Embedded vacuum insulating glass unit, and/or method of making the same

• US 7,851,034 B2
• Filed: 12/03/2007
• Issued: 12/14/2010
• Est. Priority Date: 12/03/2007
• Status: Expired due to Fees

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Cooper, David J.
• Primary Examiner(s): LONEY, DONALD J
• Application Number:
  US11/987,663
• Publication Number:
  US 20090142521A1
• Time in Patent Office: 1,107 Days
• Field of Search: 428/34, 428/212, 522/03, 522/04, 522/045, 527/861, 527/861.1, 527/861.3
• US Class Current: 428/34
• CPC Class Codes: E06B 3/6612 Evacuated glazing units
• CPC Class Codes: E06B 3/66304 Discrete spacing elements, e.g. for evacuated glazing units
• CPC Class Codes: E06B 3/66366 specially adapted for units comprising more than two panes or for attaching intermediate sheets
• CPC Class Codes: E06B 3/6775 Evacuating or filling the gap during assembly
• CPC Class Codes: Y02A 30/249 Glazing, e.g. vacuum glazing
• CPC Class Codes: Y02B 80/22 Glazing, e.g. vaccum glazing
• CPC Class Codes: Y10T 428/24942 including components having same physical characteristic in differing degree

Abstract

Certain example embodiments of this invention relate to a vacuum insulating glass (VIG) unit surrounded by two glass substrates, with at least one spacer element being disposed adjacent to and/or cradling the VIG and with a sealant sealing the entire unit at each end of the VIG, thereby reducing the chances of the VIG being damaged and/or improving the insulating features of the entire window unit. In certain example embodiments the spacer may be substantially U-shaped, whereas two pillar-like spacers may be used in connection with certain other example embodiments. The spacer element(s) may be butyl-based, foam-based, warm-edge spacer element(s), etc. The sealant may be polysulfide based, one- or two-part silicone based, polyurethane based, a dual seal equivalent sealant product, a hot melt butyl based sealant product, etc. The R-value of the window unit may be at least about 11, but typically is about 15-16, when measured at the center of the lite.

Claims

1. A window unit, comprising:

at least first, second, third and fourth substantially parallel spaced-apart glass substrates arranged in this order so as to form a center gap between the second and third, or two inner, substrates and first and second outer gaps respectively between each of the two inner substrates and the two outer substrates;

one or more spacer elements provided to maintain the first, second, third and fourth substrates in substantially parallel-apart relation to one another;

a sealant provided proximate a periphery of the window unit so as to at least partially seal the window unit,

wherein the center gap between the two inner substrates is provided at an inner gap pressure, the inner gap pressure being a pressure less than atmospheric pressure,

wherein the first and second outer gaps are provided at pressure(s) greater than the inner gap pressure,

wherein the window unit has an R-value of at least about 11 measured at a center thereof, and

wherein the sealant extends between the first and fourth glass substrates so that the second and third glass substrates are interior of the sealant.

2. The window unit of claim 1, further comprising a low-E coating provided on one or more of the substrates.

3. The window unit of claim 1, wherein the outer gaps are argon, krypton, and/or xenon inclusive gas-filled gaps.

4. The window unit of claim 1, wherein the sealant is a structural sealant.

5. The window unit of claim 1, wherein the sealant is a polysulfide based sealant, a one- or two-part silicone based sealant, a polyurethane based sealant, a dual seal equivalent sealant product, and/or a hot melt butyl based sealant product.

6. The window unit of claim 1, wherein the spacer element(s) is a butyl-based spacer element, a foam-based spacer element, and/or a warm-edge spacer element.

7. The window unit of claim 1, wherein the spacer element(s) is substantially U-shaped so as to at least partially cradle the two inner substrates between upward extending arms of the substantially U-shaped spacer element, the two outer substrates being on opposing sides of the upward extending arms of the substantially U-shaped spacer element from the two inner substrates.

8. The window unit of claim 7, further comprising an adhesive to adhere the substantially U-shaped spacer element to one or both of the two inner substrates, and/or one or both of the two outer substrates, via the upward extending arms thereof.

9. The window unit of claim 1, wherein at least two pillar-shaped spacer elements respectively provided between each inner substrate and the adjacent outer substrate substantially maintain the four substrates in substantially parallel-apart relation to one another.

10. The window unit of claim 9, further comprising an adhesive to adhere the pillar-shaped spacer elements to one or both of the two inner substrates, and/or one or both of the two outer substrates.

11. The window unit of claim 1, wherein the window unit has an R-value of between about 11 and 20 measured at a center thereof.

12. The window unit of claim 1, wherein the window unit has an R-value of from about 15-16 measured at a center thereof.

13. A window unit, comprising:

a vacuum insulating glass unit;

first and second glass substrates located on opposing sides of the vacuum insulating glass unit so as to form first and second outer gaps between the first substrate and the vacuum insulating glass unit and between the vacuum insulating glass unit and the second substrate, respectively;

at least one spacer element provided proximate to each end of the vacuum insulating glass unit so as to maintain the first and second glass substrates and the vacuum insulating glass unit in substantially parallel-apart relation to one another; and

a sealant provided at least adjacent to the at least one spacer element at each end of the major axis of the vacuum insulating glass unit so as to at least partially seal the window unit,

wherein the vacuum insulating glass unit includes an inner air gap at an inner gap pressure, the inner gap pressure being a pressure below atmospheric,

wherein the first and second outer gaps are provided at pressure(s) greater than the inner gap pressure,

wherein the window unit has an R-value of at least about 11 measured at a center thereof, and

wherein the sealant extends between the first and second glass substrates so that the vacuum insulating glass unit is interior of the sealant.

14. The window unit of claim 13, further comprising a low-E coating provided on the first substrate, the second substrate, and/or the vacuum insulating glass unit.

15. The window unit of claim 13, wherein the outer gaps are argon, krypton, and/or xenon inclusive gas-filled gaps.

16. The window unit of claim 13, wherein the sealant is a polysulfide based sealant, a one- or two-part silicone based sealant, a polyurethane based sealant, a dual seal equivalent sealant product, and/or a hot melt butyl based sealant product.

17. The window unit of claim 13, wherein the at least one spacer element is a butyl-based spacer element, a foam-based spacer element, and/or a warm-edge spacer element.

18. The window unit of claim 13, wherein the at least one spacer element is substantially U-shaped so as to at least partially cradle the vacuum insulating glass unit between upward extending arms of the substantially U-shaped spacer element, the two substrates being on opposing sides of the upward extending arms of the substantially U-shaped spacer element from the vacuum insulating glass unit.

19. The window unit of claim 18, further comprising an adhesive to adhere the substantially U-shaped spacer element to the vacuum insulating glass unit and/or one or both of the two substrates, via the upward extending arms thereof.

20. The window unit of claim 13, further comprising two pillar-shaped spacer elements respectively provided between vacuum insulating glass unit and the adjacent outer substrate proximate to each end of the major axis of the window unit so as to maintain the vacuum insulating glass unit and the two substrates in substantially parallel-apart relation to one another.

21. The window unit of claim 20, further comprising an adhesive to adhere the pillar-shaped spacer elements to vacuum insulating glass unit, and/or one or both of the two substrates.

22. The window unit of claim 13, wherein the window unit has an R-value of about 15-16 measured at a center thereof.