; at least 7 mm; at least 7.5 mm; at least 8 mm; at least 8.5 mm; at least 9 mm; at least 9.5 mm; or at least 10 mm. In some embodiments, the third pane has a thickness of: not greater than 3 mm; not greater than 3.5 mm; not greater than 4 mm; not greater than 4.5 mm; not greater than 5 mm; not greater than 5.5 mm; not greater than 6 mm; not greater than6.5 mm; not greater than 7 mm; not greater than 7.5 mm; not greater than 8 mm; not greater than 8.5 mm; not greater than 9 mm; not greater than 9.5 mm; or not greater than 10 mm.

[0036] In some embodiments, the second pane has a thickness of: at least 0.3 mm; at least 0.4 mm; at least 0.5 mm; at least 0.6 mm; at least 0.7 mm; at least 0.8mm; at least 0.9 mm; at least 1 mm; at least 1.1 mm; at least 1.2mm; at least 1.3 mm; at least 1.4 mm; at least1.5 mm; at least 1.6mm; at least 1.8 mm; or at least 2mm. In some embodiments, the second pane has a thickness of: not greater than 0.4 mm; not greater than 0.5 mm; not greater than 0.6mm; not greater than 0.7 mm; not greater than 0.8mm; not greater than 0.9 mm; not greater than 1 mm; not greater than 1.1 mm; not greater than 1.2mm; not greater than 1.3 mm; not greater than 1.4 mm; not greater than 1.5 mm; not greater than 1.6mm; not greater than 1.8 mm; not greater than 2mm; or not greater than 2.2mm.

[0037] In some embodiments, the first pane has a high CTE. In some embodiments, the third pane has a high CTE. In some embodiments, the thin glass of the second pane has a high CTE. In some embodiments, the thin glass of the second pane has a low CTE. In some embodiments, the first pane, the thin glass of the second pane, and the third pane are glass.

[0038] In some embodiments, the first pane, the thin glass of the second pane, and the third pane are selected from: a soda lime silicate glass; alumina borosilicate glass; an alkalialuminosilicate glass; an alkaline earth boro-aluminosilicate glass; or an alkali-free boro- aluminosilicate glass.

[0039] In some embodiments, the first pane and the third pane are configured from tempered sodalime glass.

[0040] In some embodiments, the thin glass has a coefficient of thermal expansion (CTE) of less than 7 x 10-6 / K.

[0041] In some embodiments, the first pane comprises a soda lime silicate glass layer, the second pane comprises an alumina borosilicate glass layer, and the third pane comprises a sodalime silicate glass layer.

[0042] In some embodiments, the total thickness of the IGU (spanning from the first major surface of the first pane to the second major surface of the third pane) is not greater than 35 mm; or not greater than 40 mm; or not greater than 45 mm; or not greater than 50 mm; or not greater than 55 mm; or not greater than 60 mm.

[0043] In some embodiments, the total thickness of the IGU (spanning from the first major surface of the first pane to the second major surface of the third pane) is least %” to not greater than 1”. In some embodiments, the total thickness of the IGU (spanning from the first major surface of the first pane to the second major surface of the third pane) is least 0.5” to not greater than 1.5”.

[0044] In some embodiments, the first pane and the third pane are composed of the same type of glass.

[0045] In some embodiments, the IGU as set forth in one or more of the embodiments disclosed herein is configured in a window, a door, a skylight, a curtain wall, and / or combinations thereof.

[0046] In some embodiments, the IGU as set forth in one or more of the embodiments disclosed herein is configured as an architectural product or an automotive product.

[0047] In some embodiments, the first zone in the gas cavity and the second zone in the gas cavity are: configured with the same cross-sectional thicknesses or are configured with different cross-sectional thicknesses (i.e. the first zone in the gas cavity is thicker than the second zone in the gas cavity or the first zone of the gas cavity is thinner than the second zone of the gas cavity).

[0048] In some embodiments, the gas cavity is filled with a non-reactive gas or an insulating gas. In some embodiments, the gas cavity is filled with at least one of: air, krypton, argon, a non-reactive gas, an inert gas, or combinations thereof.

[0049] In some embodiments, the second pane is configured as a laminate, such that the IGU is configured to pass the International Building Code safety glazing standard, including at least one of: ANSI Z97.1 (in the U.S.) and EN 12600 (in the EU).

[0050] In some embodiments, the IGU configured a frame in a window, wherein the window meets the ENERGY STAR V.7 requirements.

[0051] In some embodiments, the IGU is configured to pass a weighted noise reduction metric Rw of at least 35 dB, when measured in accordance with ISO 717-1 standard.

[0052] In another aspect of the present disclosure, a method of making an IGU is provided, comprising: attaching a suspension assembly to a first pane; applying a spacer along a perimetrical edge of at least one of the first pane and a third pane; sealing via the spacer, the first pane to the third pane, such that the suspension assembly is retained between the first pane, the third pane, and the spacer, and further wherein a sealed gas cavity is defined between the first pane and the third pane.

[0053] In some embodiments, the attaching step further comprises attaching a second pane in spaced relation from the first pane via the suspension member.

[0054] In some embodiments, the method includes attaching at least one suspension member to an outer edge region of the second pane.

[0055] In some embodiments, attaching further comprises gluing a plurality of suspension members along the outer edge region in spaced relation to each other about the perimeter of the second pane.

[0056] In some embodiments, attaching further comprises directing a bead of polymeric material along the outer edge region of a major surface of the second pane.

[0057] In some embodiments, attaching further comprises adhering a foam-adhesive member along the outer edge region of a major surface of the second pane.

[0058] In some embodiments, attaching further comprises retaining an edge portion of the second pane into a plurality of suspension members, wherein each member is configured with at least one groove to accept the edge portion.

[0059] In some embodiments, attaching further comprises retaining an edge portion of the second pane into a plurality of suspension members and further, retaining an edge portion of a second inner pane into a plurality of suspension members, wherein at least some suspension members are configured to receive both a second pane and a second inner pane therein, further wherein, the second pane and the second inner pane are configured in spaced (parallel) relation to one another.

[0060] In some embodiments, attaching further comprises attaching the suspension member in a continuous region surrounding at least 0.5 % to not greater than 5% of the perimetrical outer edge of the second pane.

[0061] In some embodiments, attaching further comprises attaching the suspension member in a continuous region surrounding at least 5 % to not greater than 95% of the perimetrical outer edge of the second pane.

[0062] In some embodiments, attaching further comprises attaching the suspension member in a continuous region surrounding at least 15 % to not greater than 75% of the perimetrical outer edge of the second pane.

[0063] In some embodiments, the suspension members surround a perimetrical portion of the second pane in the range of at least 5 % to not greater than 25%. In some embodiments, the suspension members surround a perimetrical portion of the second pane in the range of at least 15 % to not greater than 45%.

[0064] In some embodiments, the suspension members surround a perimetrical portion of the second pane in the range of: at least 5 %; at least 15%; at least 15%; at least 25%; at least 35%; at least 45%; at least 55%; at least 65%; at least 75%; at least 85%; or at least 95%. In some embodiments, the suspension members surround a perimetrical portion of the second pane in the range of: not greater than 5 %; not greater than 15%; not greater than 15%; not greater than 25%; not greater than 35%; not greater than 45%; not greater than 55%; not greater than 65%; not greater than 75%; not greater than 85%; or not greater than 95%.

[0065] In some embodiments, the applying step further comprises directing a bead of thermoplastic spacer along a perimetrical edge of at least one of the first pane and the third pane.

[0066] In some embodiments, the applying step further comprises adhering a super spacer (foam with adhesive) along a perimetrical edge of at least one of the first pane and the third pane.

[0067] In some embodiments, the applying step further comprises adhering a spacer bar (e.g. rigid spacer, metal spacer) along a perimetrical edge of at least one of the first pane and the third pane.

[0068] In some embodiments, the applying step further comprises applying the spacer to the first pane.

[0069] In some embodiments, the sealing step further comprises pressing the first pane to the third pane to attach the panes together via the spacer.

[0070] In some embodiments, the method further comprises sealing the first pane to the third pane in a gaseous environment, to entrap, via sealing step, a gas into the sealed gas cavity.

[0071] In some embodiments, the method further comprises applying the secondary seal in a single pass deposition that extends between the first pane and the third pane, to configure the secondary seal to enclose the spacer and extend along an outer edge of the IGU from the first major surface of the first pane to the second major surface of the third pane.

[0072] In another aspect of the present disclosure, a system for making suspended thin glass IGUs is provided, comprising: a suspension assembly module, configured to engage a second pane with at least one suspension member, a suspension assembly application module, configured to attach the suspension assembly, via the suspension member, to one of a first pane and a third pane; a spacer application module, configured to apply a spacer to at least one of a first pane and a third pane; and an IGU assembly module, configured to assemble the first and third pane in spaced relation to one another, wherein the seal attaches the first pane to the third pane to define a gas cavity, and further wherein, the suspension assembly is retained in the gas cavity such that the second pane is configured in spaced relation from the first pane and the third pane.

[0073] In some embodiments, the spacer application module is configured before the suspension assembly application module.

[0074] In some embodiments, the suspension assembly application module is configured before the spacer application module.

[0075] In some embodiments, triple pane assemblies (e.g. windows) with a center pane laminate have shown improved acoustic performance (as measured by standard metrics such as ASTM E413, ASTM E1332, and ISO 717-1). In some embodiments, the via the third pane, the IGU is configured as a safety glazing in accordance with ANSI Z97.1 or EN 12600 standards. In some embodiments, the IGUs station assembly comprises a weighted sound reduction metric Rwof at least 35 dB, when measured in accordance with ISO 717-1 standard.

[0076] In some embodiments, the low emissivity coatings are configured to provide an improved Solar heat gain coefficient and / or U-value. In some embodiments, solar heat gain coefficient is quantified and / or measured in accordance with ANSI / NFRC 200 - 2017_E0Al Procedure for Determining Fenestration Product Solar Heat Gain Coefficient and Visible Transmittance at Normal Incidence. In some embodiments, thermal insulation (U-value) is quantified and / or measured in accordance with ASTM E1423-14 Standard Practice for Determining Steady State Thermal Transmittance of Fenestration Systems and / or ANSI / NFRC 100 - 2017 E0A2 Procedure for Determining Fenestration Product U-factors. For example, the low emissivity coating can be comprised of a combination of metals and oxides, including nonlimiting examples of silicon nitride, metallic silver, silicon dioxide, tin oxide, zirconium oxide, and / or combinations thereof, to name a few.

[0077] Non-limiting examples of gas in the gas cavity include: inert gas (e.g. Kr, Ar), air, and mixtures thereof, to name a few.

[0078] In one embodiment, the IGU assembly passes a safety test as set out in ANSI Z97.1 standard, when measured in accordance with the standard.

[0079] In one embodiment, the IGU assembly comprises a weighted noise reduction metric Rwof at least 35 dB, when measured in accordance with ISO 717-1 standard.

[0080] In one embodiment, at least one of the first pane, the second pane, the first glass layer of the third pane, and the second glass layer of the third pane is a chemically strengthened glass.

[0081] In one embodiment, the spacer includes a desiccant, configured therein. For example, the desiccant is configured to reduce, prevent and / or eliminate presence of moisture (e.g. fog) in the gas cavity.

[0082] In one embodiment, the IGU thickness is not greater than 40 mm. In one embodiment, the IGU assembly thickness is not greater than 35 mm. In one embodiment, the IGU assembly thickness is not greater than 30 mm.

[0083] In some embodiments, the thin glass ply configured from (as non-limiting examples): Architectural Technical Glass (ATG), EAGLE XG®; Gorilla Glass®, Lotus™ among others commercially available from Coming Incorporated. In some embodiments, one or more panes is a float glass or a fusion glass. In some embodiments, the first pane and third pane are each a float glass. In some embodiments, the second pane is a fusion glass.

[0084] In some embodiments, the first pane has a thickness of not greater than 12 mm; not greater than 10 mm; not greater than 8 mm; not greater than 6 mm; not greater than 4 mm; or not greater than 3 mm. In some embodiments, the first pane has a thickness of less than 12 mm; less than 10 mm less than 8 mm; less than 6 mm; less than 4 mm; or less than 3 mm. In some embodiments, the first pane has a thickness of between 3 and 12mm; or between 4 and 10 mm; or between 6 and 8 mm; or between 3 and 6 mm.

[0085] In one embodiment, the first pane has a thickness of not greater than 6 mm. In one embodiment, the first pane has a thickness of 3 mm.

[0086] In some embodiments, the distance between panes (e.g. length of a first and / or second defined gap) is configured at between 10-16 mm (e.g. for argon enclosed gaps) or between 8-12 mm (e.g. for other gases and / or gaseous mixtures in the first and second defined gaps).

[0087] In some embodiments, the suspension member is configured to be transparent. In some embodiments, the suspension member is configured to be translucent. In some embodiments, the suspension member is configured to be covered from visual observation via at least one of the secondary seal, the window frame, and / or combinations thereof. In some embodiments, the suspension member is at least partially visible in the final IGU viewing field. In some embodiments, the suspension member is not visually detectable in the final IGU viewing field. In some embodiments, the suspension member is transparent and is configured to be in the viewing field, but is not visually detectable given at least one of the position of the suspension members, the transparency of the suspension members, the refractive index of the suspension member, and / or combinations thereof.

[0088] In some embodiments, the first pane is configured as a laminate.

[0089] In some embodiments, the third pane is configured as a laminate.

[0090] In some embodiments, the suspension member is deposited onto a pane via extrusion.

[0091] In some embodiments, the suspension member is deposited onto a pane via printing.

[0092] In some embodiments, the suspension member is deposited onto the first pane. In some embodiments, the suspension member is deposited onto the second pane. In some embodiments, the suspension member is deposited onto the third pane.

[0093] In some embodiments, the suspension member(s) are configured to cover and / or surround a minimal area between the two panes, such that the barrier to gas flow / communication between the first zone and the second zone is reduced and / or eliminated. In some embodiments, by reducing the cross-sectional percentage of perimetrical area that the suspension members take up, gas flow during the gas press step of IGU manufacturing is promoted, resulting in increased process times and / or improved gas usage yields, among other advantages.

[0094] In some embodiments, the suspension member covers a perimetrical area between the two panes of not greater than 0.5%; or not greater than 0.7%; or not greater than 1 %; not greater than 1.3%; or not greater than 1.5%; or not greater than 1.7 %; not greater than 25%; or not greater than 2.3%; or not greater than 2.5; not greater than 2.7%; or not greater than 3%; or not greater than 3.3; not greater than 3.5%; or not greater than 3.7%; or not greater than 4 %; not greater than 4.3%; or not greater than 4.5%; or not greater than 4.7 or not greater than 5%.

[0095] In some embodiments, the suspension member covers a perimetrical area between the two panes of at least 0.5%; or at least 0.7%; or at least 1 %; at least 1.3%; or at least 1.5%; or at least 1.7 %; or at least 25%; or at least 2.3%; or at least 2.5; or at least 2.7%; or at least 3%; or at least 3.3; or at least 3.5%; or at least 3.7%; or at least 4 %; or at least 4.3%; or at least 4.5%; or at least 4.7% or at least 5%.

[0096] In some embodiments, the IGU is configured as a quadruple pane IGU. In one embodiment of a quad IGU, two suspension assemblies are utilized, wherein each of a first pane (outer pane) and a third pane (outer pane) are each configured with a suspension assembly, the first suspension assembly includes a second pane (thin pane) and the second suspension assembly includes a fourth pane (thin pane). In this embodiment via the second pane and fourth pane, the gas cavity has a defined first zone (between the first pane and the second pane); asecond zone (between the second pane and the fourth pane); and a third zone (between the fourth pane and the third pane).

[0097] In one embodiment of a quad IGU, one suspension assembly is utilized, wherein each of a first pane (outer pane) and a third pane are set apart in spaced relation, with a suspension assembly having a second pane configured to attach to at least one of the first pane of the third pane. Additionally, in this embodiment, a fourth pane is configured in spaced relation from the second major surface of the third pane and is attached to the third pane such that a second gas cavity is defined therein. The third pane can be configured with a through hole of via in at least one of the pane and / or the seal in order to promote gas communication between the first gas cavity and the second gas cavity.

[0098] in some embodiments, the inset is configured to extend from the edge of the second pane (thin glass) to the edge of the spacer (e.g. spacer distance to outer edge of first pane or third pane).

[0099] With one or more embodiments described herein, it’s estimated that triple pane IGUs can be produced at a speed of at least 60 units per hour, given that the methods enable simultaneous suspended pane configuration and spacer deposition (at a TPR station), with an additional advantage of one spacer deposition / integral spacer configured between the first and third panes.

[0100] In some embodiments, the suspension assembly is configured onto the pane via a placement mechanism / positioning device, to enable improved precision and accuracy with repeated assemblies. As non-limiting examples, the suspension assembly and / or suspension member(s) are positioned to the first or third pane via a locating device and / or glass detection sensor. In some embodiments, the sensors utilize data from the spacer deposition step or the IGU control system to provide tailored length and width positioning at the first or third panes.

[0101] In some embodiments, the suspension member is attached onto the first pane or the third pane, then, the second pane (thin glass) is directed into the slots / grooves via a suction engaging tool, which attaches to and directs the thin glass into place. In some embodiments, the glass is supported as it is directed into position in the suspension member.

[0102] As used herein, a low coefficient of thermal expansion (CTE) refers to the coefficient of thermal expansion of an identified glass composition, or of a glass sheet or pane comprised thereof, as measured over a temperature range of 0-300 °C, when measured in accordance with ASTM E228 or equivalent standard.

[0103] In some embodiments, the second pane (thin glass) has a lower CTE than the first pane.

[0104] In some embodiments, the method includes: replacing at least some gas in at least one of: the first defined gap and the second defined gap with a non-reactive gas or gas mixture (e.g. non-reactive and configured to promote thermal insulation across the IGU assembly).

[0105] In some embodiments, replacing includes: actuating a valve (e.g. configured in the sealing member) to output an initial gas from at least one of the first defined gap and the second defined gap and input a non-reactive gas into at least one of the first defined gap and the second defined gap. For example, the valve is configurable to enable displacement of at least some of the existing gas (ambient air entrapped during engagement of the sealing member) with a non-reactive gas or gas mixture specifically configured for window gap usage.

[0106] In another aspect, a method of retrofitting a window assembly, comprising: removing a window assembly from a surface (e.g. wall, ceiling, floor) to define an opening; installing a IGU assembly comprising a triple pane assembly having a thin laminate not exceeding 3 mm as a third pane (e.g. center pane); and improving, via the installing step, at least one window performance criterion (when comparing the IGU assembly to the window assembly).

[0107] In some embodiments, the performance criterion includes at least one of: acoustic dampening (e.g. improved / reduced sound transmittance through the IGU assembly); safety performance (e.g. in compliance with safety rating or improved / reduced weight with thin center pane and in compliance with safety rating); improved / reduced solar heat gain coefficient (e.g. reduced; improved / reduced weight; maintained cross-sectional assembly thickness (i.e. e.g. total thickness (assembly width) of first pane, first defined gap, third pane, second defined gap, and second pane); reduced cross-sectional thickness (i.e. total thickness (assembly width) of first pane, first defined gap, third pane, second defined gap, and second pane); emissivity (e.g. improved / reduced emissivity with application or one or more low emissivity coatings); insulation (e.g. improved / reduced thermal transfer (hot or cold) from one end of the IGU assembly to the other end, through the cross-sectional width); light transmittance (improved / reduced light transmittance and / or improved filtering of one or more types of light); and / or combinations thereof.

[0108] One or more of the aforementioned IGU assembly embodiments are utilizable with one or more of the aforementioned methods set forth herein.

[0109] Additional features and advantages will be set forth in the detailed description which follows and will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

[0110] It is to be understood that both the foregoing general description and the following detailed description are merely exemplary and are intended to provide an overview or framework to understanding the nature and character of the disclosure as it is claimed.[OHl] The accompanying drawings are included to provide a further understanding of principles of the disclosure, and are incorporated in, and constitute a part of, this specification. The drawings illustrate one or more embodiment(s) and, together with the description, serve to explain, by way of example, principles and operation of the disclosure. It is to be understood that various features of the disclosure disclosed in this specification and in the drawings can be used in any and all combinations. By way of non-limiting examples, the various features of the disclosure may be combined with one another according to the following aspects.BRIEF DESCRIPTION OF THE DRAWINGS

[0112] These and other features, aspects and advantages of the present disclosure are better understood when the following detailed description of the disclosure is read with reference to the accompanying drawings, in which:

[0113] Fig. 1A and IB depict a schematic cut-away side view and plan view (respectively) of an embodiment of an IGU assembly having three panes, with the center pane configured as a suspended pane, in accordance with an embodiment of the present disclosure.

[0114] Fig. 1A depicts a schematic cut-away side view of an embodiment of an IGU assembly having three panes, with the second pane (inner pane) configured in a suspended manner via suspension members configured to engage with the first pane and the third pane inner surfaces, in accordance with an embodiment of the present disclosure.

[0115] Fig. IB depicts a schematic plan view side view of an embodiment of an IGU assembly having three panes, with the second pane (inner pane) configured in a suspended manner via suspension members configured to engage with the first pane and the third pane inner surfaces along the outermost comer regions of the second pane, in accordance with one or more aspects of the present disclosure.

[0116] Fig. 2 depicts a schematic cut-away side view of another embodiment of an IGU assembly having three panes, with the second pane (inner pane) configured in a suspendedmanner via suspension members configured to engage with the first pane, in accordance with one or more aspects of the present disclosure.

[0117] Fig. 3 depicts a schematic plan view of an embodiment of the suspension assembly, which includes the second pane and suspension members, in accordance with one or more aspects of the present disclosure.

[0118] Fig. 4A -4C depict a schematic plan view of an embodiment of an IGU (Fig. 4A) having different embodiments of suspension assemblies (4B and 4C), in accordance with one or more aspects of the present disclosure.

[0119] In Figure 4C, a schematic cut-away side view of the suspension assembly is shown, depicting a suspension member configured with a plurality of retaining regions (e.g. groove or slot), such that an outer edge portion of the second pane fits into and is retained by the suspension member and a secondary inner pane configured in spaced, parallel relation from the second pane, is fit into and retained by the suspension member, in accordance with one or more aspects of the present disclosure.

[0120] Fig. 5A and 5B depict schematic plan views of two embodiments of a triple pane IGU, wherein the suspension members are shown around the outer edge of the second pane, but in comparing Fig. 5A and Fig. 5B, the number of suspension members and / or the position of the suspension members is varied, in accordance with various aspects of the present disclosure.

[0121] Fig. 6A and Fig. 6B depict two schematic flow-charts of two embodiments for making a system for making an IGU with a suspended inner pane, in accordance with various aspects of the present disclosure.

[0122] Figs. 7A-7D depict various schematic views of a further structural configuration of the suspension member, in accordance with aspects of the present disclosure;

[0123] Figs. 8A-8D depict various schematic views of a further structural configuration of the suspension member, in accordance with aspects of the present disclosure;

[0124] Figs. 9A-9C depict various schematic views of a further structural configuration of the suspension member, in accordance with aspects of the present disclosure;

[0125] Figs. 10A and 10B depict a schematic plan view and a schematic cross-sectional view of a further structural configuration of the suspension member, in accordance with aspects of the present disclosure;

[0126] Figs. 11A-11C depict various schematic views of a further structural configuration of the suspension member, in accordance with aspects of the present disclosure;

[0127] Figs. 12A-12C depict schematic plan views of a further structural configuration of the suspension member, in accordance with aspects of the present disclosure;

[0128] Fig. 13 depicts a schematic cross-sectional view of a further structural configuration of the suspension member, in accordance with aspects of the present disclosure;

[0129] Fig. 14 depicts a schematic plan view of a further structural configuration of the suspension member, in accordance with aspects of the present disclosure;

[0130] Figs. 15A-15F depicts a series of schematic representations to illustrate steps of an IGU assembly process that uses a further structural configuration of the suspension member;

[0131] Fig. 16 depicts two schematic cross-sectional views to illustrate steps of a gas filling strategy for an IGU assembly process;

[0132] Fig. 17 depicts three sequential images to showing modeling results of a gas filing strategy similar to that illustrated in Fig. 16; and

[0133] Fig. 18 schematically shows the various parameters used for the gas fill time calculations associated with Table. 1.DETAILED DESCRIPTION

[0134] In the following detailed description, for purposes of explanation and not limitation, example embodiments disclosing specific details are set forth to provide a thorough understanding of various principles of the present disclosure. However, it will be apparent to one having ordinary skill in the art, having had the benefit of the present disclosure, that the present disclosure may be practiced in other embodiments that depart from the specific details disclosed herein. Moreover, descriptions of well-known devices, methods and materials may be omitted so as not to obscure the description of various principles of the present disclosure. Finally, wherever applicable, like reference numerals refer to like elements.

[0135] Ranges can be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. As a non-limiting example, about means less than 10% of the referenced value.

[0136] Directional terms as used herein - for example up, down, right, left, front, back, top, bottom - are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0137] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps, or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; the number or type of embodiments described in the specification.

[0138] As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a “component” includes aspects having two or more such components, unless the context clearly indicates otherwise.

[0139] Referring to Figs 1A through 5B, the IGU 10 includes three panes: a first pane 12, a second pane 14, and a third pane 16. Each of the three panes (12, 14, 16) is configured with major surfaces: the first pane 12 has a first major surface 30 and a second major surface 32; the second pane 14 has a first major surface 34 and a second major surface 36; and the third pane 16 has a first major surface 38 and a second major surface 40. The three panes are positioned and retained in spaced relation from one another. The spacer 50 retains the first pane 12 and the third pane 16 in spaced relation. A suspension assembly 20 includes the second pane 14 (inner pane) and suspension members 18, configured to retain the second pane 14 in place and / or attach or engage the second pane with at least one of the first pane 12 and the third pane 16. As the suspension members 18 do not engage circumferentially with the second pane to adhere it to either / both of the first pane 12 and the third pane 16, there is a single gas cavity 28 defined between the first pane 12, the third pane 16, and the seal 50. The second pane 14 defines a first zone 24 of the gas cavity and a second zone 26 of the gas cavity, though the two zones are in communication with each other (e.g. gas pressure is configured to equalize between the two zones). Also, as depicted in Fig. 1 A, the second pane 14 is inset 52 from the first pane 12 and the second pane 16, such that the second pane 14 is dimensionally smaller than the first pane 12 and the third pane 16. The suspension members 18 of the suspension assembly 20 areconfigured in spaced relation from the seal 50. A secondary seal 48 is configured over the spacer 50 and between the first pane 12 and third pane 16 to promote seal longevity and integrity in the IGU. The secondary seal 48 may be retained between the two panes (12, 16) or the secondary seal may extend over the outer edges of the two panes (12, 16) to protect the edges of the first and third panes 12, 16 from chipping or cracking.

[0140] Fig. 1A depicts a schematic cut-away side view of an embodiment of an IGU 10 assembly having three panes, with the second pane 14 (inner pane) configured in a suspended manner via suspension members 18 configured to engage with the first pane 12 and the third pane 16 inner surfaces (32, 38).

[0141] Fig. IB depicts a schematic plan view side view of an embodiment of an IGU 10 assembly having three panes, with the second pane 14 (inner pane) configured in a suspended manner via suspension members 18 configured to engage with the first pane 12 and the third pane 16 inner surfaces (32, 38) along the outermost corner regions of the second pane 14.

[0142] As shown in Figs. 1A and IB, this configuration of a suspension assembly 20 enabling a suspended second pane 14 (inner pane) enables the IGU 10, with three panes (12, 14, 16), to be assembled with a single spacer 50 connecting the panes (first pane 12 and third pane 16) together to form a single, sealed gas cavity 28. As shown in Figs. 1A and IB, the second pane 14 is suspended, retained such that it is separate / independent from the spacer 50. In this embodiment, the second pane 14 is attached or otherwise connected to both exterior glass panes (12, 16), the first pane and the third pane. While Figs. 1 A and IB depict suspension members 18 as a plurality of posts, with the posts positioned in each of the corners of the second pane 14. It is noted, as it is shown herein through one or more embodiments, that the suspension member configuration can vary. Suspension members 18 can be configured in various locations along the outer edge of the second pane 14, separate and / or independent from the spacer 50. Additionally, it is noted that the second pane 14 can be configured with rounded or angled corners to maximize the gap between the spacer 50 and the second pane 14.

[0143] Fig. 2 depicts a schematic cut-away side view of another embodiment of an IGU 10 assembly having three panes, with the second pane 14 (inner pane) configured in a suspended manner via suspension members 18 configured to engage with the first pane 12.

[0144] As shown in Fig. 2, the suspension members 18 are located between the second major 32 surface of the first pane 12 and the first major surface 34 of the second pane 14, such that the suspension members 18 attach the second pane 14 to the first pane 12, and the firstpane 12 is connected to the third pane 16 via the spacer 50. In this configuration, the second pane 14 is configured in spaced relation between the first pane 12 and the third pane 16.

[0145] Fig. 3 depicts a schematic plan view of an embodiment of the suspension assembly 20, which includes the second pane 14 and suspension members 18. As shown in Fig. 3, the suspension members 18 (two shown), are configured in a mostly vertical, parallel configuration adjacent to the outer edges of the second pane 14. The suspension members 18 here extend along most of the edge of the second sheet 14. As non-limiting examples, the suspension members 18 can be configured from spacer materials, including but not limited to: super spacers (foam with adhesive), rigid spacers, thermoplastic (TPR) spacer materials, to name a few. It is noted that the suspension members 18 here do not perimetrically surround the second pane 14 and are not configured to provide a sealed gas cavity between either the first 12 pane or second pane 14. In this configuration, during assembly in a vertical configuration, this suspension member configuration may be an advantaged way to enable air to escape during the press operation (i.e. sealing of first pane to third pane).

[0146] Fig. 4A -4C depict a schematic plan view of an embodiment of an IGU 10 (Fig. 4A) having different embodiments of suspension assemblies 20 (4B and 4C). In Fig. 4B, a schematic cut-away side view of the suspension assembly 20 is shown, depicting a suspension member 18 configured with a retaining region 22 (e.g. groove or slot), such that an outer edge portion of the second pane 14 fits into and is retained by the suspension member 18. In Figure 4C, a schematic cut-away side view of the suspension assembly 20 is shown, depicting a suspension member 18 configured with a plurality of retaining regions 22, 22’ (e.g. groove or slot), such that an outer edge portion of the second pane 14 fits into and is retained by the suspension member 18 and a secondary inner pane 44 configured in spaced, parallel relation from the second pane 14, is fit into and retained by the suspension member 18.

[0147] As shown in Fig. 4A and Fig. 4C, the multi-pane IGU 10 is configured as a quad-pane IGU, with the suspension assembly 20 configured with two suspended panes: the second pane 14 and the secondary inner pane 44. As with the second pane 14, the secondary inner pane 44 is not in contact with or retained by the spacer 50; rather, the suspension members 18 retain both panes 14, 44 in spaced relation from the first pane 12 and the third pane 16. In some embodiments, one or both opposing outer edges of the suspension members 18 are configured with adhesive, such that the suspension member 18 attaches to one or both of the first pane 12 and the second pane 14. In some embodiments, one or both opposing edges of the suspension member 18 are configured of a semi-flexible, compressible material such thatduring the seal / pressing step to assemble the IGU 10, the suspension member 18 is slightly deformed and compressed to be retained in position between the first pane 12 and the third pane 16. In some embodiments, the suspension members 18 are configured to be transparent or translucent, to minimize visual observation in the final IGU. In some embodiments, the suspension members 18 can also include a grid (e.g. window grilles), such that the suspension assembly 20, once positioned in place in the IGU, is configured with a window grill or grid decoration.

[0148] Fig. 5A and 5B depict schematic plan views of two embodiments of a triple pane IGU 10, wherein the suspension members 18 are shown around the outer edge of the second pane 14, but in comparing Fig. 5 A and Fig. 5B, the number of suspension members 18 and / or the position of the suspension members 18 is varied.

[0149] Fig. 6A and Fig. 6B depict two schematic flow-charts of two embodiments for making a system for making an IGU with a suspended inner pane, in accordance with various aspects of the present disclosure.

[0150] Fig. 6A depicts a schematic flow-chart of an embodiment of a system for making an IGU with a suspended inner pane, in accordance with various aspects of the present disclosure. As shown in Fig. 6A, the spacer application module applies a spacer to at least one of the first pane and the third pane. The suspension assembly module configures (attaches, adheres, connects) at least one pane, the second pane (having architecturally sized, thin glass), with one or more suspension members to provide a suspension assembly. The suspension assembly application module attaches the suspension assembly to a first pane or a third pane, where at least one of (or both of) the first pane and the third pane are configured with a spacer. The IGU assembly module assembles (presses) the first pane and the third pane together, to attach the first pane and third pane and provide an IGU, with the suspension assembly configured in a gas cavity, in spaced relation between the first pane and the third pane. In some embodiments, the IGU assembly module includes a gas press, where during pressing, an insulation or non-reactive gas is configured in the gas cavity of the sealed IGU. In some embodiments, the IGU assembly module includes a secondary seal application, where an outer edge of the IGU is coated in a rubbery or polymer material (e.g. silicone) over the seal, to provide a second seal to the IGU. It is noted that in this schematic, one or more modules may be completed manually or through automation (e.g. with robotic assist). It is estimated that this system with only one gas press / one seal for a multi-paned IGU having a suspension assembly with thin glass is capable of manufacturing 60 or more triple or quad-pane IGUs per hour.

[0151] Fig. 6B depicts a schematic flow-chart of an embodiment of a system for making an IGU with a suspended inner pane, in accordance with various aspects of the present disclosure. As shown in Fig. 6B, the suspension assembly module configures (attaches, adheres, connects) at least one pane, the second pane (having architecturally sized, thin glass), with one or more suspension members to provide a suspension assembly. The suspension assembly application module attaches the suspension assembly to a first pane or a third pane, where at least one of (or both of) the first pane and the third pane. The spacer application module then applies at least one of (or both of) the first pane and the second pane with a spacer (where the spacer is configured in spaced relation from the suspension assembly). The IGU assembly module assembles (presses) the first pane and the third pane together, to attach the first pane and third pane and provide an IGU, with the suspension assembly configured in a gas cavity, in spaced relation between the first pane and the third pane. In some embodiments, the IGU assembly module includes a gas press, where during pressing, an insulation or non- reactive gas is configured in the gas cavity of the sealed IGU. In some embodiments, the IGU assembly module includes a secondary seal application, where an outer edge of the IGU is coated in a rubbery or polymer material (e.g. silicone) over the seal, to provide a second seal to the IGU. It is noted that in this schematic, one or more modules may be completed manually or through automation (e.g. with robotic assist). It is estimated that this system with only one gas press / one seal for a multi-paned IGU having a suspension assembly with thin glass is capable of manufacturing 60 or more triple or quad-pane IGUs per hour.

[0152] Many variations and modifications may be made to the above-described embodiments of the disclosure without departing substantially from the spirit and various principles of the disclosure. For example, Figs. 7A-7D, 8A-8D, 9A-9C, 10A, 10B, 11A-11C, 12A-12C, 13, 14, 15A-15D, 16, 17, and 18 illustrate further variations and modifications of the suspension assembly 20 and the one or more suspension members 18 thereof.

[0153] Figs. 7A-7D, 8A-8D, 9A-9C, 10A, 10B, and 11A-11C show the suspension members 18 with various structural configurations while positioned around the outer edge of the second pane 14 in a similar manner as the suspension members 18 shown in Figs. 5 A and 5B. Fig. 7A shows a triple pane IGU 10 with five suspension members 18 positioned around the outer edge of the second pane 14. In particular, one suspension member 18 is positioned at the bottom edge of the IGU 10, two suspension members 18 are positioned at the left edge, one suspension member 18 is positioned at the top edge, and one suspension member is positionedat the right edge. The number and / or position of the suspension members 18 can vary, as previously noted.

[0154] Fig. 7B is a section through the IGU 10 of Fig. 7A along line A-A. The section passes through the suspension members 18 at the top and bottom edges of the IGU 10 and faces in the direction of the two suspension members 18 along the left edge of the IGU 10. Fig. 7C is a schematic perspective view of the suspension members 18 disposed at the top, right, and bottom edges of the IGU 10. Fig. 7D is a schematic perspective view of the suspension members 18 disposed at the left edge of the IGU 10. As can be seen by comparing Fig. 7C and Fig. 7D, the suspension members 18 shown in Fig. 7D are essentially identical to the suspension member 18 shown in Fig. 7C except that the suspension members 18 of Fig. 7D are connected with a stringer 54. As used herein, a “stringer” refers to one or more pieces of material (e.g., typically flat) that connects multiple suspension members 18 together. The stringer 54 can help maintain (linear) spacing between suspension members 18 disposed along the outer edges of the second pane 14. The stringer 54 can also facilitate manufacture of the IGU 10 as the suspension members 18 with stringers 54 can be rolled up on a reel and dispensed from the reel (e.g., via a robot or similar automation) during positioning of the suspension members 18.

[0155] Referring now to Fig. 7C, the suspension member 18 comprises a retaining portion 56 disposed between a pair of spring portions 58 that extend oppositely from the retaining portion 56. The retaining portion 56 comprises a retaining region (e.g., groove or slot) that is sized to receive the second pane 14 therein. In embodiments, the retaining region is configured to grip the second pane 14 and hold the suspension member 18 thereon after the suspension member 18 is positioned on the edge of the second pane 14. As shown in Fig. 7C, the spring portions 58 have a corrugated configuration that allows some compression (e.g., linear compression) of the spring portions 58 along the extent of the suspension member 18. The spring portions 58 each have a contact portion 60 (e.g., contact surface) disposed at the outermost end along the extent of the suspension member 18 and facing away from the suspension member 18.

[0156] In embodiments, the suspension members 18 shown in Figs. 7A-7D exert a compression force (e.g., a spring constant) and / or exhibit a compression configured to allow for the assembly of glass panes 12, 14, 16 of varying thicknesses into the IGU 10, as well as different gap spaces for the cavities 24, 26, 28. In such embodiments, the suspension members 18 exert a compression force and / or exhibit a compression that enables thesuspension members 18 to be compressed between the first pane 12 and the third pane 16. This compression force holds the second pane 14 in position (e.g., spaced from the spacer 50), as a result of the friction between the contact portions 60 of the suspension members 18 and the first pane 12, as well as the friction between the contact portions 60 and the third pane 16. In embodiments, the contact portions 60 of the suspension members 18 of Figs. 7A-7D can be adhered (e.g., via adhesive) or otherwise connected to the first pane 12 and / or the third pane 16. In embodiments, the suspension members 18 of Figs. 7A-7D can be formed from a thin, flexible polymer material.

[0157] Referring now to Figs. 8A-8D, aspects of another structural configuration of the suspension members 18 are shown. Fig. 8 A shows a triple pane IGU 10 with four suspension members 18 positioned around the outer edge of the second pane 14. In particular, one suspension member 18 is positioned at the bottom edge of the IGU 10, one suspension member 18 is positioned at the left edge, one suspension member 18 is positioned at the top edge, and one suspension member is positioned at the right edge. The number and / or position of the suspension members 18 can vary, as previously noted.

[0158] Fig. 8B is a section through the IGU 10 of Fig. 8 A along line A-A. The section passes through the suspension members 18 at the top and bottom edges of the IGU 10 and faces in the direction of the suspension member 18 along the left edge of the IGU 10. Fig. 8C is a schematic plan view of the suspension members 18 disposed at the different edges of the IGU 10. As shown in Fig. 8C, the suspension member 18 comprises a retaining portion 56 and a spring portion 58 that extends from and encircles or substantially encircles the retaining portion 56. The retaining portion 56 comprises a retaining region (e.g., groove or slot) that is sized to receive the second pane 14 therein . In embodiments, the retaining region is configured to grip the second pane 14 and hold the suspension member 18 thereon after the suspension member 18 is positioned on the edge of the second pane 14.

[0159] As shown in Fig. 8C, the spring portion 58 comprises a first (left) spring portion 58 and a second (right) spring portion 58, each of which partially encircles the retaining portion 56 and connects to the retaining portion 56 at common end points. In an alternative configuration shown in Fig. 8D, each of the first (left) spring portion 58 and the second (right) spring portion 58 partially encircles the retaining portion 56 and connects to the retaining portion 56 at different end points. For example, the first (left) spring portion 58 of Fig. 8D connects to the retaining portion 56 at an end point proximate the bottom of the of the retaining portion 56, and the second (right) spring portion 58 of Fig. 8D connects to the retaining portion56 at an end point proximate the top of the retaining portion 56. In the alternative configuration of Fig. 8D, the spring portions 58 and the retaining portion 56 should be designed to ensure the retaining region in the retaining portion does not twist or turn when the suspension member 18 is positioned on the edge of the second pane 14 or when the suspension assembly 20 (e.g., comprising the second pane 14 and the suspension members 18) is positioned in the IGU 10 between the first pane 12 and the third pane 16.

[0160] Referring now to Figs. 8C and 8D, the first (left) spring portion 58 and the second (right) spring portion 58 comprise contact portions 60 configured to contact the first pane 12 and the third pane 16, respectively. In embodiments, the contact portions 60 are configured to increase the surface area between the contact portions 60 and the first pane 12 and / or the third pane 16 and thereby increase the friction therebetween. In embodiments, the suspension members 18 shown in Figs. 8C and 8D exert a compression force (e.g., a spring constant) and / or exhibit a compression configured to allow for the assembly of glass panes 12, 14, 16 of varying thicknesses into the IGU 10, as well as different gap spaces for the cavities 24, 26, 28. In such embodiments, the suspension members 18 exert a compression force and / or exhibit a compression that enables the suspension members 18 to be compressed between the first pane 12 and the third pane 16. This compression force holds the second pane 14 in position (e.g., spaced from the spacer 50), as a result of the friction between the contact portions 60 of the suspension members 18 and the first pane 12, as well as the friction between the contact portions 60 and the third pane 16.

[0161] In embodiments, the contact portions 60 of the suspension members 18 of Figs. 8A-8D can be adhered (e.g., via adhesive) or otherwise connected to the first pane 12 and the third pane 16. In embodiments, the suspension members 18 of Figs. 8A-8D are formed from a flexible polymer material. In embodiments, a stringer (e.g., such as the stringer 54 described above in connection with Figs. 7B and 7D) can be used to connect two or more suspension members 18 of Figs. 8A-8D. For example, a thin stringer could be used to connect the retaining portion 56 of the suspension member 18 of Fig. 8C to the retaining portion 56 of the suspension member 18 of Fig. 8D.

[0162] Referring now to Figs. 9A-9C, aspects of another structural configuration of the suspension members 18 are shown. Fig. 9A shows a triple pane IGU 10 with four suspension members 18 positioned around the outer edge of the second pane 14. In particular, one suspension member 18 is positioned at the bottom edge of the IGU 10, one suspension member 18 is positioned at the left edge, one suspension member 18 is positioned at the top edge, andone suspension member is positioned at the right edge. The number and / or position of the suspension members 18 can vary, as previously noted.

[0163] Fig. 9B is a section through the IGU 10 of Fig. 9A along line A-A. The section passes through the suspension members 18 at the top and bottom edges of the IGU 10 and faces in the direction of the suspension member 18 along the left edge of the IGU 10. As shown in Fig. 9B, each suspension member 18 comprises a retaining portion 56 and a plurality of spring portions 58 that extend outwardly from the retaining portion 56. The retaining portion 56 comprises a retaining region (e.g., groove or slot) that is sized to receive the second pane 14 therein. In embodiments, the retaining region is configured to grip the second pane 14 and hold the suspension member 18 thereon after the suspension member 18 is positioned on the edge of the second pane 14.

[0164] In the embodiment shown in Fig. 9B, the suspension members 18 each comprise four spring portions 58. In other embodiments, the suspension members 18 can each have more or less than four spring portions 58. In embodiments, the spring portions 58 extend from the retaining portion 56 in different directions. For example, as shown in Fig. 9B, the spring portions 58 extend so as to form a shape similar to the letter X. In embodiments, the spring portions 58 can have different numbers thereof on different sides of the retaining portion 56, such as two spring portions 58 disposed on a first side of the retaining portion 56 (e.g., configured to abut the first pane 12) and one spring portion 58 on a second side of the retaining portion 56 (e.g., configured to abut the third pane 16).

[0165] Referring still to Fig. 9B, the spring portions 58 each comprise a contact portion 60 (e.g., contact surface) disposed at the outermost end thereof and configured to contact the first pane 12 or the third pane 16. In embodiments, the contact portions 60 are configured to increase the surface area between the contact portions 60 and the first pane 12 and / or the third pane 16 and thereby increase the friction therebetween. Fig. 9C shows an alternative configuration comprising two suspension members 18 connected via a stringer 54, such as described above in connection with the suspension members 18 of Fig. 7D. In the alternative configuration shown in Fig. 9C, the spring portions 58 and the contact portions 60 of each suspension member 18 have different sizes and shapes compared to the spring portions 58 and the contact portions 60 of the suspension members 18 shown in Fig. 9B. The alternative configuration of the suspension members 18 shown in Fig. 9C may facilitate fabrication of the suspension members 18, such as via plastic injection molding processes.

[0166] The spring portions 58 of the suspension members 18 of Figs. 9A-9C allow some compression (e.g., linear compression) in directions transverse to the major surfaces 34, 36 of the second pane 14. In embodiments, the suspension members 18 shown in Figs. 9A-9C exert a compression force (e.g., a spring constant) and / or exhibit a compression configured to allow for the assembly of glass panes 12, 14, 16 of varying thicknesses into the IGU 10, as well as different gap spaces for the cavities 24, 26, 28. In such embodiments, the suspension members 18 exert a compression force and / or exhibit a compression that enables the suspension members 18 to be compressed between the first pane 12 and the third pane 16. This compression force holds the second pane 14 in position (e.g., spaced from the spacer 50), as a result of the friction between the contact portions 60 of the suspension members 18 and the first pane 12, as well as the friction between the contact portions 60 and the third pane 16.

[0167] In embodiments, the contact portions 60 of the suspension members 18 of Figs. 9A-9C can be adhered (e.g., via adhesive) or otherwise connected to the first pane 12 and the third pane 16. In embodiments, the suspension members 18 of Figs. 9A-9C are formed from a flexible polymer material.

[0168] Referring now to Figs. 10A and 10B, aspects of another structural configuration of the suspension members 18 are shown. Fig. 10A shows a triple pane IGU 10 with four suspension members 18 positioned around the outer edge of the second pane 14. In particular, one suspension member 18 is positioned at the bottom edge of the IGU 10, one suspension member 18 is positioned at the left edge, one suspension member 18 is positioned at the top edge, and one suspension member is positioned at the right edge. The number and / or position of the suspension members 18 can vary, as previously noted.

[0169] Fig. 10B is a section through the IGU lO ofFig. 10A along line A-A. The section passes through the suspension members 18 at the top and bottom edges of the IGU 10 and faces in the direction of the suspension member 18 along the left edge of the IGU 10. As shown in Fig. 10B, each suspension member 18 comprises a retaining portion 56 disposed between a pair of spring portions 58 that extend oppositely from the retaining portion 56. The retaining portion 56 comprises a retaining region (e.g., groove or slot) that is sized to receive the second pane 14 therein. In embodiments, the retaining region is configured to grip the second pane 14 and hold the suspension member 18 thereon after the suspension member 18 is positioned on the edge of the second pane 14. As shown in Fig. 9B, the spring portions 58 have a corrugated configuration that allows some compression (e.g., linear compression) of the spring portions 58 along the extent of the suspension member 18. The spring portions 58 each have a contactportion 60 (e.g., contact surface) disposed at the outermost end along the extent of the suspension member 18 and facing away from the suspension member 18.

[0170] In embodiments, the suspension members 18 shown in Figs. 10A and 10B exert a compression force (e.g., a spring constant) and / or exhibit a compression configured to allow for the assembly of glass panes 12, 14, 16 of varying thicknesses into the IGU 10, as well as different gap spaces for the cavities 24, 26, 28. In such embodiments, the suspension members 18 exert a compression force and / or exhibit a compression that enables the suspension members 18 to be compressed between the first pane 12 and the third pane 16. This compression force holds the second pane 14 in position (e.g., spaced from the spacer 50), as a result of the friction between the contact portions 60 of the suspension members 18 and the first pane 12, as well as the friction between the contact portions 60 and the third pane 16. In embodiments, the contact portions 60 of the suspension members 18 of Figs. 10A and 10B can be adhered (e.g., via adhesive) or otherwise connected to the first pane 12 and / or the third pane 16. In embodiments, the suspension members 18 of Figs. 10A and 10B can be formed from a thin, flexible polymer material.

[0171] In embodiments, the suspension members 18 can have a cross section with any shape. For example, as shown in Fig. 10A, the suspension members 18 have a triangular cross- sectional shape that comprises a cutout portion 62. In other embodiments, the suspension members 18 can have different cross-sectional shapes with or without the cutout portion 62. The cutout portion 62 can be used to tune the compression and / o the compression force (e.g., spring constant) of the suspension member 18. The cutout portion 62 can also be used to reduce the volume of material needed to fabricate the suspension member 18. In embodiments, the cross-sectional shape and / or the cutout portion 62 of the suspension member 18 can be configured to reduce the visibility of the suspension member 18 into the sightline of the IGU 10. In embodiments, a stringer (e.g., such as the stringer 54 described above in connection with Figs. 7B and 7D) can be used to connect two or more suspension members 18 of Figs. 10A and 10B. For example, a thin stringer could be used to connect the retaining portions 56 of two suspension members 18 disposed along any of the edges of the IGU 10.

[0172] Referring now to Figs. 11 A-l 1C, aspects of another structural configuration of the suspension members 18 are shown. Fig. 11A shows a triple pane IGU 10 with four suspension members 18 positioned around the outer edge of the second pane 14. In particular, one suspension member 18 is positioned at the bottom edge of the IGU 10, one suspension member 18 is positioned at the left edge, one suspension member 18 is positioned at the topedge, and one suspension member is positioned at the right edge. The number and / or position of the suspension members 18 can vary, as previously noted.

[0173] Fig. 1 IB is a section through the IGU lO ofFig. HA along line A-A. The section passes through the suspension members 18 at the top and bottom edges of the IGU 10 and faces in the direction of the suspension member 18 at the left edge of the IGU 10. Fig. 11C is a schematic perspective view of the suspension members 18 disposed at the left, top, and right edges of the IGU 10. The suspension member 18 disposed at the bottom edge of the IGU 10 is similar to the suspension members 18 disposed at the left, top, and right edges of the IGU 10 except as described below. As shown in Fig. 11C, each suspension member 18 comprises a retaining portion 56 and a spring portion 58 that adjoins the retaining portion 56 and extends away from the retaining portion 56. The retaining portion 56 has a contact portion 60 (e.g., contact surface) disposed at the outermost end along the extent of the suspension member 18 and facing away from the suspension member 18. The spring portion 58 also has a contact portion 60 (e.g., contact surface) disposed at the outermost end along the extent of the suspension member 18 and facing away from the suspension member 18. The spring portions 58 of Figs. 11 A-l 1C are similar to the spring portions 58 described with reference to Figs. 7A- 7D.

[0174] The retaining portion 56 comprises a retaining spring 66 that extends from an end of the retaining portion 56 (e.g., the end spaced from the spring portion 58) in a direction towards the spring portion 58. In embodiments, the retaining spring 66 is integrally formed with the retaining portion 56. The retaining spring 66 forms an angle a relative to a base surface 68 of the suspension member 18. In embodiments, the angle a is greater than zero and less than 45°, such as less than 40°, less than 35°, or less than 30°, when the retaining spring 66 is in an uncompressed state. The retaining spring 66 is configured to be moved into a compressed state in which the angle is temporarily reduced during assembly with the second pane 14. A retaining region (e.g., groove or slot) is defined between an end of the retaining spring 66 and a protruding region 67 of the retaining portion 56 disposed between retaining spring 66 and the spring portion 58. The retaining region is configured to receive the second pane 14 therein.

[0175] In an exemplary assembly method using the suspension members 18 of Figs. 11A-11C, the suspension members 18 are positioned along the spacer 50 in a common orientation (e.g., the retaining portions 56 of all suspension members 18 are disposed on one side of the IGU 10, such as shown in Fig. 1 IB). For example, the base portion 68 of each suspension member 18 can be adhered or otherwise connected to the spacer 50. Next, thesecond pane 14 is moved towards the suspension members 18 from the side on which the retaining portions 56 are disposed until contact is made with the retaining springs 66. Under continued movement in the same direction, the retaining springs 66 move (e.g., rotate) from the uncompressed state to the compressed state, providing clearance for the second pane 14. Once the second pane 14 moves past the ends of the retaining springs 66 and into the retaining regions defined by the retaining springs 66 and the protruding regions 67, the retaining springs 66 move (e.g., rotate) from the compressed state to the uncompressed state so as to retain the second pane 14 in the retaining regions.

[0176] As can be seen by comparing Fig. 11B and Fig. 11C, the suspension member 18 at the bottom edge of the IGU 10 is similar to the suspension members 18 at the left, top, and right edges of the IGU 10 except that the suspension member 18 at the bottom edge comprises a protruding portion 70. As shown in Fig. 11B, the protruding portion 70 is configured to extend into an opening in the spacer 50 adjacent the first pane 12 (or the third pane 16) such that the protruding portion 70 is disposed between the first pane 12 (or the third pane 16) and the spacer 50. In such embodiments, the protruding portion 70 can help maintain the position of the suspension member 18 via engagement with the first pane 12 (or the third pane) and the spacer 50.

[0177] In embodiments, the suspension members 18 shown in Figs. 11A-11C exert a compression force (e.g., a spring constant) and / or exhibit a compression configured to allow for the assembly of glass panes 12, 14, 16 of varying thicknesses into the IGU 10, as well as different gap spaces for the cavities 24, 26, 28. In such embodiments, the suspension members 18 exert a compression force and / or exhibit a compression that enables the suspension members 18 to be compressed between the first pane 12 and the third pane 16. This compression force holds the second pane 14 in position (e.g., spaced from the spacer 50), as a result of the friction between the contact portions 60 of the suspension members 18 and the first pane 12, as well as the friction between the contact portions 60 and the third pane 16. In embodiments, the contact portions 60 of the suspension members 18 of Figs. 11 A-l 1C can be adhered (e.g., via adhesive) or otherwise connected to the first pane 12 or the third pane 16. In such embodiments, the base portion 68 of the suspension member 18 may or may not be adhered or otherwise connected to the spacer 50. In embodiments, the suspension members 18 of Figs. 11 A-l 1C can be formed from a flexible polymer material or a rubber material.

[0178] Referring now to Figs. 12A-12C, aspects of another structural configuration of the suspension members 18 are shown. In each of Figs. 12A-12C, the suspension member 18comprises a rigid pane holder 72 disposed between deformable members 74 that adjoin opposed ends of the rigid pane holder 72. The rigid pane holder 72 has a retaining region (e.g., groove or slot) configured to receive the second pane 14 therein. The deformable members 74 can have any configuration and / or be formed from any material that provides some compliance (e.g., compression) at the opposed ends of the rigid pane holder 72. For example, the deformable members 74 can be configured as hollow springs (e.g., hollow loops of plastic), such as shown in Figs. 12A and 12B, or the deformable members 74 can be configured as solid, deformable pad or gels, such as shown in Fig. 12C. In embodiments, the rigid pane holder 72 can comprise the same configuration of the deformable members 74 at the opposed ends, or the rigid pane holder 72 can comprise different configurations of the deformable members 74 at the opposed ends. Similar to the suspension members 18 shown in Figs. 7A-7D, 8 A-8D, 9A- 9C, and 10A, 10B, the suspension members 18 of Figs. 12A-12C can be positioned at the different edges of the second pane 14 to form a suspension assembly 20 configured to be assembled into the IGU 10 as a unit.

[0179] Referring now to Fig. 13, aspects of another structural configuration of the suspension members 18 are shown. As shown in Fig. 13, the suspension members 18 are configured as a pedestals that are connected to the first pane 12. The suspension members 18 have low profile slots 76 configured retain the second pane 14 but allow the second pane 14 to be conveyed on an IGU production system as if it was a sheet of glass. Such a configuration allows use of typical IGU assembly processes, such as gas press and argon filling.

[0180] Referring now to Fig. 14, aspects of another structural configuration of the suspension members 18 are shown. As shown in Fig. 14, the suspension member 18 is configured as a muntin onto which the second pane 14 can be attached to form the suspension assembly 20. In embodiments, the second pane 14 can be sandwiched between two muntins and thereafter assembled into the IGU.

[0181] Referring now to Figs. 15A-15F, a series of top plan views and / or cross- sectional views are shown to illustrate an exemplary assembly method using another structural configuration of the suspension member 18. Figs. 15A-15D each comprise a top plan view and a corresponding cross-sectional view to illustrate the exemplary method. Figs. 15E and 15F each comprise a pair of cross-sectional views to illustrate the exemplary method. As best shown in Fig. 15C, the suspension member 18 is configured as a frame having a shape in the form of a square ring. Fig. 15A shows a first step of the method in which a first spacer 50a is positioned (e.g., applied, adhered, formed, etc.) onto the second major surface 32 of the first (outer)pane 12. Fig. 15B shows a second step of the method in which the second pane 14 is placed on the second major surface 32 of the first pane 12 within a cavity defined by the first spacer 50a. Fig. 15C shows a third step of the method in which the suspension member 18 is placed on the first spacer 50a. As shown in Fig. 15C, the suspension member 18 is configured such that a portion of a first major surface of the suspension member 18 disposed about a periphery of the suspension member 18 rests on the first spacer 50a

[0182] Fig. 15D shows a fourth step of the method in which a second spacer 50b is positioned (e.g., applied, adhered, formed, etc.) onto a portion of a second major surface of the suspension member 18 (e.g., opposite the first major surface) disposed about a periphery of the suspension member 18. Fig. 15E shows fifth and sixth steps of the method. In the left image of Fig. 15E, the fifth step of the method is shown in which the third pane 16 is positioned (e.g., applied, adhered, formed, etc.) onto the second spacer 50b. Although Figs. 15D and 15E show the third pane 16 being positioned on the second spacer 50b, in embodiments, the second spacer 50b can be positioned (e.g., applied, adhered, formed, etc.) onto the first major surface 38 of the third pane 16 in a proceeding step, and then a subassembly comprising the third pane 16 and the second spacer 50b can be positioned together (e.g., as a unit) onto the major surface of the suspension member 18. In embodiments, the method can include a gas filling step before the third pane 16 is positioned onto the second spacer 50b. In embodiments, the gas can comprise argon.

[0183] In the right image of Fig. 15E, the IGU subassembly in the left image is inverted so that the first pane 12 and the third pane 16 are now positioned at the top and the bottom, respectively, of the IGU subassembly. Such inversion causes the second pane 14 to move (e.g., via gravity) away from the second major surface 32 of the first pane 12 in a direction towards the suspension member 18 until the second pane 14 contacts a remaining portion of the first major surface of the suspension member 18. After inversion, the second pane 14 can be bonded to the suspension member 18. For example, infrared (IR) lamps or laser radiation can be used to heat the suspension member 18 for bonding with the second pane 14.

[0184] Fig. 15F shows fifth and sixth steps of the method using an alternative configuration of the IGU subassembly. In particular, rather than using an IGU subassembly comprising two spacers 50a, 50b, as illustrated in Figs. 15A-15E, the IGU subassembly of Fig. 15F comprises a single spacer 50 that is configured to capture (e.g., intimately surround) the suspension member 18 (e.g., still configured as a frame having a shape in the form of a squarering). The inversion and bonding steps illustrated in Fig. 15F are the same as described above with respect to Fig. 15E.

[0185] Figs. 16-18 depict a gas filling strategy that can be implemented when assembling an IGU that comprises the suspension assembly 20 as described herein. The gas filling strategy comprises filling both the first zone 24 of the gas cavity 28 and the second zone 26 of the gas cavity 28 during the processing of the suspension assembly 20. For example, if the suspension assembly 20 is positioned inside the IGU subassembly before sealing with the third pane 16, such as depicted in the left image of Fig. 16, the first zone 24 of the gas cavity 28 (e.g., between the first pane 12 and the second pane 14) would have a small area to allow the gas (e.g., argon) to enter the first zone 24 during the gas filling process. Fig. 17 illustrates modeling of such a gas filling process. In Fig. 17, the left and right sides of each image approximate the left and right sides of the gas cavity 28 (e.g., defined by the first pane 12 and the third pane 16), and the dashed lines near the top and bottom of each image approximate the top and bottom of the gas cavity 28 (e.g., defined by the spacer 50). As shown from left to right in the sequential images of Fig. 17, the modeling illustrates that the first zone 24 of the gas cavity 28 functions similar to a stovepipe, e.g., since the air is lighter than argon gas, the air would pull the argon gas into the first zone 24 as it floats on the denser argon gas.

[0186] Table 1 below illustrates gas fill times for different gap sizes and different IGU sizes to reach 95% fill of argon gas. Fig. 18 illustrates the various parameters used in Table 1, including IGU height A, gap size g, spacer height A, spacer thickness ts, and width w of the first zone 24 of the gas cavity 28. The IGU width is assumed to be the same as the IGU height h. The calculations for passive fill times in a gas press assume an initial condition in which the first zone 24 of the gas cavity 28 comprises air and the second zone 26 of the gas cavity 28 comprises argon gas (100%).

[0187] Table 1. Passive Fill Times in Gas Press

[0188] As shown in Table 1, Configurations 1 and 4 show the fastest fill times at 5.1 s. Configuration 6 shows the slowest fill time at 19.5 s. If the times are not fast enough, a separate in line gas prefilling equipment can be used. Such equipment should seal the bottom of the air knife entry point to keep the argon from pulling in air during filling.

[0189] As noted above, all such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.Reference Numbers:IGU 10 first pane 12 second pane (inner pane / suspended pane) 14 third pane 16 suspension member 18 retaining region of suspension member (hold / retain suspended pane in place) 22 suspension assembly (thin pane + suspension members) 20 first zone of sealed cavity 24 second zone of sealed cavity 26 sealed gas cavity 28 first major surface of first pane 30 second major surface of first pane 32 first major surface of suspended pane 34 second major surface of suspended pane 36 first major surface of third pane 38 second major surface of third pane 40 first major surface of second suspended pane 42 second suspended pane 44 second major surface of second suspended pane 46 secondary seal 48 spacer 50 inset of second pane, suspended thin pane from first pane or third pane 52 stringer 54 retaining portion 56 spring portion(s) 58 contact portions 60 cutout portion 62 retaining portion 64 retaining spring 66 protruding region 67 base portion 68 protruding portion 70 rigid pane holder 72 deformable members 74 low profile slots 76

Claims

CLAIMSWhat is claimed is:

1. An insulating glass unit (IGU), comprising: a first pane comprising a transparent material; a suspension assembly comprising: a second pane and at least one suspension member, wherein the second pane comprises a thin glass substrate having a thickness of not greater than 2.2 mm, wherein the suspension assembly is configured to retain the second pane in spaced relation from the first pane; a third pane comprising a transparent material, wherein the third pane is configured in spaced relation from the first pane; and a spacer positioned adjacent an outer edge and connecting the first pane and the third pane to define a gas cavity therebetween.

2. The IGU of claim 1, wherein the suspension member is configured with: a retaining region to retain the second pane; and a contact portion to contact and / or engage with a second major surface of the first pane.

3. The IGU of claim 1 or claim 2, wherein the second pane does not contact the spacer.

4. The IGU of any of claims 1 to 3, wherein the second pane has a perimetrical edge that extends between opposed major surfaces of the second pane, the perimetrical edge spaced from the spacer by a gap of at least 1 mm.

5. The IGU of claim 4, wherein the gap is in a range of from about 1 mm to about 3 mm.

6. The IGU of any of claims 1 to 5, wherein the second pane is retained in spaced relation from the third pane via attachment to the first pane.

7. The IGU of any of claims 1 to 6, wherein the second pane is inset from at least one of the first pane and the third pane.

8. The IGU of any of claims 1 to 7, wherein the second pane is at least 1 mm to not greater than 15 mm dimensionally inset from at least one of the first pane and the third pane.

9. The IGU of any of claims 1 to 8, wherein the suspension member is configured to attach to the second pane via an adhesive component, a mechanical attachment component, a compressive retention between the first pane and the third pane, and / or combinations thereof.

10. The IGU of any of claims 1 to 9, wherein the suspension member is a thermoplastic spacer portion; a super spacer portion, a foam configured with adhesive, a grid, a post configured with glue, a member configured with a groove or second pane retaining region.

11. The IGU of any of claims 1 to 10, wherein via the second pane, the sealed gas cavity is configured in a first zone between the first pane and the second pane and a second zone between the second pane and the third pane.

12. The IGU of any of claims 1 to 11, wherein the second pane is unstrengthened or annealed.

13. The IGU of any of claims 1 to 11, wherein the second pane is chemically strengthened or heat strengthened.

14. The IGU of any of claims 1 to 11, wherein the second pane is configured as a safety pane, such that the second pane is configured with a safety film adhered thereon; a glass - glass laminate or a glass-polymer laminate or such that the second pane is strengthened.

15. The IGU of any of claims 1 to 14, wherein the suspension member is configured to engage the first pane and the third pane.

16. The IGU of any of claims 1 to 14, wherein the suspension member is configured to contact one of the first pane and the third pane.

17. The IGU of any one of claims 1 to 16, wherein the suspension member extends between the first pane and the third pane and contacts a major surface of the first pane and a major surface of the third pane.

18. The IGU of claim 17, wherein the suspension member comprises a retaining region configured to position the second pane spaced from the first pane and the third pane.

19. The IGU of claim 18, wherein the retaining region is configured to position the second pane spaced from the spacer.

20. The IGU of any of claims 17 to 19, wherein the suspension member is spaced from the spacer.

21. The IGU of any of claims 18 to 20, wherein the suspension member comprises a retaining portion that defines the retaining region and a spring portion that extends from the retaining portion and contacts one or more of the first pane and the second pane.

22. The IGU of claim 21, wherein the spring portion is configured to flex, compress, or combinations thereof.

23. The IGU of claim 21 or claim 22, wherein the spring portion is configured to exert a compression force and / or exhibit a compression that enables the suspension member to be compressed between the first pane and the third pane.

24. The IGU of any of claims 21 to 23, wherein the suspension member is held in position via friction between the suspension member and the first pane and friction between the suspension member and the third pane.

25. The IGU of any of claims 21 to 24, wherein the suspension member is held in position via adhesive between one or more of (i) the suspension member and the first pane and (ii) the suspension member and the third pane.

26. The IGU of any of claims 21 to 25, wherein spring portion comprises a plurality of spring portions that extend from the retaining portion.

27. The IGU of any of claims 21 to 26, wherein the retention portion is disposed between at least two of the spring portions.

28. The IGU of any of claims 21 to 27, wherein the spring portion extends linearly from the retaining portion.

29. The IGU of any of claims 21 to 28, wherein the spring portion at least partially encircles the retaining portion.

30. The IGU of claim 29, wherein the spring portion completely encircles the retaining portion.

31. The IGU of any of claims 21 to 25, wherein the retaining portion comprises a retaining spring that extends from an end of the retaining portion in a direction towards the spring portion, the retaining spring defining the retaining region between an end of the retaining spring and a protruding region of the retaining portion disposed between retaining spring and the spring portion.

32. The IGU of claim 31, wherein the retaining spring is movable between a compressed state and an uncompressed state.

33. The IGU of claim 32, wherein: the retaining spring forms an angle relative to a base surface of the suspension member, the angle is a first angle that is greater than zero and less than 45° when the retaining spring is in the uncompressed state, and the angle is a second angle that is less than the first angle when the retaining spring is in the compressed state.

34. The IGU of any of claims 1-20, wherein the suspension member comprises a retaining portion and a pair of deformable members that adjoin opposed ends of the retaining portion, the retaining portion defining the retaining region.

35. The IGU of claim 34, wherein the retaining portion is configured as a rigid pane holder.

36. The IGU of claim 1, wherein the suspension member is configured as a frame having a peripheral portion attached to the spacer, the frame having a surface portion onto which the second pane is attached, the frame and the second pane spaced from the first pane and the third pane via the spacer.

37. The IGU of any of claims 1 to 36, wherein via the suspension assembly, the first zone of the gas cavity is in communication with the second zone of the gas cavity.

38. The IGU of any of claims 1 to 37, wherein the suspension member is configured to perimetrically surround 95% of the second pane.

39. The IGU of any of claims 1 to 37, wherein the suspension member is configured to perimetrically surround not greater than 10 % of the second pane.

40. The IGU of any of claims 1 to 39, wherein the spacer is selected from at least one of: a polymer material, a thermoplastic material, a metal spacer bar material, super spacer, and / or combinations thereof.

41. The IGU of any of claims 1 to 40, wherein the IGU further comprises: a secondary seal configured to extend between the region outside of the spacer and the outer edges of the first pane and the third pane.

42. The IGU of any of claims 1 to 41, wherein the second pane comprises a thickness in the range of at least 0.4 mm to not greater than 1.6 mm.

43. The IGU of any of claims 1 to 42, wherein the first pane and the third pane have a thickness of at least 2.2 mm to not greater than 6 mm.

44. The IGU of any of claims 1 to 43, wherein the first pane and the third pane are configured from tempered sodalime glass.

45. The IGU of any of claims 1 to 44, wherein the thin glass has a coefficient of thermal expansion (CTE) of less than 7 x 10'6 / K.

46. The IGU of any of claims 1 to 45, wherein the IGU is configured in a window, a door, a skylight, a curtain wall, and / or combinations thereof.

47. The IGU of any of claims 1 to 46, configured as an architectural product or an automotive product.

48. A method of making an IGU, comprising: attaching a suspension assembly to a first pane; applying a spacer along a perimetrical edge of at least one of the first pane and a third pane; and sealing via the spacer, the first pane to the third pane, such that the suspension assembly is retained between the first pane, the third pane, and the spacer, and further wherein a sealed gas cavity is defined between the first pane and the third pane.

49. The method of claim 48, wherein the attaching step further comprises attaching a second pane in spaced relation from the first pane via a suspension member.

50. The method of claim 48 or claim 49, further comprising attaching at least one suspension member to an outer edge region of the second pane.

51. The method of claim 49, wherein attaching further comprises gluing a plurality of suspension members along the outer edge region in spaced relation to each other about the perimeter of the second pane.

52. The method of claim 48, wherein attaching further comprises directing a bead of polymeric material, as the suspension member along the outer edge region of a major surface of the second pane.

53. The method of claim 48, wherein attaching further comprises adhering a foamadhesive member as the suspension member along the outer edge region of a major surface of the second pane.

54. The method of claim 48, wherein attaching further comprises retaining an edge portion of the second pane into a plurality of suspension members, wherein each member is configured with at least one groove to accept the edge portion.

55. The method of claim 54, wherein the attaching further comprises retaining an edge portion of the second pane into a plurality of suspension members and further, retaining an edge portion of a second inner pane into a plurality of suspension members, wherein at least some suspension members are configured to receive both a second pane and a second inner pane therein, further wherein, the second pane and the second inner pane are configured in spaced (parallel) relation to one another.

56. The method of any of claims 48 to 55, wherein the attaching step further comprises attaching the suspension member in a continuous region surrounding at least 5 % to not greater than 95% of the perimetrical outer edge of the second pane.

57. The method of any of claims 48-55, wherein the attaching step further comprises attaching the suspension member in a continuous region surrounding at least 15 % to not greater than 75% of the perimetrical outer edge of the second pane.

58. The method of any of claims 48 to 57, where the applying step further comprises directing a bead of thermoplastic spacer along a perimetrical edge of at least one of the first pane and the third pane.

59. The method of any of claims 48 to 57, where the applying step further comprises adhering a super spacer along a perimetrical edge of at least one of the first pane and the third pane.

60. The method of any of claims 48 to 57, where the applying step further comprises adhering a spacer bar along a perimetrical edge of at least one of the first pane and the third pane.

61. The method of any of claims 48 to 60, wherein the sealing step further comprises pressing the first pane to the third pane to attach the panes together via the spacer.

62. The method of any of claims 48 to 61 wherein, the method comprises sealing the first pane to the third pane in a gaseous environment, to configure, via sealing step, an insulating or non-reactive gas into the sealed gas cavity.

63. The method of any of claims 48 to 62, wherein the method further comprises applying the secondary seal in a single pass deposition that extends between the first pane and the third pane, to configure the secondary seal to enclose the spacer and extend along an outer edge of the IGU from the first major surface of the first pane to the second major surface of the third pane.

64. A system for making suspended thin glass IGUs, comprising: a suspension assembly module configured to engage a second pane with at least one suspension member, a suspension assembly application module configured to attach the suspension assembly via the suspension member to one of a first pane and a third pane; a spacer application module configured to apply a spacer to at least one of a first pane and a third pane; and an IGU assembly module configured to assemble the first pane and the third pane in spaced relation to one another, wherein the spacer attaches the first pane to the third pane to define a gas cavity, and further wherein, the suspension assembly is retained in the gas cavity such that the second pane is configured in spaced relation from the first pane and the third pane.

65. The system of claim 64, wherein the spacer application module is configured before the suspension assembly application module.

66. The system of claim 64, wherein the suspension assembly application module is configured before the spacer application module.

Images