Insulating glass unit with asymmetrical between-pane spaces

• US 8,595,994 B1
• Filed: 08/06/2012
• Issued: 12/03/2013
• Est. Priority Date: 05/30/2012
• Status: Active Grant

• Current Assignee: Cardinal IG Company (Cardinal Glass Industries Incorporated)
• Original Assignee: Cardinal IG Company (Cardinal Glass Industries Incorporated)
• Inventors: Grommesh, Robert C., Zurn, Benjamin James, Palmer, Richard Alan
• Primary Examiner(s): LAUX, JESSICA L
• Application Number:
  US13/567,489
• Publication Number:
  US 20130318892A1
• Time in Patent Office: 484 Days
• Field of Search: 522/045.93, 522/045.95, 522/045.3, 522/046, 522/046.1, 522/046.2, 527/861, 527/861.1, 527/861.3, 521/713, 522/00, 428/34
• US Class Current: 52/171.3
• CPC Class Codes: E06B 2003/6638 with coatings
• CPC Class Codes: E06B 3/6604 comprising false glazing bars or similar decorations between the panes connectors therefor E06B3/6675
• CPC Class Codes: E06B 3/66304 Discrete spacing elements, e.g. for evacuated glazing units
• CPC Class Codes: E06B 3/66314 of tubular shape E06B3/66323 and E06B3/66333 take precedence
• CPC Class Codes: E06B 3/66328 of rubber, plastics or similar materials E06B3/66314, E06B3/66323 and E06B3/66342 take precedence; transparent materials E06B3/66333
• CPC Class Codes: E06B 3/6775 Evacuating or filling the gap during assembly
• CPC Class Codes: Y10T 428/24752 Laterally noncoextensive components
• CPC Class Codes: Y10T 428/2495 Thickness [relative or absolute]
• CPC Class Codes: Y10T 428/24967 Absolute thicknesses specified
• CPC Class Codes: Y10T 428/31533 Of polythioether
• CPC Class Codes: Y10T 428/31605 Next to free metal
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/31696 Including polyene monomers [e.g., butadiene, etc.]

Abstract

An insulating glass unit may include at least three panes of transparent material and at least two spacers positioned between different panes of the unit. For example, a first spacer may hold a first pane of transparent material a first separation distance from a second pane of transparent material and a second spacer may hold the second pane of transparent material a second separation distance from a third pane of transparent material. In some examples, the insulating glass unit is configured so that the first separation distance is greater than the second separation distance. In such examples, the insulating glass unit may have a comparatively larger first between-pane space and a comparatively smaller second between-pane space. In some applications, the insulating glass unit may exhibit thermal and sound insulating properties approximately equal to a triple-pane insulating glass unit while having size characteristics approximately equal to a double-pane insulating glass unit.

Claims

1. An insulating glass unit comprising:

a first pane of transparent material;

a second pane of transparent material that is generally parallel to the first pane of transparent material;

a first spacer positioned between the first pane of transparent material and the second pane of transparent material to define a first between-pane space, the first spacer sealing the first between-pane space from gas exchange with a surrounding environment and holding the first pane of transparent material a first separation distance from the second pane of transparent material;

a third pane of transparent material that is generally parallel to the second pane of transparent material; and

a second spacer positioned between the second pane of transparent material and the third pane of transparent material to define a second between-pane space, the second spacer sealing the second between-pane space from gas exchange with the surrounding environment and holding the second pane of transparent material a second separation distance from the third pane of transparent material, the second spacer comprising a primary sealant extending from the second pane of transparent material to the third pane of transparent material and a gas diffusion barrier layer, wherein the gas diffusion barrier layer is a continuous strip defining a first terminal end and a second terminal end, and the second terminal end overlaps the first terminal end so as to prevent gas diffusion at a junction between the first terminal end and the second terminal end,

wherein the first separation distance is greater than the second separation distance and the first spacer is separated from the second spacer by the second pane of transparent material, and

wherein the first between-pane space and the second between-pane space are each filled with an insulating gas.

2. The insulating glass unit of claim 1, wherein the first pane of transparent material defines a first pane thickness, the second pane of transparent material defines a second pane thickness, the third pane of transparent material defines a third pane thickness, and the second pane thickness is less than the first pane thickness and the third pane thickness.

3. The insulating glass unit of claim 2, wherein the first pane thickness is the same as the third pane thickness.

4. The insulating glass unit of claim 1, wherein the second spacer further comprises a secondary sealant and the gas diffusion barrier layer positioned between the primary sealant and the secondary sealant.

5. The insulating glass unit of claim 4, wherein the first spacer comprises a tubular spacer defining a first side surface positioned adjacent the first pane of transparent material, a second side surface positioned adjacent the second pane of transparent material, a top surface exposed to the first between-pane space and connecting the first side surface to the second side surface, and a bottom surface connecting the first side surface to the second side surface, and further comprising a sealant positioned between the first side surface and the first pane of transparent material and the second side surface and the second pane of transparent material so as to seal the first spacer to the first pane of transparent material and the second pane of transparent material.

6. The insulating glass unit of claim 5, wherein the tubular spacer comprises metal.

7. The insulating glass unit of claim 4, wherein the gas diffusion barrier layer comprises metal.

8. The insulating glass unit of claim 4, wherein the gas diffusion barrier layer is a planar strip of metal that defines a first side and a second side opposite the first side, the first side of the planar strip of metal being in contact with the primary sealant and the second side of the planar strip of metal being in contact with the secondary sealant.

9. The insulating glass unit of claim 4, wherein the second pane of transparent material and the third pane of transparent material defines a common perimeter, the second spacer extends about the common perimeter with the primary sealant positioned closer to the second between-pane space than the secondary sealant, and the planar strip of metal extends about the common perimeter.

10. The insulating glass unit of claim 4, wherein a thickness of the gas diffusion barrier layer is less than 5 percent of an overall thickness of the second spacer.

11. The insulating glass unit of claim 8, wherein the planar strip of metal comprises at least one of aluminum and stainless steel.

12. The insulating glass unit of claim 1, wherein the primary sealant comprises at least one of a butyl rubber sealant, a polysulfide sealant, and a polyurethane sealant, the secondary sealant comprises at least one of the butyl rubber sealant, the polysulfide sealant, the polyurethane sealant, and a silicone sealant, and the primary sealant is different than the secondary sealant.

13. The insulating glass unit of claim 1, wherein the primary sealant comprises butyl rubber and the secondary sealant comprises silicone.

14. The insulating glass unit of claim 1, wherein the first pane of transparent material, the second pane of transparent material, and the third pane of transparent material each comprise clear sodium-lime-silica float glass.

15. The insulating glass unit of claim 1, further comprising an aperture extending through the second pane of transparent material so that the first between-pane space is in gas communication with the second between-pane space.

16. The insulating glass unit of claim 1, further comprising decorative grilles positioned in the first between-pane space.

17. The insulating glass unit of claim 1, wherein the first separation distance ranges from approximately 6.5 mm to approximately 21 mm, and the second separation distance ranges from approximately 2 mm to approximately 6 mm.

18. The insulating glass unit of claim 1, further comprising a frame positioned around the first pane of transparent material, the first spacer, the second pane of transparent material, the second spacer, and the third pane of transparent material, the frame being configured to mount the insulating glass unit so that a major length of the insulating glass unit is oriented at a non-perpendicular angle with respect to ground.

19. The insulating glass unit of claim 1, further comprising a fourth pane of transparent material and a third spacer positioned between at least one of the first pane of transparent material and the fourth pane of transparent material or the third pane of transparent material and the fourth pane of transparent material, the third spacer defining a third between-pane space that is sealed from gas exchange with a surrounding environment.

20. An insulating glass system comprising:

a building having an exterior wall; and

an insulating glass unit that comprises;

a first pane of transparent material;

a second pane of transparent material that is generally parallel to the first pane of transparent material;

a first spacer positioned between the first pane of transparent material and the second pane of transparent material to define a first between-pane space, the first spacer sealing the first between-pane space from gas exchange with a surrounding environment and holding the first pane of transparent material a first separation distance from the second pane of transparent material;

a third pane of transparent material that is generally parallel to the second pane of transparent material; and

a second spacer positioned between the second pane of transparent material and the third pane of transparent material to define a second between-pane space, the second spacer sealing the second between-pane space from gas exchange with the surrounding environment and holding the second pane of transparent material a second separation distance from the third pane of transparent material, the second spacer comprising a primary sealant extending from the second pane of transparent material to the third pane of transparent material and a gas diffusion barrier layer, wherein the gas diffusion barrier layer is a continuous strip defining a first terminal end and a second terminal end, and the second terminal end overlaps the first terminal end so as to prevent gas diffusion at a junction between the first terminal end and the second terminal end,

wherein the first separation distance of the insulating glass unit is greater than the second separation distance of the insulating glass unit and the first spacer is separated from the second spacer by the second pane of transparent material,

wherein the first between-pane space and the second between-pane space are each filled with an insulating gas, and

wherein the insulating glass unit is mounted in the exterior wall of the building such that a major length of the insulating glass unit is oriented at a non-perpendicular angle with respect to ground.

21. The insulating glass system of claim 20, wherein the exterior wall of the building is a roof.

22. The insulating glass system of claim 20, further comprising a frame positioned around the first pane of transparent material, the first spacer, the second pane of transparent material, the second spacer, and the third pane of transparent material, the frame being configured to mount the insulating glass unit so that the major length of the insulating glass unit is oriented at the non-perpendicular angle with respect to ground.

23. The insulating glass system of claim 20, wherein the insulating glass unit is mounted in the exterior wall of the building such that the major length of the insulating glass unit is oriented parallel to ground.

24. The insulating glass system of claim 20, wherein the insulating glass unit is mounted in the exterior wall of the building such that the major length of the insulating glass unit defines an angle with respect to an axis extending perpendicular to ground that ranges from approximately 25 degrees to approximately 90 degrees.

25. The insulating glass system of claim 20, wherein the first pane of transparent material defines a first pane thickness, the second pane of transparent material defines a second pane thickness, the third pane of transparent material defines a third pane thickness, and the second pane thickness is less than the first pane thickness and the third pane thickness.

26. The insulating glass system of claim 20, wherein the second spacer further comprises a secondary sealant and a gas diffusion barrier layer positioned between the primary sealant and the secondary sealant.

27. The insulating glass system of claim 26, wherein the first spacer comprises a tubular spacer defining a first side surface positioned adjacent the first pane of transparent material, a second side surface positioned adjacent the second pane of transparent material, a top surface exposed to the first between-pane space and connecting the first side surface to the second side surface, and a bottom surface connecting the first side surface to the second side surface, and further comprising a sealant positioned between the first side surface and the first pane of transparent material and the second side surface and the second pane of transparent material so as to seal the first spacer to the first pane of transparent material and the second pane of transparent material.

28. The insulating glass system of claim 27, wherein the tubular spacer comprises metal.

29. The insulating glass system of claim 26, wherein the gas diffusion barrier layer is a planar strip of metal that defines a first side and a second side opposite the first side, the first side of the planar strip of metal being in contact with the primary sealant and the second side of the planar strip of metal being in contact with the secondary sealant.

30. The insulating glass system of claim 29, wherein the planar strip of metal comprises at least one of aluminum and stainless steel, the primary sealant comprises butyl rubber, and the secondary sealant comprises silicone.

31. The insulating glass system of claim 26, wherein the second pane of transparent material and the third pane of transparent material defines a common perimeter, the second spacer extends about the common perimeter with the primary sealant positioned closer to the second between-pane space than the secondary sealant.

32. The insulating glass system of claim 26, wherein a thickness of the gas diffusion barrier layer is less than 5 percent of an overall thickness of the second spacer.

33. A method comprising:

positioning a first spacer between a first pane of transparent material and a second pane of transparent material so as to seal a first between-pane space defined between the first pane of transparent material and the second pane of transparent material from gas exchange with a surrounding environment and hold the first pane of transparent material a first separation distance from the second pane of transparent material;

positioning a second spacer between the second pane of transparent material and a third pane of transparent material so as to seal a second between-pane space defined between the second pane of transparent material and the third pane of transparent material from gas exchange with the surrounding environment and hold the second pane of transparent material a second separation distance from the third pane of transparent material, wherein positioning the second spacer comprising positioning a primary sealant to extend from the second pane of transparent material to the third pane of transparent material and positioning a gas diffusion barrier layer between the second pane of transparent material and the third pane of transparent material, wherein the gas diffusion barrier layer is a continuous strip defining a first terminal end and a second terminal end, and the second terminal end overlaps the first terminal end so as to prevent gas diffusion at a junction between the first terminal end and the second terminal end,

wherein the first separation distance is greater than the second separation distance and the first spacer is separated from the second spacer by the second pane of transparent material, and

wherein the first between-pane space and the second between-pane space are each filled with an insulating gas.

34. The method of claim 33, wherein the first spacer comprises a tubular spacer and positioning the first spacer between the first pane of transparent material and the second pane of transparent material comprises applying a sealant between a first side surface of the tubular spacer and the first pane of transparent material and applying the sealant between a second side surface of the tubular spacer and the second pane of transparent material.

35. The method of claim 34, wherein positioning the second spacer between the second pane of transparent material and the third pane of transparent material comprises positioning the primary sealant about the perimeter of the second pane of transparent material and the third pane of transparent material, applying the gas diffusion barrier layer about the perimeter of the second pane of transparent material and the third pane of transparent material, the gas diffusion barrier layer defining a first side that is applied in contact with the primary sealant and a second side opposite the first side, and applying a secondary sealant between the second pane of transparent material and the third pane of transparent material so that the secondary sealant is in contact with the second side of the gas diffusion barrier layer.

36. The method of claim 34, wherein the first separation distance ranges from approximately 6.5 mm to approximately 21 mm and the second separation distance ranges from approximately 2 mm to approximately 6 mm.