Light-diffusing, insulating, glazing system component

• US 6,699,558 B1
• Filed: 07/17/2002
• Issued: 03/02/2004
• Est. Priority Date: 09/22/1999
• Status: Expired due to Term

• Current Assignee: Advanced Glazing Technologies Ltd.
• Original Assignee: Advanced Glazings Ltd.
• Inventors: Milburn, Douglas I.
• Primary Examiner(s): Jones, Deborah
• Assistant Examiner(s): BOSS, WENDY L
• Application Number:
  US10/088,635
• Time in Patent Office: 594 Days
• Field of Search: 428/73, 428/34, 428/116-118, 428/138, 428/178, 428/34.1, 428/913, 156/60, 156/109, 156/290, 527/831, 527/861, 527/861.3, 527/931, 527/931.1, 527/941, 359/591, 359/596
• US Class Current: 428/73
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/20 Inorganic coating
• CPC Class Codes: B32B 2305/024 Honeycomb
• CPC Class Codes: B32B 2307/40 having particular optical properties
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2323/10 Polypropylene
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 37/146 whereby one or more of the layers is a honeycomb structure
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04C 2/54 Slab-like translucent elements floors for transmitting light E04B5/46; translucent or open-work ceilings E04B9/32, E04B9/34; translucent roof coverings E04D3/06, E04D3/28
• CPC Class Codes: Y10T 428/13 Hollow or container type article [e.g., tube, vase, etc.]
• CPC Class Codes: Y10T 428/236 Honeycomb type cells extend perpendicularly to nonthickness layer
• CPC Class Codes: Y10T 428/24149 Honeycomb-like

Abstract

A light diffusing insulating glazing insert consists of a flexible thin-walled honeycomb transparent insulation, to which is bonded a diffusing sheet, on one or both sides This provides a practical solution to problems related to utilizing thin-walled flexible honeycombs in glazing units consisting of two sheets of glass, plastic, or similar and a spacer/frame, as standard for window and skylight applications. Use of such a glazing insert adds insulation and light diffusion to the glazing system.

Claims

1. A glazing system comprising a composite light diffusing insulating glazing insert sandwiched between two rigid transparent panes, said composite light diffusing glazing insert comprising a flexible transparent honeycomb insulating core layer defining a plurality of honeycomb cells, said honeycomb insulating core layer being sufficiently thin-walled that it sags under its own weight, and a flexible skinning layer bonded to each major surface of said core layer, each said flexible skinning layer having sufficient tensile and compressional stress to hold its own shape over said cells whereby said flexible skinning layers rigidize said honeycomb insulating core layer.

2. A glazing system as claimed in claim 1, wherein each said skinning layer is bonded to said core layer by adhesive or heat sealing.

3. A glazing system as claimed in claim 1, wherein each said skinning layer is selected from the group consisting of;

veil, mat, roving, glass cloth, plastic cloth, natural fiber cloth, plastic film, and paper.

4. A glazing system as claimed in claim 1, wherein said transparent core layer also diffuses light.

6. A rigid light-diffusing glazing system as claimed in claim 1, wherein said core layer is made of polypropylene.

5. A composite light diffusing insulating glazing insert comprising a flexible honeycomb insulating core layer defining a plurality of honeycomb cells, and a flexible skinning layer bonded to each major surface of said core layer, each said flexible skinning layer having sufficient tensile and compressional stress to hold its own shape over the dimensions of said cells whereby said composite glazing insert is substantially rigid, and wherein each said skinning layer is indium-tin-oxide coated fibreglass.

7. A method of making a glazing system comprising:

a) fabricating a composite rigid light diffusing insulating glazing insert by attaching a flexible skinning layer to each major surface of a flexible transparent honeycomb insulating core layer defining a plurality of honeycomb cells, said honeycomb insulating core layer being sufficiently thin-walled that it sags under its own weight, and each said flexible skinning layer having sufficient tensile and compressional stress to hold its own shape over the dimensions of said cells so that said flexible skinning layers rigidize said honeycomb insulating core layer, and

b) sandwiching said composite rigid light diffusing insulating glazing insert between two transparent panes.

11. A method as claimed in claim 7, wherein said core layer is first laid flat on a supporting surface, a first said skinning layer is applied to a first major surface of said core layer, a heated roller is applied to said first said skinning layer to bond said first said skinning layer to said first major surface, said core layer is flipped over, a second said skinning layer is applied to a second major surface of said core layer, and a heated roller is applied to said second skinning layer on said second major surface to bond said second skinning layer to said second major surface.

12. A method as claimed in claim 11, wherein a spacer is provided around said core layer to limit the compression of the core layer during application of said heated roller.

13. A method as claimed in claim 12, wherein said core layer is made of polypropylene.

8. A method as claimed in cairn 7, wherein said skinning layer is sealed to said core layer by passing said core between rollers.

9. A method as claimed in claim 8, wherein said rollers are hot rollers and each said skinning layer is heat-sealed to said core layer.

10. A method as claimed in claim 9, wherein said skinning layer is bonded to the core layer with an adhesive.