Insulated glass unit including a thin laminate pane

Abstract

An insulated glass unit (10) includes (a) a first outer pane (12); (b) a second outer pane (14); (c) an inner pane (16) disposed between the first outer pane (12) and the second outer pane (14), the inner pane (12) comprising a first primary surface (24) facing the first outer pane and a second primary surface (26) facing the second outer pane (14), and (d) at least one spacer element (18) defining (i) a first space (36) between the first outer pane (12) and the inner pane (16) and (ii) a second space (38) between the inner pane (16) and the second outer pane (14). At least one of the first outer pane (12), the second outer pane (14), and the inner pane (16) is a laminate (44) including (i) a first glass sheet (46), (ii) a second glass sheet (48), (iii) an interlayer (50) disposed between the first glass sheet (46) and the second glass sheet (48), and (iv) a thickness that is less than or equal to 2.2 mm.

Description

Atorney Docket No.: SP24-142PCTINSULATED GLASS UNIT INCLUDING A THIN LAMINATE PANECROSS-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 / 684,092 filed August 16, 2024, the content of which is incorporated herein by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure pertains to an insulated glass unit, and more particularly to an insulated glass unit with at least three panes, one of which is a relatively thin laminate pane.BACKGROUND

[0003] The anticipated newest version of ENERGY STAR requirements for residential windows, doors, and skylights (collectively here just “window”) will impose a minimum U- factor in the Northern climate zone of 0.22. The U-factor is a measure of how well the window prevents heat from escaping from an interior space to an external environment through the window. The lower the value of the U-factor, the less the window transfers heat.

[0004] To meet the new U-factor minimum value, windows will likely need to take the form of triple pane insulated glass units (“IGUs”). Triple pane IGUs utilize three panes separated from each other. The arrangement reduces heat transfer between the interior space and the external environment through the IGU compared to if only two glass panes were utilized.

[0005] However, there is a problem in that triple pane IGUs can be suboptimal in terms of weight, ease of manufacture, and cost. The problem arises from the incorporation of three largely identical panes of thick soda lime glass.SUMMARY

[0006] The present disclosure addresses that problem with an IGU that includes three or more panes, at least one of which is a relatively thin laminate pane and one of a variety of disclosed spacer elements that define at least partially a first space and a second space between the three or more panes.

[0007] According to a first aspect of the present disclosure, an insulated glass unit comprises: (a) a first outer pane; (b) a second outer pane; (c) an inner pane disposed between the first outer pane and the second outer pane, the inner pane comprising a first primary surface facing the first outer pane and a second primary surface facing the second outer pane, and (d) at least one spacer element defining (i) a first space between the first outer pane and the inner pane and (ii) a second space between the inner pane and the second outer pane, wherein at least one of theAtorney Docket No.: SP24-142PCT first outer pane, the second outer pane, and the inner pane is a laminate comprising (i) a first glass sheet, (ii) a second glass sheet, (iii) an interlayer disposed between the first glass sheet and the second glass sheet, and (iv) a thickness that is less than or equal to 2.2 mm.

[0008] According to a second aspect of the present disclosure, the insulated glass unit of the first aspect is presented, wherein the thickness of the laminate is less than or equal to 1.0 mm.

[0009] According to a third aspect of the present disclosure, the insulated glass unit of any one of the first through second aspects is presented, wherein the interlayer is a thermoplastic polymer.

[0010] According to a fourth aspect of the present disclosure, the insulated glass unit of any one of the first through third aspects is presented, wherein the interlayer is polyvinyl butyral, ethylene vinyl acetate (EVA), thermoplastic polyurethane, an ionoplast, or a combination thereof.

[0011] According to a fifth aspect of the present disclosure, the insulated glass unit of any one of the first through second aspects is presented, wherein the interlayer is a cured resin or an adhesive.

[0012] According to a sixth aspect of the present disclosure, the insulated glass unit of any one of the first through fifth aspects is presented, wherein (i) the first outer pane further comprises a perimeter edge, and the perimeter edge of the first outer pane comprises a first edge portion and a second edge portion that are parallel to each other, (ii) the second outer pane further comprises a perimeter edge, and the perimeter edge of the first outer pane comprises a first edge portion and a second edge portion that are parallel to each other, and (iii) the inner pane further comprises a perimeter edge, and the perimeter edge of the first outer pane comprises a first edge portion and a second edge portion that are parallel to each other.

[0013] According to a seventh aspect of the present disclosure, the insulated glass unit of the sixth aspect is presented, wherein the first edge portion of the first outer pane, the first edge portion of the second outer pane, and the first edge portion of the inner pane are all coplanar with or tangential to a common plane.

[0014] According to an eighth aspect of the present disclosure, the insulated glass unit of any one of the sixth through seventh aspects is presented, wherein (i) the first edge portion of the first outer pane and the first edge portion of the second outer pane are coplanar with or tangential to a first outer common plane, (ii) the second edge portion of the first outer pane and the second edge portion of the second outer pane are coplanar with or tangential to a second outer common plane, wherein the second outer common plane is parallel to the first outerAtorney Docket No.: SP24-142PCT common plane, and (iii) the first edge portion and the second edge portion of the inner pane are coplanar with or tangential to a first inner plane and a second inner plane that are each parallel to, and disposed between, the first outer common plane and the second outer common plane.

[0015] According to a ninth aspect of the present disclosure, the insulated glass unit of any one of the first through eighth aspects is presented, wherein the at least one spacer element comprises a first spacer at least partially defining the first space and a second spacer at least partially defining the second space.

[0016] According to a tenth aspect of the present disclosure, the insulated glass unit of the ninth aspect is presented, wherein (a) the first spacer comprises (i) a first spacer portion disposed proximate a first edge portion of a perimeter edge of the inner pane and (ii) a second spacer portion disposed proximate a second edge portion of the perimeter edge of the inner pane, and (b) the second spacer comprises (i) a first spacer portion disposed proximate the first edge portion of the perimeter edge of the inner pane and (ii) a second spacer portion disposed proximate the second edge portion of the perimeter edge of the inner pane.

[0017] According to an eleventh aspect of the present disclosure, the insulated glass unit of the tenth aspect is presented, wherein (i) a first spacer plane bisects the first spacer portion of the first spacer, (ii) a second spacer plane bisects the first spacer portion of the second spacer, (iii) a third spacer plane bisects the second spacer portion of the first spacer, (iv) a fourth spacer plane bisects the second spacer portion of the second spacer, and (v) the first spacer plane, the second spacer plane, the third spacer plane, and the fourth spacer plane are orthogonal to the outward primary surface of the first outer pane.

[0018] According to a twelfth aspect of the present disclosure, the insulated glass unit of the eleventh aspect is presented, wherein (i) the first spacer plane and the second spacer plane are co-planar with each other, and (ii) the third spacer plane and the fourth spacer plane are coplanar with each other.

[0019] According to a thirteenth aspect of the present disclosure, the insulated glass unit of the eleventh aspect is presented, wherein the second spacer plane and the fourth spacer plane are sandwiched between the first spacer plane and the third spacer plane.

[0020] According to a fourteenth aspect of the present disclosure, the insulated glass unit of the eleventh aspect is presented, wherein the second spacer plane and the third spacer plane are sandwiched between the first spacer plane and the fourth spacer plane.Atorney Docket No.: SP24-142PCT

[0021] According to a fifteenth aspect of the present disclosure, the insulated glass unit of any one of the eleventh through fourteenth aspects is presented, wherein (i) the first spacer further comprises a recess receiving the first edge portion and the second edge portion of the perimeter edge of the inner pane and contacting the first primary surface of the inner pane, and (ii) the second spacer further comprises a recess receiving the first edge portion and the second edge portion of the perimeter edge of the inner pane and contacting the second primary surface of the inner pane.

[0022] According to a sixteenth aspect of the present disclosure, the insulated glass unit of the fifteenth aspect is presented, wherein a gap disposed proximate the first edge portion of the perimeter edge of the inner pane and the second edge portion of the perimeter edge of the inner pane separates the first spacer and the second spacer.

[0023] According to a seventeenth aspect of the present disclosure, the insulated glass unit of the fifteenth aspect is presented, wherein the first spacer and the second spacer contact each other facing the first edge portion of the perimeter edge of the inner pane and the second edge portion of the perimeter edge of the inner pane.

[0024] According to an eighteenth aspect of the present disclosure, the insulated glass unit of any one of the fifteenth through seventeenth aspects is presented, wherein the first spacer and the second spacer are mirror images of each other.

[0025] According to a nineteenth aspect of the present disclosure, the insulated glass unit of any one of the eleventh through eighteenth aspects is presented, wherein (i) one of the first spacer and the second spacer further comprises a recess receiving the first edge portion and the second edge portion of the perimeter edge of the inner pane, while the other of the first spacer and the second spacer does not further comprise such a recess, and (ii) the first spacer and the second spacer mate proximate the recess to at least partially envelope the first edge portion and the second edge portion of the perimeter edge of the inner pane.

[0026] According to a twentieth aspect of the present disclosure, the insulated glass unit of any one of the first through nineteenth aspects is presented, wherein (i) the at least one spacer element is a pocket spacer comprising a recess receiving a first edge portion and a second edge portion of a perimeter edge of the inner pane, and (ii) the pocket spacer contacts an inner primary surface of the first outer pane and an inner primary surface of the second outer pane.

[0027] According to a twenty-first aspect of the present disclosure, the insulated glass unit of the twentieth aspect is presented, wherein the recess of the pocket spacer contacts both the first primary surface of the inner pane and the second primary surface of the inner pane.Atorney Docket No.: SP24-142PCT

[0028] According to a twenty-second aspect of the present disclosure, the insulated glass unit of the twentieth aspect is presented, wherein the recess of the pocket spacer is separated from the first primary surface of the inner pane and the second primary surface of the inner pane.

[0029] According to a twenty -third aspect of the present disclosure, the insulated glass unit of the twentieth aspect is presented, wherein the recess of the pocket spacer contacts one of the first primary surface and the second primary surface of the inner pane but not contact the other of the first primary surface and the second primary surface of the inner pane.

[0030] Additional features and advantages will be set forth in the detailed description which follows, and in part 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.

[0031] 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 claims. The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments, and together with the description serve to explain principles and operation of the various embodiments.BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In the Drawings:

[0033] FIG. l is a front perspective view of an IGU of the present disclosure, illustrating a first outer pane and a spacer element disposed behind the first outer pane;

[0034] FIG. 2 is an elevational cross-sectional view of the IGU taken through line II-II of FIG. 1, illustrating, in addition to the first outer pane, a second outer pane, and an inner pane in the form of a laminate between the first outer pane and the second outer pane;

[0035] FIG. 3 is an elevational cross-sectional view of the IGU like FIG. 2, illustrating the laminate including a first glass sheet, a second glass sheet, and an interlayer between the first glass sheet and the second glass sheet;

[0036] FIG. 4 is an elevational cross-sectional view of the IGU like FIG. 2, illustrating a spacer element including a first spacer with a first spacer portion and a second spacer portion and a second spacer with a first spacer portion and a second spacer portion;

[0037] FIG. 5 is an elevational cross-sectional view of the IGU like FIG. 2, illustrating a first spacer plane bisecting the first spacer portion of the first spacer, a second spacer plane bisecting the first spacer portion of the second spacer, a third spacer plane bisecting the second spacerAtorney Docket No.: SP24-142PCT portion of the first spacer, and a fourth spacer plane bisecting the second spacer portion of the second spacer;

[0038] FIG. 6 is an elevational cross-sectional view of the IGU like FIG. 2, illustrating the second spacer plane and the third spacer plane sandwiched between the first spacer plane and the fourth spacer plane;

[0039] FIG. 7 is an elevational cross-sectional view of the IGU like FIG. 2, illustrating the first outer pane and the second outer pane each having a first edge portion aligned along a first outer common plane and each having a second edge portion aligned along a second outer common plane;

[0040] FIG. 8 is an elevational cross-sectional view of the IGU like FIG. 2, illustrating the inner pane having a first edge portion forming a first inner plane and a second edge portion forming a second inner plane, with the first inner plane and the second inner plane sandwiched between the first outer common plane and the second outer common plane;

[0041] FIG. 9 is an elevational cross-sectional view of the IGU like FIG. 2, illustrating the first spacer portion including a recess receiving the first edge portion and the second edge portion of the inner pane, and the second spacer portion including a recess receiving the first edge portion and the second of the inner pane;

[0042] FIG. 10 is an elevational cross-sectional view of the IGU like FIG. 2, illustrating the second spacer portion but not the first spacer portion including a recess receiving the first edge portion and the second edge portion of the inner pane;

[0043] FIG. 11 is an elevational cross-sectional view of the IGU like FIG. 2, illustrating a pocket spacer as the spacer element defining partially a first space between the first outer pane and the inner pane and a second space between the inner pane and the second outer pane;

[0044] FIG. 12 is an elevational cross-sectional view of the IGU like FIG. 2, illustrating the pocket spacer including a recess receiving the first edge portion and the second edge portion of the inner pane but not touching a first primary surface of the inner pane facing the first outer pane or a second primary surface of the inner pane facing the second outer pane; and

[0045] FIG. 13 is an elevational cross-sectional view of the IGU like FIG. 2, illustrating the recess of the pocket spacer receiving the first edge portion and the second edge portion of the inner pane while touching the second primary surface of the inner pane but not touching the first primary surface of the inner pane.Atorney Docket No.: SP24-142PCTDETAILED DESCRIPTION

[0046] Reference will now be made in detail to the present preferred embodiments, examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.

[0047] Referring to FIGS. 1 and 2, various embodiments of an insulated glass unit (IGU) 10 are herein described. The embodiments of the IGU 10 disclosed herein include a first outer pane 12, a second outer pane 14, an inner pane 16, and at least one spacer element 18. In use, either the first outer pane 12 or the second outer pane 14 faces an external environment 20 (e.g., outside), while the other of the first outer pane 12 and the second outer pane 14 faces an internal environment 22 (e.g., inside). The first outer pane 12 and the second outer pane 14 are sheetlike in dimensions. The first outer pane 12 includes an outward primary surface 24 positioned to face away from the second outer pane 14 and an inward primary surface 26 positioned to face toward the second outer pane 14. Similarly, the second outer pane 14 includes an outward primary surface 28 positioned to face away from the first outer pane 12 and an inward primary surface 30 positioned to face the first outer pane 12. The inner pane 16 is disposed between the first outer pane 12 and the second outer pane 14. The inner pane 16 includes a first primary surface 32 positioned to face the first outer pane 12 and a second primary surface 34 positioned to face the second outer pane 14. The outward primary surfaces 24, 28, the inward primary surfaces 26, 30, the first primary surface 32, and the second primary surface 34 are planar to the extent possible within manufacturing capabilities and parallel to each other.

[0048] The at least one spacer element 18 defines a first space 36 and a second space 38. The first space 36 is between the first outer pane 12 and the inner pane 16. The second space 38 is between the inner pane 16 and the second outer pane 14. In embodiments, one or more of the first space 36 and the second space 38 are filled with a gas, such as a noble gas (e.g., Ar, Kr, Xe) or air. Filling the first space 36 and the second space 38 with a gas can reduce conductive heat transfer through the IGU 10 because of the low thermal conductivity of the gas, as well as improve acoustic insulation due to their increased atomic weights. In other embodiments, the first space 36 and the second space 38 are evacuated so as to have a pressure that is lower than atmospheric pressure.

[0049] In embodiments, the first outer pane 12 and the second outer pane 14 have a glass composition. For example, one or both of the first outer pane 12 and the second outer pane 14 can have a soda lime glass composition, although other glass compositions can be used without limitation, such as aluminosilicate glass compositions and alkali aluminosilicate glassAtorney Docket No.: SP24-142PCT compositions. One or both of the first outer pane 12 and the second outer pane 14 can be made by a float manufacturing process or a fusion draw manufacturing process. One or both of the first outer pane 12 and the second outer pane 14 can be chemically strengthened (e.g., subjected to ion-exchange) or thermally tempered. In embodiments, at least one of the inward primary surface 26 of the first outer pane 12 and the inward primary surface 30 of the second outer pane 14 can be coated with at least one low emissivity coating. Low emissivity coatings are known in the art and may include, without limitation, sputter-coated and pyrolytic coatings comprising, for example, one or more metals and / or metal oxides such as silver, titanium, and fluorine-doped tin oxide, to name a few.

[0050] The first outer pane 12 has a thickness 40 and the second outer pane 14 has a thickness 42. The thickness 40 of the first outer pane 12 is the shortest straight-line distance between the outward primary surface 24 and the inward primary surface 26. The thickness 42 of the second outer pane 14 is the shortest straight-line distance between the outward primary surface 28 and the inward primary surface 30. In embodiments, the thickness 40 of the first outer pane 12 and the thickness 42 of the second outer pane 14 are both greater than 2.2 mm. The thickness 40 of the first outer pane 12 and / or the thickness 42 of the second outer pane 14 can be greater than 2.2 mm, 2.5 mm, 3.0 mm, 3.5 mm, 4.0 mm, 4.5 mm, 5.0 mm, 5.5 mm, 6.0 mm, 6.5 mm, 7.0 mm, 7.5 mm, 8.0 mm, 8.5 mm, 9.0 mm, 9.5 mm, 10.0 mm, or within any range bound by any two of those values (e.g., from 3.0 mm to 5.5 mm, from 4.0 mm to 8.5 mm, and so on). The thickness 40 can be the same or can be different than the thickness 42.

[0051] At least one of the first outer pane 12, the second outer pane 14, and the inner pane 16 is a laminate 44. The laminate 44 includes a first glass sheet 46, a second glass sheet 48, and an interlayer 50. The interlayer 50 is disposed between the first glass sheet 46 and the second glass sheet 48. The Drawings illustrate the inner pane 16 in the form of the laminate 44. However, one or both of the first outer pane 12 and the second outer pane 14 could be the laminate 44 instead of or in addition to the inner pane 16. In embodiments when the laminate 44 is the inner pane 16, the first glass sheet 46 provides the first primary surface 32 facing the first outer pane 12, and the second glass sheet 48 provides the second primary surface 34 facing the second outer pane 14.

[0052] The laminate 44 has a thickness 52. The thickness 52 is the straight-line distance between the first glass sheet 46 and the second glass sheet 48. In the embodiments illustrated, the thickness 52 is the shortest straight-line distance between the first primary surface 32 and the second primary surface 34. The thickness 52 is less than or equal to 2.2 mm, or even lessAtorney Docket No.: SP24-142PCT than or equal to 1.0 mm. For example, the thickness 52 of the laminate 44 can be 0.20 mm, 0.30 mm, 0.40 mm, 0.50 mm, 0.60 mm, 0.70 mm, 0.80 mm, 0.90 mm, 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6 mm, 1.7 mm, 1.8 mm, 1.9 mm, 2.0 mm, 2.1 mm, less than 2.2 mm, or within any range bound by any two of those values (e.g., from 0.80 mm to 1.4 mm, from 0.90 mm to 1.9 mm, and so on).

[0053] In embodiments, the first glass sheet 46 has a thickness 54 of less than or equal to 1.0 mm. For example, the thickness 54 of the first glass sheet 46 can be 0.10 mm, 0.20 mm, 0.30 mm, 0.40 mm, 0.50 mm, 0.60 mm, 0.70 mm, 0.80 mm, 0.90 mm, 1.0 mm, or within any range bound by any two of those values (e.g., from 0.30 mm to 0.80 mm, from 0.10 mm to 0.50 mm, and so on).

[0054] In embodiments, the second glass sheet 48 has a thickness 56 of less than or equal to 1.0 mm. For example, the thickness 56 of the second glass sheet 48 can be 0.10 mm, 0.20 mm, 0.30 mm, 0.40 mm, 0.50 mm, 0.60 mm, 0.70 mm, 0.80 mm, 0.90 mm, 1.0 mm, or within any range bound by any two of those values (e.g., from 0.30 mm to 0.80 mm, from 0.10 mm to 0.50 mm, and so on). The thicknesses 54, 56 of the first glass sheet 46 and the second glass sheet 48, respectively, can be the same but need not be.

[0055] In embodiments, the interlayer 50 has a thickness 58 within a range of from 0.10 mm to 1.0 mm. For example, the thickness 58 of the interlayer 50 can be 0.10 mm, 0.15 mm, 0.20 mm, 0.25 mm, 0.30 mm, 0.35 mm, 0.40 mm, 0.45 mm, 0.50 mm, 0.55 mm, 0.60 mm, 0.65 mm, 0.70 mm, 0.75 mm, 0.80 mm, 0.85 mm, 0.90 mm, 0.95 mm, 1.0 mm, or within any range bound by any two of those values (e.g., from 0.65 mm to 0.80 mm, from 0.85 mm to 1.0 mm, and so on).

[0056] The first glass sheet 46 and the second glass sheet 48 of the laminate 44 each have a glass composition. The glass composition can be a boro-aluminosilicate glass composition, such as an alkaline earth boro-aluminosilicate glass composition, or an alkali-free boro- aluminosilicate glass composition. Exemplary commercial glass products include, but are not limited to, Coming® Willow®, EAGLE XG®, and Lotus® glasses. The first glass sheet 46 and the second glass sheet 48 of the laminate 44 can be fusion formed.

[0057] The interlayer 50 of the laminate 44 bonds the first glass sheet 46 and the second glass sheet 48 together. In embodiments, the interlayer 50 is a polymer, such as a thermoplastic polymer. The polymer can be an acoustic dampening polymer configured for noise reduction. For example, the acoustic dampening polymer can be configured with multiple layers (e.g. 3 layers of polymer), one layer (i.e. a central or middle layer in 3-layer polymer example) ofAtorney Docket No.: SP24-142PCT which is a relatively soft polymer compared to the other two layers. A commercially available example of an acoustic dampening polymer is QS 41 (by Solutia, a Subsidiary of Eastman Chemical Company). The polymer can be a tinted polymer configured for light absorption. More particularly, the tinted polymer is formulated to absorb at least some ultraviolet (UV) light, infra-red light, visible light, and / or combinations thereof. In embodiments, the interlayer 50 is polyvinyl butyral, ethylene vinyl acetate (EVA), thermoplastic polyurethane, an ionoplast (e.g., SentryGlas® from Kuraray America, Inc., USA), or a combination thereof. The lamination to form the laminate 44 may be done by any of several techniques known to individuals skilled in the art, such as nip roll-autoclave, vacuum bag-autoclave, flat bedautoclave, or any combination of temperature / vacuum / pressing to soften the interlayer 50 and achieve bonding to the first glass sheet 46 and the second glass sheet 48.

[0058] In other embodiments, the interlayer 50 is an adhesive, such as an optically clear adhesive. In those embodiments, the adhesive is applied from a release sheet to the first glass sheet 46, then again to the second glass sheet 48, and then the adhesive sides of the two glass sheets 46, 48 are joined together. Pressure is applied, such as with a nip roll system, to complete the bonding of the first glass sheet 46 and the second glass sheet 48.

[0059] In still other embodiments, the interlayer 50 is a cured resin. Self-curing or crosslinkable resins may be used, such as UV curable resins or room temperature vulcanizing (RTV) materials. Suitable resins are UV curable acrylics or self-cross-linking acrylics, as well as optically clear thermosetting resins. To form the laminate 44 of these embodiments, the liquid resin is applied between the first glass sheet 46 and the second glass sheet 48, and then cured. The resin may be poured into a gap between the first glass sheet 46 and the second glass sheet 48. Alternatively, the resin can be roll coated onto the first glass sheet 46, then the second glass sheet 48 is placed on the resin, and then the resin is cured.

[0060] In embodiments, the interlayer 50 is UV stable for architectural use. The interlayer 50 can include additives to improve UV stability.

[0061] The first outer pane 12 includes a perimeter edge 60. The perimeter edge 60 of the first outer pane 12 includes a first edge portion 62 and a second edge portion 64. The first edge portion 62 and the second edge portion 64 are parallel to each other. In the Drawings, the first edge portion 62 and the second edge portion 64 are oriented to be a top edge portion and a bottom edge portion. However, the particular orientation illustrated is not meant to be limiting.

[0062] The second outer pane 14 includes a perimeter edge 66. The perimeter edge 66 of the second outer pane 14 includes a first edge portion 68 and a second edge portion 70. The firstAtorney Docket No.: SP24-142PCT edge portion 68 and the second edge portion 70 are parallel to each other. In the Drawings, the first edge portion 68 and the second edge portion 70 are oriented to be a top edge portion and a bottom edge portion. However, the particular orientation illustrated is not meant to be limiting.

[0063] The inner pane 16, which can be the laminate 44, includes a perimeter edge 72. The perimeter edge 72 of the inner pane 16 includes a first edge portion 74 and a second edge portion 76. The first edge portion 74 and the second edge portion 76 are parallel to each other. In the Drawings, the first edge portion 74 and the second edge portion 76 are oriented to be a top edge portion and a bottom edge portion. However, the particular orientation illustrated is not meant to be limiting.

[0064] In embodiments, such as that illustrated at FIG. 2, the first edge portion 62 of the first outer pane 12, the first edge portion 68 of the second outer pane 14, and the first edge portion 74 of the inner pane 16 are all coplanar with or tangential to a common plane 78. Stated another way, the first edge portion 62 of the first outer pane 12, the first edge portion 68 of the second outer pane 14, and the first edge portion 74 of the inner pane 16 are all aligned with each other. Similarly, the second edge portion 64 of the first outer pane 12, the second edge portion 70 of the second outer pane 14, and the second edge portion 76 of the inner pane 16 are all coplanar with or tangential to a common plane 80. Stated another way, the second edge portion 64 of the first outer pane 12, the second edge portion 70 of the second outer pane 14, and the second edge portion 76 of the inner pane 16 are all aligned with each other.

[0065] Referring now to FIG. 3, in other embodiments, the first edge portion 62 of the first outer pane 12 and the first edge portion 68 of the second outer pane 14 are coplanar with or tangential to a first outer common plane 82. The second edge portion 64 of the first outer pane 12 and the second edge portion 70 of the second outer pane 14 are coplanar with or tangential to a second outer common plane 84. The second outer common plane 84 is parallel to the first outer common plane 82. The first edge portion 74 of the inner pane 16 is coplanar with or tangential to a first inner plane 86. The second edge portion 76 of the inner pane 16 is coplanar with or tangential to a second inner plane 88. The first inner plane 86 and the second inner plane 88 are parallel to each other and both are parallel to the first outer common plane 82 and the second outer common plane 84. However, the first inner plane 86 and the second inner plane 88 are disposed between the first outer common plane 82 and the second outer common plane 84. Stated another way, the first edge portion 62 of the first outer pane 12 is aligned with the first edge portion 68 of the second outer pane 14, the second edge portion 64 of the firstAtorney Docket No.: SP24-142PCT outer pane 12 is aligned with the second edge portion 70 of the second outer pane 14, and the first edge portion 74 and the second edge portion 76 of the inner pane 16 are offset inward from the first edge portions 62, 68 and the second edge portions 64, 70 of the first outer pane 12 and the second outer pane 14.

[0066] Referring still to FIGS. 2 and 3, in embodiments, the at least one spacer element 18 includes a first spacer 90 and a second spacer 92. The first spacer 90 defines, along with the first outer pane 12 and the inner pane 16, the first space 36 separating the first outer pane 12 and the inner pane 16. The second spacer 92 defines, along with the inner pane 16 and the second outer pane 14, the second space 38 separating the inner pane 16 and the second outer pane 14. The first spacer 90 includes a first spacer portion 94 and a second spacer portion 96. The first spacer portion 94 of the first spacer 90 is disposed closer to the first edge portion 74 of the inner pane 16 than the second spacer portion 96 of the first spacer 90. The second spacer portion 96 of the first spacer 90 is disposed closer to second edge portion 76 of the inner pane 16 than the first spacer portion 94 of the first spacer 90. Likewise, the second spacer 92 includes a first spacer portion 98 and a second spacer portion 100. The first spacer portion 98 of the second spacer 92 is disposed closer to the first edge portion 74 of the inner pane 16 than the second spacer portion 100 of the second spacer 92. The second spacer portion 100 of the second spacer 92 is disposed closer to second edge portion 76 of the inner pane 16 than the first spacer portion 98 of the second spacer 92.

[0067] In embodiments, a first spacer plane 102 bisects the first spacer portion 94 of the first spacer 90. In addition, a second spacer plane 104 bisects the first spacer portion 98 of the second spacer 92. Further, a third spacer plane 106 bisects the second spacer portion 96 of the first spacer 90. Finally, a fourth spacer plane 108 bisects the second spacer portion 100 of the second spacer 92. “Bisect” here means conceptually divides at least approximately equally in half, such as in terms of volume or weight. The first spacer plane 102, the second spacer plane 104, the third spacer plane 106, and the fourth spacer plane 108 will now be utilized to describe relative positioning of the first spacer portion 94 of the first spacer 90, the second spacer portion 96 of the first spacer 90, the first spacer portion 98 of the second spacer 92, and the second spacer portion 100 of the second spacer 92.

[0068] In embodiments, such as those illustrated at FIGS. 2 and 3, the first spacer plane 102 and the second spacer plane 104 are co-planar with each other. In addition, the third spacer plane 106 and the fourth spacer plane 108 are co-planar with each other. Stated another way, in these embodiments, the first spacer portion 94 of the first spacer 90 and the first spacerAtorney Docket No.: SP24-142PCT portion 98 of the second spacer 92 are aligned with each other, and the second spacer portion 96 of the first spacer 90 and the second spacer portion 100 of the second spacer 92 are aligned with each other.

[0069] Referring now to FIGS. 4 and 5, in embodiments, the second spacer plane 104 and the fourth spacer plane 108 are sandwiched between the first spacer plane 102 and the third spacer plane 106. Stated another way, the first spacer portion 98 and the second spacer portion 100 of the second spacer 92 are disposed more inward (e.g., away from the second edge portion 76 of the inner pane 16) than the first spacer portion 94 and the second spacer portion 96 of the first spacer 90.

[0070] Referring now to FIGS. 6 and 7, in embodiments, the second spacer plane 104 and the third spacer plane 106 are sandwiched between the first spacer plane 102 and the fourth spacer plane 108. Stated another way, the first spacer 90 is disposed closer to the first edge portion 74 of the inner pane 16 than the second spacer 92. As a result, the first spacer portion 94 of the first spacer 90 is disposed closer to the first edge portion 74 of the inner pane 16 than the first spacer portion 98 of the second spacer 92. Similarly, the second spacer portion 96 of the first spacer 90 is disposed closer to the first edge portion 74 of the inner pane 16 than the second spacer portion 100 of the second spacer 92.

[0071] Referring now to FIGS. 8 and 9, the first spacer 90 includes a recess 110 and the second spacer 92 includes a recess 112. The recess 110 of the first spacer 90 is disposed at least at the first spacer portion 94 and the second spacer portion 96 of the first spacer 90. The recess 112 of the second spacer 92 is disposed at least at the first spacer portion 98 and the second spacer portion 100 of the second spacer 92. The recess 110 at the first spacer portion 94 of first spacer 90 receives the first edge portion 74 of the inner pane 16. The recess 110 at the second spacer portion 96 of the first spacer 90 receives the second edge portion 76 of the inner pane 16. The recess 110 of the first spacer 90 contacts the first primary surface 32 of the inner pane 16. The recess 112 at the first spacer portion 98 of the second spacer 92 receives the first edge portion 74 of the inner pane 16. The recess 112 at the second spacer portion 100 of the second spacer 92 receives the second edge portion 76 of the inner pane 16. In the embodiment of FIG. 8, a gap 114 disposed proximate the first edge portion 74 of the inner pane 16 and the second edge portion 76 of the inner pane 16 separates the first spacer 90 and the second spacer 92. Stated another way, in that embodiment, the first spacer 90 and the second spacer 92 do not contact each other. However, in the embodiment of FIG. 9, the first spacer 90 and the second spacer 92 contact each other facing the first edge portion 74 of the inner pane 16 and the second edgeAtorney Docket No.: SP24-142PCT portion 76 of the inner pane 16. Stated another way, there is no gap 114 disposed proximate the first edge portion 74 of the inner pane 16 and the second edge portion 76 of the inner pane 16 that separates the first spacer 90 from the second spacer 92. In embodiments, the first spacer 90 and the second spacer 92 are mirror images of each other.

[0072] Referring now to FIG. 10, one of the first spacer 90 and the second spacer 92 further includes a recess 116. The recess 116 receives the first edge portion 74 and the second edge portion 76 of the inner pane 16. The other of the first spacer 90 and the second spacer 92 does not further comprise such a recess. Instead, the first spacer 90 and the second spacer 92 mate proximate the recess 116 to at least partially envelope the first edge portion 74 and the second edge portion 76 of the inner pane 16.

[0073] Referring now to FIGS. 11-13, the at least one spacer element 18 is a pocket spacer 118. The pocket spacer 118 includes a recess 120 that receives the first edge portion 74 and the second edge portion 76 of the inner pane 16. In addition, the pocket spacer 118 contacts the inward primary surface 26 of the first outer pane 12 and the inward primary surface 30 of the second outer pane 14. Stated another way, instead of the first spacer 90 defining partially the first space 36 and the second spacer 92 partially defining the second space 38, the pocket spacer 118 defines partially both the first space 36 and the second space 38, along with the first outer pane 12, the inner pane 16, and the second outer pane 14. In embodiments, such as that illustrated at FIG. 11, the recess 120 of the pocket spacer 118 contacts both the first primary surface 32 of the inner pane 16 and the second primary surface 34 of the inner pane 16. In other embodiments, such as that illustrated at FIG. 12, the recess 120 of the pocket spacer 118 is separated from the first primary surface 32 of the inner pane 16 and the second primary surface 34 of the inner pane 16. In still other embodiments, such as that illustrated at FIG. 13, the recess 120 of the pocket spacer 118 contacts one of the first primary surface 32 and the second primary surface 34 of the inner pane 16 but not the other of the first primary surface 32 and the second primary surface 34 of the inner pane 16.

[0074] The IGU 10 of the present disclosure addresses the problem mentioned in the Background in a variety of ways. The laminate 44 of the IGU 10 allows whichever of the first outer pane 12, the inner pane 16, or the second outer pane 14 that takes the form of the laminate 44 to have the thickness 52 of less than or equal to 2.2 mm and still satisfy the standards of ANSI Z97.1 and / or EN 12600. Single glass panes having a thickness of less than or equal to 2.2 mm are difficult to strengthen through chemical or thermal techniques sufficiently to pass the standards of ANSI Z97.1 and / or EN 12600. However, with appropriate selection of theAtorney Docket No.: SP24-142PCT interlayer 50, the laminate 44 can satisfy those standards while having the thickness 52 of less than or equal to 2.2 mm. The thickness 52 of the laminate 44, being relatively thin, reduces the weight of the IGU 10 as a whole compared to if three relatively thick and fully strengthened glass panes were utilized. In short, reducing the thickness of one of the panes of the IGU 10, such as the inner pane 16, reduces the weight of the IGU 10 - and making that pane take the form of the laminate 44 allows the pane to also satisfy the aforementioned standards. Thus, IGUs can be manufactured as triple pane IGUs that satisfy ENERGY STAR (version 7) standards, are not prohibitively heavy, and satisfy the aforementioned ANSI and EN standards. Further, the embodiments of the at least one spacer element 18 disclosed herein ease manufacturability and lower the cost of the IGU 10.

[0075] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the claims.

Claims

Atorney Docket No.: SP24-142PCTCLAIM(S)What is claimed is:

1. An insulated glass unit comprising: a first outer pane; a second outer pane; an inner pane disposed between the first outer pane and the second outer pane, the inner pane comprising a first primary surface facing the first outer pane and a second primary surface facing the second outer pane, and at least one spacer element defining (i) a first space between the first outer pane and the inner pane and (ii) a second space between the inner pane and the second outer pane, wherein at least one of the first outer pane, the second outer pane, and the inner pane is a laminate comprising a first glass sheet, a second glass sheet, an interlayer disposed between the first glass sheet and the second glass sheet, and a thickness that is less than or equal to 2.2 mm.

2. The insulated glass unit of claim 1, wherein the thickness of the laminate is less than or equal to 1.0 mm.

3. The insulated glass unit of any one of claims 1-2, wherein the interlayer is a thermoplastic polymer.

4. The insulated glass unit of any one of claims 1-3, wherein the interlayer is polyvinyl butyral, ethylene vinyl acetate (EVA), thermoplastic polyurethane, an ionoplast, or a combination thereof.

5. The insulated glass unit of any one of claims 1-2, wherein the interlayer is a cured resin or an adhesive.

6. The insulated glass unit of any one of claims 1-5, wherein the first outer pane further comprises a perimeter edge, and the perimeter edge of the first outer pane comprises a first edge portion and a second edge portion that are parallel to each other,Atorney Docket No.: SP24-142PCT the second outer pane further comprises a perimeter edge, and the perimeter edge of the first outer pane comprises a first edge portion and a second edge portion that are parallel to each other, and the inner pane further comprises a perimeter edge, and the perimeter edge of the first outer pane comprises a first edge portion and a second edge portion that are parallel to each other.

7. The insulated glass unit of claim 6, wherein the first edge portion of the first outer pane, the first edge portion of the second outer pane, and the first edge portion of the inner pane are all coplanar with or tangential to a common plane.

8. The insulated glass unit of any one of claims 6-7, wherein the first edge portion of the first outer pane and the first edge portion of the second outer pane are coplanar with or tangential to a first outer common plane, the second edge portion of the first outer pane and the second edge portion of the second outer pane are coplanar with or tangential to a second outer common plane, wherein the second outer common plane is parallel to the first outer common plane, and the first edge portion and the second edge portion of the inner pane are coplanar with or tangential to a first inner plane and a second inner plane that are each parallel to, and disposed between, the first outer common plane and the second outer common plane.

9. The insulated glass unit of any one of claims 1-8, wherein the at least one spacer element comprises a first spacer at least partially defining the first space and a second spacer at least partially defining the second space.

10. The insulated glass unit of claim 9, wherein the first spacer comprises (i) a first spacer portion disposed proximate a first edge portion of a perimeter edge of the inner pane and (ii) a second spacer portion disposed proximate a second edge portion of the perimeter edge of the inner pane, and the second spacer comprises (i) a first spacer portion disposed proximate the first edge portion of the perimeter edge of the inner pane and (ii) a second spacer portion disposed proximate the second edge portion of the perimeter edge of the inner pane.Atorney Docket No.: SP24-142PCT11. The insulated glass unit of claim 10, wherein a first spacer plane bisects the first spacer portion of the first spacer, a second spacer plane bisects the first spacer portion of the second spacer, a third spacer plane bisects the second spacer portion of the first spacer, a fourth spacer plane bisects the second spacer portion of the second spacer, and the first spacer plane, the second spacer plane, the third spacer plane, and the fourth spacer plane are orthogonal to an outward primary surface of the first outer pane.

12. The insulated glass unit of claim 11, wherein the first spacer plane and the second spacer plane are co-planar with each other, and the third spacer plane and the fourth spacer plane are co-planar with each other.

13. The insulated glass unit of claim 11, wherein the second spacer plane and the fourth spacer plane are sandwiched between the first spacer plane and the third spacer plane.

14. The insulated glass unit of claim 11, wherein the second spacer plane and the third spacer plane are sandwiched between the first spacer plane and the fourth spacer plane.

15. The insulated glass unit of any one of claims 11-14, wherein the first spacer further comprises a recess receiving the first edge portion and the second edge portion of the perimeter edge of the inner pane and contacting the first primary surface of the inner pane, and the second spacer further comprises a recess receiving the first edge portion and the second edge portion of the perimeter edge of the inner pane and contacting the second primary surface of the inner pane.

16. The insulated glass unit of claim 15, wherein a gap disposed proximate the first edge portion of the perimeter edge of the inner pane and the second edge portion of the perimeter edge of the inner pane separates the first spacer and the second spacer.Atorney Docket No.: SP24-142PCT17. The insulated glass unit of claim 15, wherein the first spacer and the second spacer contact each other facing the first edge portion of the perimeter edge of the inner pane and the second edge portion of the perimeter edge of the inner pane.

18. The insulated glass unit of any one of claims 15-17, wherein the first spacer and the second spacer are mirror images of each other.

19. The insulated glass unit of any one of claims 11-18, wherein one of the first spacer and the second spacer further comprises a recess receiving the first edge portion and the second edge portion of the perimeter edge of the inner pane, while the other of the first spacer and the second spacer does not further comprise such a recess, and the first spacer and the second spacer mate proximate the recess to at least partially envelope the first edge portion and the second edge portion of the perimeter edge of the inner pane.

20. The insulated glass unit of any one of claims 1-19, wherein the at least one spacer element is a pocket spacer comprising a recess receiving a first edge portion and a second edge portion of a perimeter edge of the inner pane, and the pocket spacer contacts an inner primary surface of the first outer pane and an inner primary surface of the second outer pane.

21. The insulated glass unit of claim 20, wherein the recess of the pocket spacer contacts both the first primary surface of the inner pane and the second primary surface of the inner pane.

22. The insulated glass unit of claim 20, wherein the recess of the pocket spacer is separated from the first primary surface of the inner pane and the second primary surface of the inner pane.

23. The insulated glass unit of claim 20, whereinAtorney Docket No.: SP24-142PCT the recess of the pocket spacer contacts one of the first primary surface and the second primary surface of the inner pane but not the other of the first primary surface and the second primary surface of the inner pane.

Images