System and methods of attaching retention members to insulating glazing units

Embodiments herein relate to methods for attachment of a retention member to an insulating glazing unit, resulting structures, and systems for the accomplishing the same. In some embodiments, a method of attaching a retention member to an insulating glazing unit can include placing a spacer unit between a first pane of glass and a second pane of glass to form the insulating glazing unit and applying an adhesive composition to at least one of a perimeter of the insulating glazing unit and the retention member. The method can further include mounting the retention member onto perimeter edges of at least one of the first pane and the second pane. Other embodiments are also included herein.

FIELD

The present invention generally relates to systems and methods for retaining one or more layers of glass within a frame of a fenestration unit, and in particular to methods for attachment of a retention member to an insulating glazing unit, resulting structures, and systems for the accomplishing the same.

BACKGROUND

Given often harsher environmental conditions encountered in coastal areas, there have been increasingly stringent standards, rules and regulations being passed about fenestration units such as windows and doors and the ability of such windows and doors to withstand extreme environmental conditions. For example, in many coastal areas, such as in Florida and along the eastern seaboard, hurricanes and tropical storms having gale force winds and the incidence of wind-borne debris are a yearly occurrence and threat. In addition, it is important for the glass subassemblies of such coastal impact windows and doors to be supported and retained within their window sash or frame assemblies or door panel or frame assemblies after impact, and/or after the glass has been broken to provide blast mitigation protection. Still further, these windows and doors generally must provide enhanced insulation capabilities when exposed to temperature extremes, especially in summer months when temperatures in some coastal areas can reach well over 100° F., while in the winter months, temperatures can be well below freezing.

Currently, for the manufacture of coastal impact products, in order to form such products with the desired levels of strength and stability to retain the insulated glass assembly after contact with windborne debris, additional time generally must be spent during the manufacturing process. A common method in the industry to achieve this retention is to add additional glazing material to the gap between the edge of the insulated glass assembly and the sash or frame to increase the bond area between the glass assembly and the sash or frame, in a process commonly referred to as back glazing. Such glazing material must be applied all around the glass edge in a complete and as full an application as possible. This generally requires significant craftsmanship/skill on the part of the workers, and considerable additional manufacturing time to ensure that the back-glazing is sufficient to meet required missile impact and pressure cycling (due to windborne debris) test standards for such coastal impact products. Additionally, this method requires all the work to be done in-line during the assembly of the sash/frame, causing a potential drop in efficiency and capacity of the manufacturing assembly line.

SUMMARY

Embodiments herein relate to systems and methods for retaining one or more layers of glass within a frame of a fenestration unit, and in particular to methods for attachment of a retention member to an insulating glazing unit, resulting structures, and systems for the accomplishing the same

In some embodiments, a method of attaching a retention member to an insulating glazing unit is included herein. The method can include placing a spacer unit between a first pane of glass and a second pane of glass to form the insulating glazing unit and applying an adhesive composition to at least one of a perimeter of the insulating glazing unit and the retention member. The method can further include mounting the retention member onto perimeter edges of at least one of the first pane and the second pane.

In some embodiments, a method of attaching a retention member to an insulating glazing unit is included herein. The method can include obtaining the insulating glazing unit, the insulating glazing unit comprising a first pane, a second pane, and a spacer unit disposed between the first pane and the second pane. The method can also include applying an adhesive composition to at least one of a perimeter of the insulating glazing unit or the retention member and applying the retention member to the perimeter edges of the first pane and the second pane.

DETAILED DESCRIPTION

As referenced above, environmental conditions encountered in coastal areas is generally harsh. Fenestration products for such environments must meet strict testing criteria structural integrity and impact resilience.

Generally, fenestration units for such environments include at least one laminate pane that is designed to retain structural integrity even after substantial impacts from debris. In many cases, the laminate pane can be an interior laminate pane with an exterior pane being a non-laminate. However, in some cases, interior and exterior panes can be laminate. In some cases, the exterior pane can be a laminate while the interior pane is not.

Laminate panes typically include a first glass layer, a second glass layer, and a polymeric material disposed between the first glass layer and the second glass layer. Embodiments herein include specialized components referred to as retention members that help to retain the laminate pane within the frame of the fenestration unit.

Referring now toFIG.1, a schematic view of an insulated glass fenestration unit having a laminated glass structure is shown in accordance with various embodiments herein.FIG.1specifically illustrates a portion of a window or door assembly100. The window or door assembly100includes a frame member102. The window or door assembly100also includes a glass subassembly113. The glass subassembly113has a width104and a height106.

Referring now toFIG.2, a cross-sectional view of a portion of an insulated glass fenestration unit is shown as taken along line2-2′ ofFIG.1in accordance with various embodiments herein. The window or door assembly includes a frame member102. The frame member102includes an attachment surface232. The frame member102also includes an edge233.

The window or door assembly can include a channel214, which can be defined at least in part by the frame member102. The channel214can include a lower end286. In various embodiments, at attachment surface232can be disposed on the lower end286of the channel214.

The window or door assembly can include a glass subassembly113. The glass subassembly113can include an interior laminate pane212. The glass subassembly113can also include an exterior pane227.

The glass subassembly113can include a proximal end272. The glass subassembly113can also include an inside facing surface284and an outside facing surface282. The glass subassembly113also includes a sealing spacer226. The sealing spacer226can serve to maintain a spacing distance between the interior laminate pane212and the exterior pane227. The sealing spacer226can also serve to attach the interior laminate pane212to the exterior pane227. The glass subassembly113also includes a space268between the interior laminate pane212and the exterior pane227. The glass subassembly113also includes a secondary sealant273. In various embodiments, the secondary sealant273can be disposed between the interior laminate pane212and the exterior pane227, but on the opposite side of the sealing spacer226from the space268.

The interior laminate pane212typically includes a first glass layer211, a second glass layer252, and a polymeric material262disposed between the first glass layer211and the second glass layer252.

In various embodiments, the polymeric material262of the interior laminate pane212can include various polymers. In various embodiments, the polymeric material262disposed between the first glass layer211and the second glass layer252can include at least one of an ionoplast, a cast-in-place polymer, a thermoplastic, and a thermoset. In some embodiments, the polymeric material262can be elastomeric. In some embodiments, the polymeric material262can be non-elastomeric. In various embodiments, the polymeric material262disposed between the first glass layer211and the second glass layer252can include at least one of polyvinyl butyral (PVB), SGP (SENTRYGLAS PLUS), polyethylene terephthalate (PET), polyurethane (PUR), and ethylene-co-vinyl acetate (EVA), and hydrids/alloys/laminates/copolymers/composites thereof.

The polymeric material262disposed between the first glass layer211and the second glass layer252can have a thickness of various dimensions. In some embodiments, the thickness can be greater than or equal to 10, 20, 30, 45, 60, 75, or 90 mils. In some embodiments, the thickness can be less than or equal to 150, 135, 120, 105, or 90 mils. In some embodiments, the thickness can fall within a range of 30 to 150 mils, or 45 to 135 mils, or 60 to 120 mils, or 75 to 105 mils, or can be about 90 mils.

The glass layers can have thicknesses of various dimensions. In some embodiments, the thickness of the glass layers can be greater than or equal to 60, 75, 90, 120, or 150 mils. In some embodiments, the thickness can be less than or equal to 300, 200, or 150 mils. In some embodiments, the thickness can fall within a range of 60 to 300 mils, or 90 to 200 mils.

In various embodiments, the first glass layer211and the second glass layer252are the same thickness. In other embodiments, wherein the first glass layer211and the second glass layer252have different thicknesses.

In various embodiments, the polymeric material262may not be limited to being just between the glass layers of the interior laminate pane212. By way of example, the polymeric material262can be disposed over at least a portion of a proximal end272of the interior laminate pane212.

In various embodiments, the polymeric material262that is disposed over at least a portion of the proximal end272of the interior laminate pane212is the same as the polymeric material262disposed between the first glass layer211and the second glass layer252. In various embodiments, the polymeric material262that is disposed over at least a portion of the proximal end272of the interior laminate pane212is integral with the polymeric material262disposed between the first glass layer211and the second glass layer252. In various embodiments, the polymeric material262that is disposed over at least a portion of the proximal end272of the interior laminate pane212is joined to the polymeric material262disposed between the first glass layer211and the second glass layer252via thermal, mechanical, or chemical bonds, or other means.

In various embodiments, the proximal end272of the glass subassembly113can be received and seated within the channel214.

An inside facing surface284can be on the interior laminate pane212. An outside facing surface282can be on the exterior pane227. In various embodiments, the outside facing surface282can be proximate the lower end286of the channel214. In various embodiments, the outside facing surface282of the glass subassembly113is attached to the channel214of the frame member102with a glazing material237. In various embodiments, a sealing spacer226can be disposed between the interior laminate pane212and the exterior pane227.

Window or door assemblies herein can include a retention member210. In various embodiments, the retention member210can engage at least a portion of the interior laminate pane212. In various embodiments, the retention member210having an elongation and tensile strength sufficient to provide the glass subassembly113with shock absorption and force dissipation protection that meets or exceeds one or more of ASTM E1886 (pressure cycling), ASTM E1996 (large and small missile impact), TAS 201 (impact), and/or TAS 203 (pressure cycling) standards.

The retention member210can include a base portion221. In various embodiments, the base portion221can extend along and engage at least a portion of the proximal end272of the glass subassembly113. In various embodiments, the base portion221can be of a length sufficient to project into and engage a heel bead225within the channel214to couple the retention member210to the frame member102. In various embodiments, the base portion221can extend along and engage at least a portion of the proximal end272of the glass subassembly113. In various embodiments, the base portion221can be of a width sufficient to project into and engage the bed glazing231to couple the retention member210to the frame member102.

A window or door assembly (not shown in this view) includes a glazing material237. In various embodiments, the glazing material237can be disposed on the attachment surface232at the lower end286of the channel214. The glazing material237can include a bed glazing231. Optionally, the bed glazing231can include a heel bead225portion.

The window or door assembly can also include a glass stop243. In some embodiments, the glass stop243can specifically be an interior glass stop, but the glass stop243can also be an exterior glass stop. The glass stop243includes a lower surface228. In various embodiments, the glass stop243can have a body including a lower surface228that extends along the inside facing surface284of the glass subassembly113. In some embodiments, the retention member210can be engaged between the lower surface228of the glass stop243and the inside facing surface284of the glass subassembly113.

The frame member102and/or glass stop243can be formed of various materials. In some embodiment the frame member102and/or glass stop243can be formed of a solid or a hollow material. In some embodiment the frame member102and/or glass stop243can be formed of wood, a wood product, a composite including wood such as wood fibers, a polymer (such as PVC, polylactic acid, and the like), a composite including a polymer, a metal (including, but not limited to aluminum and stainless steel), a composite including glass fibers, fiberglass, a composite including ceramic materials, a composite including particulate materials, FIBREX, and the like. In various embodiments, the frame member102and/or glass stop243can be formed of an extruded profile. In various embodiments, the frame member102and/or glass stop243can be formed of a pultruded material.

In various embodiments, wherein the interior laminate pane212comprises a first glass layer, a second glass layer, and a polymeric material262disposed between the first glass layer211and the second glass layer.

In various embodiments, the retention member210includes a series of strips of a fibrous fabric or tape reinforcing material404applied in succession about the inside facing surface284and a proximal end272portion of the glass subassembly113received within the channel214of the frame. In various embodiments, the retention member210includes a body having a series of openings formed therethrough to facilitate passage of an adhesive material through the retention member. Further details of exemplary retention members210are described in greater detail below.

It will be appreciated that retention members used herein can include a single layer of material or can include a plurality of layers of materials. Referring now toFIG.3, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. This view shows the frame member102with the attachment surface232and the edge233. This view also shows the glass stop243including lower surface228. This view also shows the channel214and the lower end286. This view also shows the glass subassembly113including an interior laminate pane212, an exterior pane227, the glass subassembly113including a proximal end272. The glass subassembly113also includes an inside facing surface284, outside facing surface282, and sealing spacer226and encloses space268. The glass subassembly113also includes secondary sealant273. A glazing material includes a bed glazing231and, in some embodiments, the bed glazing231includes a heel bead225. The interior laminate pane212includes a first glass layer211, second glass layer252, and polymeric material262disposed there between. This view also shows a retention member210including a plurality of layers. The retention member210includes a base portion221.

Many different constructions for retention members are contemplated herein. In some embodiments, retention members herein can include a single layer of material that can provide structural integrity as well as desired adhesion. However, in various embodiments, the retention member210can include multiple layers of materials with each layer serving a specific function. The following provides some non-limiting examples.

Referring now toFIG.4, a cross-sectional view of a portion of a retention member210is shown in accordance with various embodiments herein. The retention member210can include a reinforcing material404. The retention member210can also include a polymeric layer402. In some embodiments, the polymeric layer402can be and/or can function as an adhesive. In some embodiments, the reinforcing material404can be embedded within the polymeric layer402. However, in other embodiments, the reinforcing material404and the polymeric layer402can be separate discrete components. In various embodiments, the reinforcing material404can be attached to a surface of the polymeric layer. In various embodiments, the reinforcing material404can be adhered to a surface of the polymeric layer.

The choice of adhesive for attachment of the retention member to the insulating glass subassembly (and for other adhesives herein) is not particularly limited, provided the adhesive bonds with sufficient strength to at least portions of the associated surfaces of the insulating glass subassembly and to the retention member, and provided that the bonding is long-term, without significant bond deterioration over the life of the window.

Adhesives herein can include pressure-sensitive adhesives (PSAs), hot melt adhesives, structural adhesives, and the like. One useful adhesive includes VHB transfer adhesive, available from 3M Company, of Maplewood, Minn. The VHB adhesive, which can be laminated to the retention member and is provided with a removable liner to protect the adhesive until the retention member is ready for application to the glazing unit, at which time the liner typically will be removed just prior to application.

Adhesives herein can also include silicone materials such as silicone RTV (room temperature vulcanizing) sealants are useful for attaching and sealing glass members to frames or sashes. Hot melt silicone materials have also been found useful. Both types of silicone materials are available in various grades from Dow Corning Corporation, Midland, Mich. Adhesives and sealants based on polyurethane, polyamide, polyvinyl acetate, other known polymers, and copolymers and other combinations thereof, may also be useful.

In some cases, it also can be useful to apply a primer to the interior side of the glass subassembly and/or other surfaces to which the adhesive materials for attachment of the retention member to the insulating glass subassembly, prior to application of retention member in order to further improve adhesion of retention member to the glass. Suitable primers are available from 3M, as well as from other sources. Suitable methods for applying liquids, in particular, the primer, to solid surfaces in well-defined strips are also well-known, and include the use of sponges, rollers, and combinations thereof, as well as other like fluid application devices. In other embodiments, retention member may be attached to subassembly by a flowable adhesive such as a silicone material of the type used in bed glazing.

In various embodiments herein, reinforcing material404can specifically include fibrous and/or non-fibrous materials. Referring now toFIG.5, a cross-sectional view of a portion of a retention member210is shown in accordance with various embodiments herein. In this embodiment, the retention member210includes a fibrous reinforcing material502. In some embodiments, a non-fibrous energy-absorbing material can be included, such as an elastomer, a rubber, or another flexible and/or compressible material. A polymeric layer402, which could be an adhesive layer, or another type of polymeric layer can also be included. In various embodiments, wherein the fibrous reinforcing material502is adhered to a surface of the polymeric layer402. In various embodiments, the fibrous reinforcing material502is integrated into the polymeric layer402.

In various embodiments herein, the retention member210can include three of more layers. Referring now toFIG.6, a cross-sectional view of a portion of a retention member210is shown in accordance with various embodiments herein. In this embodiment, the retention member210includes a reinforcing material404, a fibrous reinforcing material502, and a polymeric layer402. As before, in some embodiments the polymeric layer402can be an adhesive layer. However, in other embodiments, the polymeric layer402can include a non-adhesive polymer layer. Referring now toFIG.7, a cross-sectional view of a portion of another example of a retention member210is shown in accordance with various embodiments herein. In this embodiment, the retention member210includes a reinforcing material404, a fibrous reinforcing material502, and a second reinforcing material704(or layer). Thus, in this example, the fibrous reinforcing material502is sandwiched between other materials, such as between a first polymeric layer and a second polymeric layer (and in some cases at least one of the polymeric layers can be an adhesive layer).

Many different configurations are contemplated herein. Referring now toFIG.8, a cross-sectional view of a portion of a retention member210is shown in accordance with various embodiments herein. In this example, the retention member210includes a reinforcing material404, a fibrous reinforcing material502, and a polymeric layer402(such as an adhesive layer).

In various embodiments, the retention member210can include at least two layers of a fibrous material. In various embodiments, the at least two layers can be separated by a non-fibrous material layer. Referring now toFIG.9, a cross-sectional view of a portion of a retention member210is shown in accordance with various embodiments herein. In this embodiment, the retention member210includes a reinforcing material404, a first fibrous reinforcing material502, and a second fibrous reinforcing material layer902.

In various embodiments, polymeric materials herein (including, but not limited to polymeric materials of the retention member, the various glazings, the frame, the glass stop, adhesives, sealants, and the like) can be filled with other components or materials. Referring now toFIG.10, a cross-sectional view of a portion of a retention member210is shown in accordance with various embodiments herein. The retention member210includes a reinforcing material404. The reinforcing material404can include a polymeric composition1004and a filler material1002. In various embodiments, the filler material1002can be entrained within the polymeric composition1004. The filler material can be of various types and can have many different functions. In some embodiments, the filler material1002can include a modulus modifying material.

In various embodiments, the filler material1002can include particulates. In various embodiments, the filler material1002can include organic or inorganic materials. In some embodiments, the filler material1002can include at least one of talc and calcium carbonate.

In various embodiments, the filler material1002can include fibers. The fibers can be of various sizes. In some embodiments, the fiber length can be greater than or equal to 0.1 mm, 0.5 mm, 1 mm, 2 mm, 3 mm, 6 mm, 9 mm, 12 mm, or 15 mm. In some embodiments, the length can be less than or equal to 30 mm, 27 mm, 24 mm, 21 mm, 18 mm, or 15 mm. In some embodiments, the length can fall within a range of 0.1 mm to 30.0 mm, or 3 mm to 27 mm, or 6 mm to 24 mm, or 9 mm to 21 mm, or 12 mm to 18 mm. In various embodiments, the fibers having an average length of greater than 0.5 mm and less than 10 mm.

The fibers can include many different materials. In some embodiments, the fibers comprising at least one of wood fibers, glass fibers, hybrid fibers, metal fibers, polyamide fibers (NYLON), para-aramid fibers (KEVLAR), and carbon fibers.

In various embodiments herein, filled materials can be included along with non-filled materials. Referring now toFIG.11, a cross-sectional view of a portion of a retention member210is shown in accordance with various embodiments herein. The retention member210includes first reinforcing material404(or layer) and second reinforcing material704(or layer). In this example, first reinforcing material404is filled with a filler material and second reinforcing material704is now.

In some embodiments, a reinforcing material herein can specifically include a mesh or like materials such as a scrim. Referring now toFIG.12, a schematic view of a mesh1202is shown in accordance with various embodiments herein. The mesh1202can include mesh strands1204. In this example, at least some of the mesh stands are oriented at an angle. In various embodiments, the mesh1202specifically includes mesh strands1204extending at an angle to a surface normal (e.g., a geometric normal—a line normal to a plane) of the inside facing surface284on the interior laminate pane212.

The angle of orientation is not particularly limited. However, in some embodiments, the strand angles can be greater than or equal to 0, 5, 10, 15, 20, 25, 30, 35, 40, or 45 degrees. In some embodiments, the strand angle can be less than or equal to 90, 85, 80, 75, 70, 65, 60, 55, 50, or 45 degrees. In some embodiments, the strand angle can fall within a range of 0 to 90 degrees, or 5 to 85 degrees, or 10 to 80 degrees, or 15 to 75 degrees, or 20 to 70 degrees, or 25 to 65 degrees, or 30 to 60 degrees, or 35 to 55 degrees, or 40 to 50 degrees, or can be about 45 degrees.

Referring now toFIG.13, a schematic view of a mesh1202is shown in accordance with various embodiments herein. The mesh1202includes mesh strands1204extending substantially parallel to a surface normal of the glass subassembly along with mesh strands that are directly perpendicular thereto.

In some embodiments, multiple layers of a mesh can be used, while in other embodiments only a single layer of mesh is used. In some embodiments, the reinforcing material404can include at least two layers of a mesh.

Referring now toFIG.14, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. This view shows the frame member102with the attachment surface232and the edge233. This view also shows the glass stop243including lower surface228. This view also shows the channel214and the lower end286. This view also shows the glass subassembly113including an interior laminate pane212, an exterior pane227, the glass subassembly113including a proximal end272. The glass subassembly113also includes an inside facing surface284, outside facing surface282, and sealing spacer226and encloses space268. The glass subassembly113also includes secondary sealant273. A glazing material includes a bed glazing231and, in some embodiments, the bed glazing231includes a heel bead225. The interior laminate pane212includes a first glass layer211, second glass layer252, and polymeric material262disposed there between.

The retention member210includes a base portion221. The retention member210also includes a first surface portion1402. The retention member210also includes a second surface portion1404. First surface portion1402and the second surface portion1404can be optimized for adherence to materials with different properties, such as different surface energy. In various embodiments, the first surface portion1402can have a first surface energy and a second surface portion1404can have a second surface energy. In various embodiments, wherein the first surface portion1402and the second surface portion1404are disposed on opposite sides of the retention member. However, in some embodiments, the first surface portion1402and the second surface portion1404are disposed on the same side of the retention member but spaced from one another. In various embodiments, at least one of the first surface portion1402and the second surface portion1404comprises a priming material or other surface coating or treatment to alter properties thereof.

In some embodiments, the size of the inside facing surface284of the interior laminate pane212can be less than the size of an outside facing surface1584of the interior laminate pane212. As such, in various embodiments, a width and/or height of the inside facing surface284less than a width and/or height of the outside facing surface. As one example, the first glass layer211can be smaller than the second glass layer252. As another example, the interior laminate pane212can be tapered inward around its periphery. In some embodiments, the retention member can follow the taper of the interior laminate pane212.

Referring now toFIG.15, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. This view shows the frame member102with the attachment surface232and the edge233. This view also shows the glass stop243including lower surface228. This view also shows the channel214and the lower end286. This view also shows the glass subassembly113including an interior laminate pane212, an exterior pane227, the glass subassembly113including a proximal end272. The glass subassembly113also includes an inside facing surface284, outside facing surface282, and sealing spacer226and encloses space268. The glass subassembly113also includes secondary sealant273. A glazing material includes a bed glazing231and, in some embodiments, the bed glazing231includes a heel bead225. The interior laminate pane212includes a first glass layer211, second glass layer252, and polymeric material262disposed there between.

The window or door assembly also includes a retention member210to help secure the interior laminate pane212. The retention member210includes a base portion221. The retention member210also includes a fold1502. The retention member210also includes an angled base portion1504. The angled base portion1504follows an angled portion of the edge of the interior laminate pane212.

In this example, a contact distance between the polymeric material262disposed between the first glass layer211and the second glass layer252and the retention member210is different than a thickness of the polymeric material262disposed between the first glass layer211and the second glass layer252. In specific, the contact distance between the polymeric material262disposed between the first glass layer211and the second glass layer252and the retention member210is different than a thickness of the polymeric material262disposed between the first glass layer211and the second glass layer252. While not intending to be bound by theory, the interface between (directly or indirectly) the polymeric material262and other components, such as the retention member210is believed to impact the structural integrity of the window or door assembly, and, specifically the structural integrity of the interior laminate pane212within the frame. By angling the interior laminate pane212inward, the contact distance can be increased without increasing the thickness of the polymeric material262within the interior laminate pane212.

The contact area (B) for this configuration can be approximated as B=(A/Cos θ1), where the larger θ1is up to 90 degrees, the larger the contact area is. In various embodiments θ1can be greater than or equal to 0, 5, 10, 15, 20, 25, 30, 35, 40, or 45 degrees. In some embodiments, the strand angle can be less than or equal to 90, 85, 80, 75, 70, 65, 60, 55, 50, or 45 degrees. In some embodiments, the strand angle can fall within a range of 0 to 90 degrees, or 5 to 85 degrees, or 10 to 80 degrees, or 15 to 75 degrees, or 20 to 70 degrees, or 25 to 65 degrees, or 30 to 60 degrees, or 35 to 55 degrees, or 40 to 50 degrees, or can be about 45 degrees.

However, as will be seen regarding further examples described herein, the example ofFIG.15is not the only way to increase contact area between the polymeric material262and other components of the system. Further, in contrast to the embodiment ofFIG.15, in other embodiments a contact distance between the polymeric material262disposed between the first glass layer211and the second glass layer252and the retention member210is the same as a thickness of the polymeric material262disposed between the first glass layer211and the second glass layer.

Referring now toFIG.16, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. This view shows the frame member102with the attachment surface232and the edge233. This view also shows the glass stop243including lower surface228. This view also shows the channel214and the lower end286. This view also shows the glass subassembly113including an interior laminate pane212, an exterior pane227, the glass subassembly113including a proximal end272. The glass subassembly113also includes an inside facing surface284, outside facing surface282, and sealing spacer226and encloses space268. The glass subassembly113also includes secondary sealant273. A glazing material includes a bed glazing231and, in some embodiments, the bed glazing231includes a heel bead225. The interior laminate pane212includes a first glass layer211, second glass layer252, and polymeric material262disposed there between. The window or door assembly also includes a retention member210to help secure the interior laminate pane212. The retention member210includes a base portion221.

The interior laminate pane212also includes a proximal end1602of interior laminate pane212. The exterior pane227includes a proximal end1604of exterior pane227. In this embodiment, the proximal end1602of interior laminate pane212and the proximal end1604of exterior pane227are not coterminous. Rather, the proximal end1604of exterior pane227extends outward a greater distance than proximal end1602of interior laminate pane212.

The specific amount of this distance is not particular limited, but, in various embodiments can be greater than or equal to 1 mm, 2 mm, 3 mm, 3 mm, 4 mm, or 5 mm. In some embodiments, the distance can be less than or equal to 20 mm, 17 mm, 14 mm, 11 mm, 8 mm, or 5 mm. In some embodiments, the distance can fall within a range of 1 mm to 20 mm, or 2 mm to 17 mm, or 3 mm to 14 mm, or 3 mm to 11 mm, or 4 mm to 8 mm, or can be about 5 mm.

In various embodiments, a polymeric material is disposed over at least a portion of the proximal end272of the interior laminate pane. While not intending to be bound by theory, this is believed to enhance adhesion and structural integrity. This can be achieved in various ways. By way of example, in some embodiments, excessive polymeric material resulting from the assembly process can be left behind instead of removed. In other embodiments, the coverage of the polymeric material can be intentionally extended.

In this embodiment, the interior laminate pane212includes an inner overlapping polymeric composition1606. The inner overlapping polymeric composition1606overlaps a portion of the proximal end1602of interior laminate pane212. The interior laminate pane212also includes an outer overlapping polymeric composition1608. The outer overlapping polymeric composition1608also overlaps a portion of the proximal end1602of interior laminate pane212. In some embodiments, the inner overlapping polymeric composition1606and the outer overlapping polymeric composition1608can be the same as the polymeric material262disposed between the first glass layer211and the second glass layer252. However, in other embodiments, these components can be formed of different polymer compositions.

In various embodiments, the polymeric material262disposed over at least a portion of the proximal end272of the interior laminate pane212is integral with the polymeric material262disposed between the first glass layer211and the second glass layer252. In various embodiments, the polymeric material262disposed over at least a portion of the proximal end272of the interior laminate pane212is joined to the polymeric material262disposed between the first glass layer211and the second glass layer252via a thermal, mechanical, or chemical bond.

Referring now toFIG.17, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein.FIG.17is generally likeFIG.16. However, in this embodiment, the outer overlapping polymeric composition1608overlaps the secondary sealant273and the exterior pane227. In some embodiments, the outer overlapping polymeric composition1608is flush with outside facing surface282.

Referring now toFIG.18, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. This view shows the frame member102with the attachment surface232and the edge233. This view also shows the glass stop243including lower surface228. This view also shows the channel214and the lower end286. This view also shows the glass subassembly113including an interior laminate pane212, an exterior pane227, the glass subassembly113including a proximal end272. The glass subassembly113also includes an inside facing surface284, outside facing surface282, and sealing spacer226and encloses space268. The glass subassembly113also includes secondary sealant273. A glazing material includes a bed glazing231and, in some embodiments, the bed glazing231includes a heel bead225. The interior laminate pane212includes a first glass layer211, second glass layer252, and polymeric material262disposed there between. The window or door assembly also includes a retention member210to help secure the interior laminate pane212. The retention member210includes a base portion221.

In this embodiment, the retention member210also includes a leg portion1822. In various embodiments, the leg portion1822can project at an angle with respect to the elongated base portion221and attached to the inside facing surface284of the glass subassembly. In various embodiments, the leg portion1822can overlap a portion of the inside facing surface284on the interior laminate pane212.

Referring now toFIG.19, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. This view shows the frame member102with the attachment surface232and the edge233. This view also shows the glass stop243including lower surface228. This view also shows the channel214and the lower end286. This view also shows the glass subassembly113including an interior laminate pane212, an exterior pane227, the glass subassembly113including a proximal end272. The glass subassembly113also includes an inside facing surface284, outside facing surface282, and sealing spacer226and encloses space268. The glass subassembly113also includes secondary sealant273. A glazing material includes a bed glazing231and, in some embodiments, the bed glazing231includes a heel bead225. The interior laminate pane212includes a first glass layer211, second glass layer252, and polymeric material262disposed there between.

The window or door assembly also includes a retention member210to help secure the interior laminate pane212. The retention member210includes a base portion221. The retention member210also includes a leg portion1822. In this embodiment, the leg portion1822can overlap a surface of polymeric material262that is exposed by virtue of the first glass layer211being smaller and having a peripheral edge inward from the second glass layer252. This configuration can substantially increase the contact area between the polymeric material262and the retention member210.

In various embodiments, a polymeric material of the retention member is the same as the polymeric material262disposed between the first glass layer211and the second glass layer252. In various embodiments, a polymeric material of the retention member is integral with the polymeric material262disposed between the first glass layer211and the second glass layer252. In various embodiments, the polymeric material of the retention member is attached to the polymeric material262disposed between the first glass layer211and the second glass layer252through a thermal, mechanical, or chemical bond, or through other means.

Referring now toFIG.20, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein.FIG.20is likeFIG.18. However, in this embodiment, the retention member210includes a base portion221, a leg portion1822, and a bed2022portion that is adjacent the bed glazing and that overlaps a portion of the outside facing surface282.

In some embodiments, various configurations are included herein that result in the glass stop contributing more substantially to the overall strength of the structure. Referring now toFIG.21, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. This view shows the frame member102with the attachment surface232and the edge233. This view also shows the channel214and the lower end286. This view also shows the glass subassembly113including an interior laminate pane212, an exterior pane227, the glass subassembly113including a proximal end272. The glass subassembly113also includes an inside facing surface284, outside facing surface282, and sealing spacer226and encloses space268. The glass subassembly113also includes secondary sealant273. A glazing material includes a bed glazing231and, in some embodiments, the bed glazing231includes a heel bead225. The interior laminate pane212includes a first glass layer211, second glass layer252, and polymeric material262disposed there between.

This view also shows the glass stop243including lower surface228. The retention member210includes a base portion221and a leg portion1822. The leg portion1822can pass between the lower surface228of the glass stop243and the inside facing surface284of the interior laminate pane212.

In various embodiments, further components can be included to increase the structural integrity of the door or window assembly. For example, in some embodiments, a material or structure can be disposed between the proximal end272and/or the retention member210and the frame member102.

Referring now toFIG.22, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. This view shows the frame member102with the attachment surface232and the edge233. This view also shows the glass stop243including lower surface228. This view also shows the channel214and the lower end286. This view also shows the glass subassembly113including an interior laminate pane212, an exterior pane227, the glass subassembly113including a proximal end272. The glass subassembly113also includes an inside facing surface284, outside facing surface282, and sealing spacer226and encloses space268. The glass subassembly113also includes secondary sealant273. A glazing material includes a bed glazing231and, in some embodiments, the bed glazing231includes a heel bead225. The interior laminate pane212includes a first glass layer211, second glass layer252, and polymeric material262disposed there between. The window or door assembly also includes a retention member210to help secure the interior laminate pane212. The retention member210includes a base portion221.

In various embodiments, a back glazing material2202is further included and is positioned between the proximal end272of the glass subassembly113and the frame member. In some embodiments, there is a gap between the heel bead225and/or bed glazing231and the back glazing material2202. In various embodiments, the back glazing material2202can be the same as the material used for the bed glazing231and/or the heel bead225. However, in other embodiments, different materials can be used.

In various embodiments, a shim can used in place of or in addition to the back glazing material2202. The shim can serve to limit lateral motion between the proximal end272of the glass subassembly113and the frame member102.

In some embodiments, the glass stop243can include structures to allow it to contribute more greatly to overall structural integrity of the window or door assembly.

Referring now toFIG.23, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. This view shows the frame member102with the attachment surface232and the edge233. This view also shows the glass stop243including lower surface228. This view also shows the channel214and the lower end286. This view also shows the glass subassembly113including an interior laminate pane212, an exterior pane227, the glass subassembly113including a proximal end272. The glass subassembly113also includes an inside facing surface284, outside facing surface282, and sealing spacer226and encloses space268. The glass subassembly113also includes secondary sealant273. A glazing material includes a bed glazing231and, in some embodiments, the bed glazing231includes a heel bead225. The interior laminate pane212includes a first glass layer211, second glass layer252, and polymeric material262disposed there between. The window or door assembly also includes a retention member210to help secure the interior laminate pane212. The retention member210includes a base portion221.

The window or door assembly includes a glass stop243. The glass stop243includes a lower surface228. The glass stop243also includes a leg2302. The leg2302can extend downwardly into the space between the proximal end272of the glass subassembly113and the frame member102.

In some embodiments, portions of the proximal end272of the glass subassembly113(and components thereof such as the interior laminate pane212) can be shaped or otherwise formed to include surface features/contours in order to increase the surface area thereof and/or provide for better bonding opportunities between components.

Referring now toFIG.24, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. This view shows the frame member102with the attachment surface232and the edge233. This view also shows the glass stop243including lower surface228. This view also shows the channel214and the lower end286. This view also shows the glass subassembly113including an interior laminate pane212, an exterior pane227, the glass subassembly113including a proximal end272. The glass subassembly113also includes an inside facing surface284, outside facing surface282, and sealing spacer226and encloses space268. The glass subassembly113also includes secondary sealant273. A glazing material includes a bed glazing231and, in some embodiments, the bed glazing231includes a heel bead225(to provide additional bonding area and to place a portion of the bond in shear loading rather than tensile loading). The interior laminate pane212includes a first glass layer211, second glass layer252, and polymeric material262disposed there between. The window or door assembly also includes a retention member210to help secure the interior laminate pane212. The retention member210includes a base portion221. The window or door assembly includes a glass stop243. The glass stop243includes a lower surface228.

A proximal end of interior laminate pane (not shown in this view) includes surface features/contours2402. The retention member210can interface with the surface features/contours2402. In some embodiments, the proximal end272of the interior laminate pane212is ground forming surface contours2402. In some embodiments, the surface contours2402include channels oriented within a plane of the interior laminate pane212.

Referring now toFIG.25, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein.FIG.25is generally similar toFIG.24. LikeFIG.24,FIG.25shows that the proximal end272of the interior laminate pane212has surface features/contours2402. However, in this embodiment, the overlapping polymeric composition1606and the overlapping polymeric composition1608interface with the surface features/contours2402.

In some embodiments, the base portion of the retention member210is substantially straight. However, in other embodiments, the base portion of the retention member210can be curved. Further, in some embodiments, a portion of the retention member210can be directly between the first glass layer211and the second glass layer252of the interior laminate pane212.

Referring now toFIG.26, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. This view shows the frame member102with the attachment surface232and the edge233. This view also shows the glass stop243including lower surface228. This view also shows the channel214and the lower end286. This view also shows the glass subassembly113including an interior laminate pane212, an exterior pane227, the glass subassembly113including a proximal end272. The glass subassembly113also includes an inside facing surface284, outside facing surface282, and sealing spacer226and encloses space268. The glass subassembly113also includes secondary sealant273. A glazing material includes a bed glazing231and, in some embodiments, the bed glazing231includes a heel bead225.

The choice of adhesive compositions useful for the bed glazing and the heel bead is not particularly limited, provided the adhesive materials exhibit adequate adhesion and sealing for the life of the window or door. Adhesives herein (for the bed glazing/heel bead and other adhesives) can include silicone materials such as silicone RTV (room temperature vulcanizing) sealants are useful for attaching and sealing glass members to frames or sashes. Hot melt silicone materials have also been found useful. Both types of silicone materials are available in various grades from Dow Corning Corporation, Midland, Mich. Adhesives and sealants based on polyurethane, polyamide, polyvinyl acetate, other known polymers, and copolymers and other combinations thereof, may also be useful. It will be appreciated that the material used for the heel bead in a particular window or door application need not be the same as the material used for the bed glazing in that window or door. For example, since the heel bead adhesive material and the bed glazing adhesive material typically bond to surfaces having different surface adhesion properties, it can be beneficial to choose different adhesive materials for the heel bead and the bed glazing to optimize bond strength. Additionally, it can be beneficial to choose heel bead materials that optimize mechanical integrity, while choosing bed glazing materials that optimize sealing between a glass surface and the sash.

The interior laminate pane212includes a first glass layer211, second glass layer252, and polymeric material262disposed there between. The window or door assembly also includes a retention member210to help secure the interior laminate pane212. The retention member210includes a base portion221. The window or door assembly includes a glass stop243. The glass stop243includes a lower surface228.

The window or door assembly includes a retention member210. The retention member210includes a base portion221. The retention member210also includes a portion directly between interior laminate pane and exterior pane2602. In various embodiments, at least a portion of the retention member210contacts the sealing spacer226. In various embodiments, at least a portion of the retention member210is positioned between the sealing spacer226and at least a portion of the secondary sealant273. In various embodiments, wherein at least a portion of the retention member210is positioned to be directly between the interior laminate pane212and the exterior pane227. Referring now toFIG.27, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. In this embodiment, at least a portion of the retention member210is positioned to be directly between the interior laminate pane212and the exterior pane227, but the retention member210does not directly contact the sealing spacer226.

In some embodiments, a retention member210can be embedded within the secondary sealant273. Referring now toFIG.28, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein.FIG.28is generally similar toFIG.2, however in this embodiment the retention member is embedded within the secondary sealant273and, specifically, within a portion2873of the secondary sealant273that is to the outer periphery of the proximal end of the glass subassembly272. It will be appreciated that this can be formed in various ways. For example, in some embodiments, application of the secondary sealant273can include a portion that is disposed over the outer periphery of the proximal end of the glass subassembly272and then a retention member (in various forms, but in some cases specifically in the form of a mesh) can pushed into the secondary sealant portion2873. In some embodiments, a first portion of the secondary sealant273can be applied, then the retention member210can be applied, then a second portion of the secondary sealant273can be applied over the retention member210.

Many different sealing spacers can be used with embodiments herein. Referring now toFIG.29, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein. This view shows the frame member102with the attachment surface232and the edge233. This view also shows the glass stop243including lower surface228. This view also shows the channel214and the lower end286. This view also shows the glass subassembly113including an interior laminate pane212, an exterior pane227, the glass subassembly113including a proximal end272. The glass subassembly113also includes an inside facing surface284, outside facing surface282, and sealing spacer226and encloses space268. The glass subassembly113also includes secondary sealant273. A glazing material includes a bed glazing231and, in some embodiments, the bed glazing231includes a heel bead225. The interior laminate pane212includes a first glass layer211, second glass layer252, and polymeric material262disposed there between. The window or door assembly also includes a retention member210to help secure the interior laminate pane212. The retention member210includes a base portion221. The window or door assembly includes a glass stop243. The glass stop243includes a lower surface228.

In this embodiment, the sealing spacer includes a polymeric sealing spacer2726. The polymeric sealing spacer2826is disposed between the interior laminate pane212and the exterior pane227.

Referring now toFIG.30, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein.FIG.30is generally similar toFIG.29. However, in this embodiment, the sealing spacer takes the form of a metal box type sealing spacer2926.

Referring now toFIG.31, a cross-sectional view of a portion of an insulated glass fenestration unit is shown in accordance with various embodiments herein.FIG.31is generally similar toFIG.21. However, in this embodiment, a top glazing material3131is disposed contacting the glass stop243and the leg portion1822. The top glazing material3131can be formed of the same material used to make the heal bead225and/or the bed glazing231. However, in some embodiments, the top glazing material3131can be formed of a different material than the heal bead225and/or the bed glazing231. In some embodiments, the top glazing material3131can directly contact the inside facing surface284, such as if the leg portion1822of the retention member210is omitted.

Retention Member

The retention member of embodiments herein can take on many different forms and configurations and can be made of many different materials.

In various embodiments, the retention member includes a planar material. In various embodiments, the retention member includes a folded planar material. In some embodiments, the retention member includes an extrudate.

Functionally, the retention member can have an elongation and tensile strength sufficient to provide the glass subassembly113with shock absorption and force dissipation protection that meets or exceeds one or more of ASTM E1886 and ASTM E1996 large and small missile impact and pressure cycling standards, and TAS 201, 202 and 203 (High-Velocity Hurricane Zones—Impact Tests for Wind-Borne Debris) building requirements, and AAMA 506 standards.

In some embodiments, the retention member includes a single layer of material. However, in various other embodiments, the retention member includes a plurality of layers. In various embodiments, the retention member includes from 2 to 6 layers of materials.

In various embodiments, the retention member includes a reinforcing material. In various embodiments, the reinforcing material comprising at least one layer of a fibrous material. The fibrous material can include fibers such as at least one of glass fibers, hybrid fibers, polyamide fibers (NYLON), para-aramid fibers (KEVLAR), polyethylene fibers, and carbon fibers.

In various embodiments, the fibrous material comprising a woven or non-woven material. In various embodiments, the fibrous material comprising directionally oriented or non-directionally oriented fibers.

In various embodiments, the retention member includes a metal layer as a reinforcing material.

In various embodiments, the retention member includes at least one polymeric layer including a first polymer and the polymeric material disposed between the first glass layer and the second glass layer of the interior laminate pane including a second polymer, wherein the first polymer and the second polymer adhere to one another. In some embodiments, the first polymer and the second polymer are the same.

In various embodiments, the retention member includes a base portion having dimensions sufficient to project into and engage a heel bead (if present) to couple the interior laminate pane to the frame member. In various embodiments, the retention member includes a base portion having dimensions sufficient to project into and engage a bed glazing to couple the interior laminate pane to the frame member.

It will be appreciated that retention members herein can be formed in various ways. In some embodiments, the retention member can be preformed and then applied onto the glass subassembly. However, in other embodiments, the retention member can be formed in-situ on the glass subassembly. In some embodiments, different components are attached/bonded/connected/welded to one another (chemically, mechanically, thermally, ultrasonically, etc.) in advance of application to the glass subassembly. However, in other embodiments, different components of the retention member can be attached to one another during application to the glass subassembly.

In some embodiments, the retention member can be attached to other components herein using various techniques. By way of example, the retention member can be attached/bonded/connected/welded to any of the other components (such as those shown in the FIGS. described herein) chemically, mechanically, thermally, ultrasonically, or using other techniques. In some embodiments, different portions of the retention member can be attached to other components using different techniques. For example, one portion of the retention member can be attached to a bed glazing using one technique (such as chemically using an adhesive) and a second portion of the retention member can be attached to a laminate pane using a different technique (such as thermally or ultrasonically welded).

In some embodiments, some or all polymeric components of the retention member can be precured. However, in other embodiments, some or all polymeric components of the retention member can be applied in an uncured state (or “wet”) and then later cured, such as in later steps of the glass subassembly manufacturing process or during manufacturing the fenestration unit.

Various steps can be taken to result in the retention member having a desired thickness. By way of example, in some embodiments, the retention member can be molded to a specific thickness, can be extruded to have a specific thickness, can be cut-down to specific thickness, can be expanded to a specific thickness (such as using a blowing agent or the like), can be blade-coated to a specific thickness, can be spray-coated to a specific thickness, or the like. In some embodiments, such as where a component is applied in an uncured state, a roller or similar device (such as a squeegee) can be passed over the retention member to force out any air pockets or gaps.

In various embodiments herein, the retention member can exhibit a degree of expansion that can be suitable to absorb a portion of energy as well as transfer a portion of energy. In some embodiments, the retention member can exhibit a degree of elongation of about 50, 60, 70, 80, 90, 100, 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 220, 240, 260, 280, or 300 percent, or an amount falling within a range between any of the foregoing.

It will be appreciated that the retention member can have various thicknesses. In some embodiments, the retention member can have a thickness of about 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5 mm, or more, or a thickness falling within a range between any of the foregoing.

In some embodiments, the retention member can have a uniform thickness.

However, in other embodiments, the retention member can vary in thickness with either the portion adjacent the interior laminate pane being thicker or thinner than the portion adjacent the exterior pane.

Methods

Many different methods are contemplated herein, including, but not limited to, methods of making, methods of using, and the like. In an embodiment, a method of making a glass subassembly for a window or door assembly is included. The method can include positioning a sealing spacer between an interior laminate pane of glass and an exterior pane of glass forming an insulating glazing unit. The method can further include applying a retention member to span perimeter edges of the interior laminate pane of glass and the exterior pane of glass. The method can further include depositing a bed glazing into a channel defined within a frame. The method can further include seating the insulating glazing unit into the channel and into contact with the bed glazing.

In an embodiment, the method can further include positioning a glass stop on an opposite side of the insulating glazing unit from the bed glazing. In an embodiment, the retention member can include a curable polymeric composition, wherein the curable polymeric composition is cured before applying the retention member. In an embodiment, the retention member can include a curable polymeric composition, wherein the curable polymeric composition is cured after applying the retention member.

In an embodiment of the method, applying a retention member is performed as part of an in-line window or door manufacturing process. In an embodiment of the method, applying a retention member is performed as part of an insulating glazing unit (IGU) manufacturing process. In an embodiment of the method, applying a retention member is performed as part of a laminate glass manufacturing process.

In an embodiment, the method can further include transporting the insulating glazing unit to another manufacturing facility after applying a retention member and before depositing a bed glazing.

Further aspects of fenestration units and related methods are described in U.S. Pat. No. 9,163,449, the content of which is herein incorporated by reference.

In an embodiment of the method, the retention member is preformed and then applied over the perimeter edges of the interior laminate pane of glass and the exterior pane of glass. In an embodiment of the method, the retention member is formed in situ over the perimeter edges of the interior laminate pane of glass and the exterior pane of glass.

In an embodiment of the method, at least one component of the retention member is precured prior to application over the perimeter edges of the interior laminate pane of glass and the exterior pane of glass. In an embodiment of the method, at least one component of the retention member is not precured prior to application over the perimeter edges of the interior laminate pane of glass and the exterior pane of glass. Curing can include various operations including, but not limited to, drying, heating, baking, irradiating, reacting, or the like.

In an embodiment of the method, applying a retention member to span perimeter edges of the interior laminate pane of glass and the exterior pane of glass includes embedding a retention member component within a portion of a secondary sealant. In an embodiment, the retention member component can include a mesh, however, many other materials suitable for inclusion in a retention member are also described herein.

Referring now toFIG.32, a schematic view is shown of a component of a sealing spacer during an assembly process in accordance with various embodiments herein. In this view a first spacer member3202, such as a piece of a metal (aluminum, stainless steel, various alloys, ferrous metals, etc.) or ceramic or plastic is obtained and placed. Then, other components are added thereto. Referring now toFIG.33, a schematic view is shown of components of a sealing spacer during an assembly process in accordance with various embodiments herein. In this view supports3304are placed onto the first spacer member3202and/or bonded thereto (chemically, mechanically, or thermally). In some embodiments, the supports3304can include a polymer, such as a polyamide (NYLON), but not limited to just polyamides. In some embodiments, the supports3304can be extruded. In some embodiments, the supports3304can be extruded onto the first spacer member.

Referring now toFIG.34, a schematic view of components of a sealing spacer during an assembly process in accordance with various embodiments herein. In this view, a second spacer member3412is applied. Optionally, a desiccant3406is also included as part of the assembly. In some embodiments, a “roll-trusion” process can be followed in order to assemble these components together into a sealing spacer. Further aspects of spacer assemblies and methods of assembling the same are described in U.S. Pat. No. 8,967,219, the content of which is herein incorporated by reference.

In various embodiments, a retention member or a portion thereof can be applied to the sealing spacer. Referring now toFIG.35, a schematic view of components of a sealing spacer3526during an assembly process in accordance with various embodiments herein. In this view, a retention member portion210and, optionally, a layer of adhesive material3510(which can be any of the adhesive described herein), is deposited onto the sealing spacer3526.

A sealing spacer3526so formed can then be positioned between panes of a glass subassembly113. Referring now toFIG.36is a cross-sectional view of a portion of a glass subassembly113with a retention member210in accordance with various embodiments herein. In this view, the sealing spacer3526is placed with a primary sealant3602(which can be polyisobutylene (PIB) or another polymer) along with a secondary sealant273. In this view, the retention member210can include two portions, with one portion between the panes of glass and the other outside on the edge. In some embodiments, these two portions can be attached/bonded/welded/adhered together using chemical, mechanical, or thermal techniques.

Referring now toFIG.37is a cross-sectional view of a portion of a glass subassembly113with a retention member210in accordance with various embodiments herein.FIG.37is generally similar toFIG.36. However,FIG.37shows the secondary sealant273outside of just the area directly between the panes of the glass subassembly113and covering the edge of the glass subassembly113, overlapping the edges of the interior and exterior panes.

In some cases, a spacer assembly can include a MYLAR vapor barrier. In such cases, a retention member210herein can, in some cases, be connected to the MYLAR vapor barrier either directly or indirectly using, for example, chemical, mechanical, or thermal techniques.

It will be appreciated that many different techniques and devices can be used to manufacture retention members. Referring now toFIG.38, a perspective view of a coating chamber3802in accordance with various embodiments herein. A flowable polymeric composition can be drawn from a supply tank3804using a pump3806(or another apparatus) and pass to an orifice3808of the coating chamber3802. While only one orifice3808is shown in this view, it will be appreciated that various embodiments herein can include an orifice on the top and an orifice on the bottom. Further, in various embodiments, orifices can be located on the sides of the coating chamber3802. In some embodiments, multiple orifices can be located on a particular side such as 2, 3, 4, or 5 orifices on the top.

In this embodiment, the coating chamber3802can include a top half3810and a bottom half3812, though it will be appreciated that many different coating chamber designs are included herein including one-piece designs. The top half3810and the bottom half3812can be held together using a clamp or a similar apparatus. A fibrous substrate3814can be fed into the coating chamber3802through a substrate ingress port3818. The fibrous substrate3814can exit the coating chamber3802through a substrate egress port (not shown in this view). Inside the coating chamber3802, the flowable polymeric composition can pass into gaps defined by adjacent fibers in the fibrous substrate3814. In some embodiments, the flowable polymeric composition can be under pressure as it enters the coating chamber3802and can be pushed into the fibrous substrate3814under pressure. The coating chamber3802can also be referred to as an application chamber. As the now-coated fibrous substrate exits the coating chamber3802it forms a retention member3816(or coated fibrous substrate).

In various embodiments, pump speed dispensing the flowable polymeric composition is matched with the speed of the fibrous substrate being passed through the coating chamber to get appropriate coverage.

It will be appreciated that various additional steps can be performed after the retention member leaves the coating chamber. By way of example, it can pass through a texturing roll block to increase the surface area thereof for better adhesion (for example, a surface of the coated fibrous substrate can have a surface area at least 20% greater than an otherwise identical flat surface), it can pass through a nip roller to further promote passage of the flowable polymeric composition into a fibrous matrix of the fibrous substrate, it can pass through a curing station, it can have a release liner adhered to one or more sides thereof, it can pass through a sizing blade or blades, and the like.

Referring now toFIG.39, a front elevational view of the coating chamber3802in accordance with various embodiments herein. This view shows the top half3810and the bottom half3812of the coating chamber3802.

Referring now toFIG.40, a cross-sectional view of the coating chamber3802is shown as taken along line40-40′ ofFIG.39in accordance with various embodiments herein. This view shows the fibrous substrate3814entering the coating chamber3802and then passing out as a retention member3816. The flowable polymeric composition can pass down through the orifice3808and contact the fibrous substrate3814from the top. The coating chamber3802can define an inner volume and a channel4002going around the sides and underneath of the fibrous substrate3814such that the flowable polymeric composition can also contact the fibrous substrate3814from the bottom.

Referring now toFIG.41, a side elevational view of a coating chamber3802in accordance with various embodiments herein. This view shows the top half3810and the bottom half3812of the coating chamber3802as well as the fibrous substrate3814entering the coating chamber3802and the retention member3816exiting the coating chamber3802.

Referring now toFIG.42, a cross-sectional view of the coating chamber is shown as taken along line42-42′ ofFIG.39in accordance with various embodiments herein. This view shows the top half3810and the bottom half3812of the coating chamber3802as well as the fibrous substrate3814. The flowable polymeric composition can enter the coating chamber3802through the orifice3808. The fibrous substrate3814passes through an inner volume4202where the flowable composition can contact the fibrous substrate3814.

It will be appreciated that the fibrous substrate3814can take on many different configurations herein. Referring now toFIG.43, a schematic view of a retention member3816in accordance with various embodiments herein. In this example, the fibrous substrate3814is within a mass of the flowable polymeric composition4306. In this example, the fibrous substrate3814can include fibers that are aligned4302with the direction of the movement of the fibrous substrate3814through the coating chamber as while as fibers that are transverse4304to the direction of movement of the fibrous substrate3814. However, it will be appreciated that fibers can be oriented in many different ways. In some embodiments, the fibers can be a non-oriented or randomly oriented fibrous mat.

In some embodiments, the amount of the flowable polymeric composition4306can be substantially uniform across the fibrous substrate3814. However, in other embodiments, the amount of the flowable polymeric composition4306can vary across the fibrous substrate3814. By way of example, in some embodiments, the amount within a middle area4308of the fibrous substrate3814can be different. In some embodiments, the amount in the middle area4308can be more or less than the amount at the edges of the fibrous substrate3814. In some embodiments, there may be substantially no flowable polymeric composition4306in the middle and the composition may only be on the edges. Many different configurations are contemplated herein.

In various embodiments, the retention member can be manufactured and then stored and/or shipped before being applied to a glass subassembly and/or a fenestration unit.

Referring now toFIG.44, a schematic view is shown of a retention member3816being applied to a glass subassembly113in accordance with various embodiments herein. In this example, the retention member3816has been previously manufactured and is drawn off of a roll4406of retention member3816material. A release liner can be disposed on a surface of the retention member3816and then taken off during the assembly process. The retention member3816is applied to the edges of the glass subassembly113using an applicator device4410.

However, in other embodiments, the retention member3816can be manufactured in-line with a fenestration unit assembly process and/or glass subassembly manufacturing process and be applied either before or after the flowable polymeric composition is cured.

Referring now toFIG.45, a schematic view of a retention member3816being applied to a glass subassembly113in accordance with various embodiments herein. In this example, the retention member3816is manufactured in-line and then applied to the edges of the glass subassembly113using an applicator device4410. As referenced before, the flowable polymeric composition can be cured either before or after the retention member3816is applied to the edges of the glass subassembly113. Further, in some examples, the flowable polymeric composition can be cured, and then just before the retention member is applied to the glass subassembly113an additional amount of an uncured flowable polymeric composition is applied which can serve as an adhesive.

It will be appreciated that patterns of deposition of the flowable polymeric composition upon the fibrous substrate can be achieved through the shape of the egress port of the coating chamber. For example, in some embodiments, the contours of the egress port can be such that they are very in size to the fibrous substrate itself and thus act almost like a doctor blade in removing excess amounts of the flowable polymeric composition from around the profile of the fibrous substrate itself. However, in some embodiments, one or more channels or other open portions can be disposed within the inner surface of the egress port resulting in the formation of beads or other placements of the flowable polymeric composition on the fibrous substrate (and therefore on the retention member). In some cases, such beads or placements of the flowable polymeric composition can be used for purposes such as to provide an additional amount of the flowable polymeric composition to act as an adhesive to secure the retention member to a portion of the fenestration unit such as the glass subassembly or another portion.

Thus, it will be appreciated that egress ports herein can have various shapes and, in some embodiments, can include one or more channels or openings having various profiles. Referring now toFIG.46, a rear elevational view of a coating chamber3802showing an egress port4602in accordance with various embodiments herein. This view shows the top half3810and the bottom half3812of the coating chamber3802as well as the retention member3816coming out of the egress port4602. The top half3810forms an upper surface4604of the egress port4602and the bottom half3812forms a lower surface4608of the egress port4602. A passage4606or aperture between the upper surface4604and the lower surface4608allows the retention member3816to pass out of the coating chamber3802with a desired amount of the flowable polymeric composition disposed therein. If the passage4606or aperture closely conforms to the size of the fibrous substrate, then little extra flowable polymeric composition remains to the outside of the fibrous substrate profile. However, the passage4606or aperture can include one or more channels or other open portions to allow for beads or selective placements of the flowable polymeric composition.

Referring now toFIG.47, a rear elevational view of a coating chamber3802is shown including an egress port4602in accordance with various embodiments herein. In this example, the upper surface4604includes two channels4702that result in beads of the flowable polymeric composition in the same shape being deposited on the retention member3816. In this case, the channels4702are substantially rectangular. However, it will be appreciated that they could have many different shapes and sizes. In some embodiments, the channels4702can have a width of about 0.1 to 60 mm, such as 0.1, 1, 2, 3, 4, 5, 7.5, 10, 15, 20, 30, 40, 50, or 60 mm or an amount falling within a range between any of the foregoing. In some embodiments, the channels4702can have a height of about 0.1 to 25 mm, such as 0.1, 1, 2, 3, 4, 5, 7.5, 10, 15, 20, or 25 mm, or an amount falling within a range between any of the foregoing. The total number of channels can vary. In some embodiments, there can be 1, 2, 3, 4, 5, 6, 8, 10, 15 or 20 or more channels, or a number of channels falling within a range between any of the foregoing.

FIG.48is a rear elevational view of a coating chamber3802showing an egress port4602in accordance with various embodiments herein.FIG.48is generally similar toFIG.47. However, in this example, there is a single channel4702that is centrally located and curvilinear in shape.FIG.49is a rear elevational view of a coating chamber3802showing an egress port4602in accordance with various embodiments herein.FIG.49is generally similar toFIG.47. However, in this example, there is a single channel4702that is centrally located and substantially rectangular in shape.FIG.50is a rear elevational view of a coating chamber3802showing an egress port4602in accordance with various embodiments herein.FIG.50is generally similar toFIG.47. However, in this example, there is a single channel4702that is centrally located and substantially hemispherical (forming a half-circle) in shape.FIG.51is a rear elevational view of a coating chamber3802showing an egress port4602in accordance with various embodiments herein.FIG.51is generally similar toFIG.47. However, in this example, there are two channels4702located near opposite ends of the retention member3816.FIG.52is a rear elevational view of a coating chamber3802showing an egress port4602in accordance with various embodiments herein.FIG.52is generally similar toFIG.47. However, in this example, there are three channels4702, with one being centrally located and curvilinear and the other two being located near opposite ends of the retention member3816and having a different shape than the central channel4702.FIG.53is a rear elevational view of a coating chamber3802showing an egress port4602in accordance with various embodiments herein.FIG.53is generally similar toFIG.47. However, in this example, there is a single channel4702that is centrally located and having a different shape than the channels shown inFIG.47. Many different channels shapes and sizes are contemplated herein. While the channels ofFIGS.47-53are disposed on the upper surface4604of the egress port4602it will be appreciated that channels herein can also be formed on the lower surface4608of the egress port4602.

Many different methods are contemplated herein, including, but not limited to, methods of making, methods of using, and the like. Aspects of operations described elsewhere herein can be performed as operations of one or more methods in accordance with various embodiments herein.

In an embodiment, a method of making a retention member is included, the method can include supplying a flowable polymeric composition into a coating chamber, feeding a fibrous substrate through the coating chamber (the coating chamber defining a substrate ingress port and a substrate egress port) and passing the flowable polymeric composition into gaps defined by adjacent fibers in the fibrous substrate.

In an embodiment of the method, the pressure inside the coating chamber is not atmospheric. In an embodiment of the method, the pressure inside the coating chamber is from 50 PSI to 2500 PSI.

In an embodiment, the fibrous substrate can include a substantially planar material with a plurality of fibers extending in a direction transverse to a direction of movement of the fibrous substrate through the coating chamber. In an embodiment, the fibers can include at least one of wood fibers, glass fibers, hybrid fibers, metal fibers, polyamide fibers (NYLON), para-aramid fibers (KEVLAR), and carbon fibers. In an embodiment of the method, the fibers are woven together. In an embodiment of the method, the fibers are nonwoven. In an embodiment, the fibrous substrate further can include a plurality of fibers extending in a direction parallel to a direction of movement of the fibrous substrate through the coating chamber.

In an embodiment, the coating chamber can include a top housing and a bottom housing. In an embodiment of the method, the flowable polymeric composition enters the coating chamber through one of the top housing and the bottom housing and then contacts the other housing. In an embodiment of the method, the flowable polymeric composition is pushed through the fibrous substrate from a first side (such as a top side) to a second side (such as a bottom side). In an embodiment of the method, the flowable polymeric composition flows around the fibrous substrate.

In an embodiment of the method, an amount of the flowable polymeric composition deposited on a top side of the fibrous substrate is different than the amount deposited on a bottom side of the fibrous substrate. In an embodiment of the method, an amount of the flowable polymeric composition deposited on a top side of the fibrous substrate includes one or more beads of the flowable polymeric composition.

In an embodiment, the flowable composition can include an elastomeric polymer composition. In an embodiment, the flowable composition can include an uncured polysiloxane composition, an uncured polyurethane composition, an uncured modified polysiloxane, and an uncured acrylic polymer.

In an embodiment, the method can further include curing the flowable composition after the fibrous substrate exits the coating chamber using one or more of heat, ambient moisture, ultraviolet light, and a catalyst.

In an embodiment of the method, the fibrous substrate exits the egress port with a coating of the flowable polymeric composition on both a top side and a bottom side of the fibrous substrate. In an embodiment of the method, the fibrous substrate exits the egress port with a coating of the flowable polymeric composition that is discontinuous across at least one of a top side and a bottom side of the fibrous substrate. In an embodiment of the method, the fibrous substrate exits the egress port with the flowable polymeric composition impregnated therein.

In an embodiment, the method can further include applying the coated fibrous substrate to an edge portion of an insulating glazing unit (IGU). In an embodiment, the method can further include applying the coated fibrous substrate to an edge portion of the insulating glazing unit (IGU) with the flowable polymeric composition in an uncured state. In an embodiment, the method can further include applying the coated fibrous substrate to an edge portion of the insulating glazing unit (IGU) with the flowable polymeric composition in a cured state. In an embodiment, the method can further include applying the coated fibrous substrate to an edge portion of the insulating glazing unit (IGU) with a portion of the flowable polymeric composition in a cured state and a portion in an uncured state. In an embodiment, can include applying a portion of the flowable polymeric composition is applied, curing the applied portion, then applying a second portion of the flowable polymeric composition.

In an embodiment, the method can further include applying the coated fibrous substrate to an insulating glazing unit (IGU) to interconnect an exterior pane and an interior pane. In an embodiment, the method can further include applying the coated fibrous substrate to an insulating glazing unit (IGU) to interconnect at least one of an interior pane and an exterior pane to a frame member and/or a sash. In an embodiment of the method, the coated fibrous substrate is connected directly or indirectly to a secondary sealant of an insulating glazing unit (IGU). In an embodiment, the interior pane can include a laminate glass pane.

In an embodiment, the substrate egress port can include an upper surface and a lower surface, wherein the upper surface includes one or more channels. In an embodiment of the method, the channels are substantially polygonal in cross-section. In an embodiment of the method, the channels are substantially curvilinear in cross-section.

In an embodiment of the method, a surface of the coated fibrous substrate is textured. In an embodiment of the method, a surface of the coated fibrous substrate has a surface area at least 20% greater than an otherwise identical flat surface.

In an embodiment, a method of making a fenestration unit is included, the method including obtaining a retention member, applying the retention member to an insulating glazing unit (IGU), wherein the retention member is formed by supplying a flowable polymeric composition into a coating chamber, feeding a fibrous substrate through the coating chamber, the coating chamber defining a substrate ingress port and a substrate egress port, and passing the flowable polymeric composition into gaps defined by adjacent fibers in the fibrous substrate.

In an embodiment, the method can further include applying the coated fibrous substrate to an edge portion of the insulating glazing unit (IGU). In an embodiment, the method can further include applying the coated fibrous substrate to an edge portion of the insulating glazing unit (IGU) with the flowable polymeric composition in an uncured state. In an embodiment, the method can further include applying the coated fibrous substrate to an edge portion of the insulating glazing unit (IGU) with the flowable polymeric composition in a cured state. In an embodiment, the method can further include applying the coated fibrous substrate to an edge portion of the insulating glazing unit (IGU) with a portion of the flowable polymeric composition in a cured state and a portion in an uncured state. In an embodiment, can include applying a portion of the flowable polymeric composition is applied, curing the applied portion, then applying a second portion of the flowable polymeric composition.

In an embodiment, the method can further include interconnecting an exterior pane and an interior pane with the retention member. In an embodiment, the method can further include interconnecting at least one of an interior pane and an exterior pane to a frame member and/or a sash with the retention member.

Referring now toFIG.54, a cross-sectional view is shown illustrating various stages of attachment of a retention member to an insulating glazing unit in accordance with various embodiments herein. It will be appreciated that the stages depicted inFIG.54are selected for ease of illustration and do not necessarily correspond to specific, discrete operations and do not necessarily illustrate all operations that may be performed. Similarly, it will be appreciated that some operations that are shown and described can be omitted in some cases. At stage “A”, the insulating glazing unit5400(or glass subassembly) is obtained or is assembled using operations not depicted in this view. The insulating glazing unit5400includes an interior side5450and an exterior side5452. The insulating glazing unit5400can include a first pane5402(which can be a laminated pane or a non-laminated pane), a second pane5404(which can be a laminated pane or a non-laminated pane), a spacer unit5406disposed between the first pane5402and the second pane5404.

The insulating glazing unit can also include a secondary sealant5408between the first pane5402and the second pane5404. However, it will be appreciated that some insulating glazing unit constructions do not include a secondary sealant. The insulating glazing unit5400can include a channel5420that is bounded by the first pane5402, the second pane5404, the secondary sealant5408(if present—otherwise by the spacer unit5406), and the perimeter edge of the first pane5402and the second pane5404.

At stage “B”, an adhesive composition5410is applied to a perimeter of the insulating glazing unit5400or a component thereof. In some embodiments, an adhesive composition5410is specifically applied to at least one of a perimeter edge5440of the first pane5402and a perimeter edge5440the second pane5404. In some cases, the adhesive composition5410can specifically be applied within the channel5420, but in sufficient volume to immediately or later cover at least one of the perimeter edges of the first pane5402and the perimeter edges of the second pane5404. In some embodiments, the volume of adhesive composition5410applied is greater than the volume of the channel5420. In some embodiments, the volume of adhesive composition5410applied is less than the volume of the channel5420. In some embodiments, a vision system can be used in order to track the size of the channel5420(to account for variance in the insulating glazing unit) and feedback from the vision system can be used to adjust the amount of adhesive composition5410that is deposited. In other embodiments, a volumetric pump or other system can be used to volumetrically control the amount of sealant that is applied. This can be adjusted to be representative of the particular dimensions of the glazing channel based on manufacturing data (e.g., the size of the insulating glazing unit—overall width/height; the spacing unit dimensions, determined channel width and recessed information) provided to a PLC control unit.

In some embodiments, the adhesive composition5410can be expelled from a nozzle and the nozzle can be positioned so as to promote the adhesive composition5410fully filling the channel5420without air pockets. For example, the nozzle can be positioned within the channel5420down near the spacer unit5406, such that the adhesive composition5410is applied adjacent to the spacer unit first. The nozzle can be of various shapes. In some embodiments, the nozzle can be configured to lay a shaped bead of adhesive composition5410that limits excess deposition and reduces the need for troweling or similar shaping/removing operations. In some embodiments, the adhesive composition5410can be applied using a hand-assist or auto-glazer with a rotating head. In some embodiments, the hand-assist or auto-glazer or a component thereof may travel, but may or may not rotate. In some embodiments, the adhesive composition5410can be applied using a fixed-head applicator.

The adhesive composition can be any of the materials as described elsewhere herein for an adhesive or a secondary sealant. In some embodiments, the secondary sealant5408and the adhesive composition5410are the same composition. In some embodiments, the secondary sealant5408and the adhesive composition5410are the same composition and are applied at the same time and/or as part of the same processing operation. In some embodiments, the adhesive composition5410can used as the secondary sealant5408. In some embodiments, the secondary sealant5408can be used as the adhesive composition5410. In some embodiments, the secondary sealant5408and the adhesive composition5410are different compositions. In some specific embodiments, the adhesive composition5410specifically includes a two-part silicone composition.

In some embodiments, the insulating glazing unit5400is positioned vertically or within 15 degrees of vertical before the operation of applying the adhesive composition. However, in other embodiments, the insulating glazing unit5400is positioned horizontally or within 15 degrees of horizontal before the operation of applying the adhesive composition. In some embodiments, the insulating glazing unit is positioned horizontally on a conveyor belt.

It will be appreciated that in some embodiments, the secondary sealant5408and the adhesive composition5410can be applied simultaneously. However, in other embodiments, the secondary sealant5408is applied first and then the adhesive composition5410is applied separately. In some embodiments, the secondary sealant5408is applied and allowed to cure before the adhesive composition5410is added. In some embodiments, the secondary sealant5408and the adhesive composition5410directly contact one another. In other embodiments, there may be a gap or other material disposed between the secondary sealant5408and the adhesive composition5410.

After applying the adhesive composition5410onto the perimeter edge of the first pane5402and the second pane5404, various other operations can take place before mounting of the retention member. For example, in some embodiments, a troweling operation can be performed (manually or in an automated fashion) that can remove excess adhesive composition5410and/or shape the adhesive composition5410. In some embodiments, excess adhesive composition can be removed from the first pane and the second pane.

At stage “C”, a retention member5412is mounted onto perimeter edges of the first pane5402and the second pane5404by applying it onto the adhesive composition5410. In some embodiments, the retention member5412is premade and taken off a roll (not shown in this view). In some embodiments, the retention member5412is specifically taken off a roll under tension. However, in some embodiments, the retention member5412can be made just before being applied using various techniques including those described previously herein.

Various other operations can be performed on the retention member5412. In some embodiments, the retention member5412can be cut at various points to specific lengths. In some embodiments, the retention member5412has a length greater than at least one side of the first pane5402and the second pane5404. In some embodiments, the retention member5412has a length greater than at least one side of the first pane5402and the second pane5404. In some embodiments, the retention member5412has a length greater than or equal to the sum of the perimeter sides of the first pane5402or the second pane5404. In some embodiments, the retention member5412is cut into pieces such that at least some pieces have lengths of less than or equal to the length of at least one side of the first pane5402and the second pane5404. In some embodiments, cutting the retention member5412to a specific length can occur prior to the retention member contacting the adhesive composition and/or prior to the retention member5412contacting a perimeter edge of the first pane5402and the second pane5404. In some embodiments, cutting the retention member5412to length can occur after the retention member contacts the adhesive composition and/or after the retention member5412contacts a perimeter edge of the first pane5402and the second pane5404. In some embodiments, the retention member5412can have notches or slits cut into it at various points such as at or near corners to facilitate a better fit (conformance) with the shape of corners. In some embodiments, the retention member5412can be trimmed to a specific width. However, in other embodiments, the retention member5412is not trimmed to a specific width.

In some embodiments, pressure can be applied to an outside surface of the retention member5412during or after the operation of mounting the retention member5412to the perimeter of the insulating glazing unit to urge the retention member5412into full contact with the adhesive composition5410and/or to cause the adhesive composition5410to wet out on the retention member5412. In some embodiments, pressure can be applied sufficient to wet out the adhesive composition, but also maintain a desired adhesive composition thickness. In some embodiments, the retention member5412is pushed into the adhesive composition5410sufficiently far to contact a standoff structure disposed along the perimeter edge of at least one of the first pane and the second pane. In some embodiments, the adhesive composition can include particulate matter (such as polymeric or glass beads, spheres or other shapes) that can assist in setting/maintaining a desired adhesive composition thickness.

In some embodiments, the retention member5412is pushed into the adhesive composition5410sufficiently far so that a shortest distance between a fibrous support structure inside the retention member5412and an outer peripheral edge of the first and second pane (e.g., a distance between an adjacent side of a fibrous support structure of the retention member and an outer peripheral edge of the first and second pane) is a specific distance. For example, the specific distance can be about 0.01, 0.02, 0.04, 0.04, 0.05, 0.07, 0.1, 0.12, 0.14, 0.16, 0.18, 0.2, 0.3, 0.5 inches or more, or an amount falling within a range between any of the foregoing. In some embodiments, the specific distance can be approximately 0.04 to 0.16 inches.

It will be appreciated that pressure can be applied to the outside surface of the retention member5412in various ways. In some embodiments, a roller can be pushed against and rolled along the outside surface of the retention member5412. In some embodiments, a plate can be pushed against the outside surface of the retention member5412. In some embodiments, the outside surface of the retention member5412can be pushed against a plate or other structure. In some embodiments, a blade or other implement can be pushed against and across the outside surface of the retention member5412. In some embodiments, a device used to apply pressure can include a standoff or spacer to prevent the applied pressure from undesirably making the layer of adhesive composition too thin.

At stage “D”, excess adhesive composition5410is removed. It will be appreciated that this can be performed in various ways. In some embodiments, a sharp instrument (such as a knife), a dull instrument, a trowel, or another device that can be passed along to remove excess adhesive composition5410. Excess adhesive composition5410can be removed before or after it has cured. In some embodiments, a protective tape can be disposed around a perimeter face of at least one of the first pane and the second pane. This protective tape can be used to facilitate removal of excess adhesive composition5410.

In some cases, excess adhesive composition5410can be removed after letting the adhesive composition5410cure for about 0.25, 0.5, 1.5, 3, 8, 12, 24 hours or more. In some embodiments, an accumulator system or indexing carousel (that indexes units in/out as they are processed and cured) could be used to allow for the adhesive composition5410to cure. In some embodiments, racks with drawers that pull out to set the insulating glazing unit in (so as to not disturb uncured edges) could be used. Transfers in/out of the drawers can be facilitated with hoists in some embodiments. In some embodiments, a “baker's rack” device can be used to hold insulating glazing units. In some embodiments, insulating glazing units can be effectively suspended using suction cups on surfaces of the panes to keep edges undisturbed during cure time. In some embodiments, a rack can be used that allows vertical stacking of the insulating glass units on an edge with a release material that the adhesive composition does not bond to and/or the reinforcement member sufficiently creates a barrier to prevent handling issues when stacked in this fashion.

In some embodiments, excess adhesive composition5410can be removed at more than one stage of the process. For example, after adhesive composition5410is initially applied at stage “B” then the adhesive composition5410can be shaped and/or partially removed and then again later shaped and/or partially removed at stage “D”. However, in some embodiments, it will be appreciated that removal or trimming steps can be omitted if excess material from previous steps is minimized or eliminated.

Referring now toFIG.55, a cross-sectional view is shown illustrating various stages of attachment of a retention member to an insulating glazing unit in accordance with various embodiments herein. It will be appreciated that the stages inFIG.55are selected for ease of illustration of specific aspects and do not necessarily correspond to specific, discrete operations and do not illustrate all operations. Stages “A” and “B” shown inFIG.55are generally similar to those shown inFIG.54.

However, inFIG.55, stage “C” includes an operation of removing excess adhesive composition5410and/or shaping or troweling before the retention member5412is mounted. In some embodiments, the adhesive composition5410is shaped as depicted for stage “C” ofFIG.55. The excess adhesive composition5410can be removed and/or shaped using any of the tools or techniques described elsewhere herein. At stage “D”, the retention member is then mounted. In some embodiments, the retention member5412is mounted while the adhesive composition is still capable of bonding (e.g., before it has cured). In other embodiments, the adhesive composition is allowed to cure, but a skim coat of another adhesive composition (which could be the same as the other adhesive composition or different) is applied directly to a surface of the retention member5412before it is mounted (and/or a skim coat is applied directly to the insulating glazing unit).

Referring now toFIG.56, a cross-sectional view is shown illustrating various stages of attachment of a retention member to an insulating glazing unit in accordance with various embodiments herein. It will be appreciated that the stages inFIG.56are selected for ease of illustration of specific aspects and do not necessarily correspond to specific, discrete operations and do not illustrate all operations.

At stage “A” ofFIG.56, an adhesive composition5410is applied to a surface of the retention member5412. In some embodiments, the amount of adhesive composition5410could be relatively small, such as with a skim coat. In other embodiments, a significant amount (sufficient to at least partially fill the channel) can be applied. At stage “B”, the adhesive coated retention member5412is then mounted onto the insulating glazing unit5400. In some embodiments, pressure can be applied to an outside surface of the retention member5412after the operation of mounting the retention member5412to the perimeter edges of the first and second panes. At stage “C”, excess adhesive composition5410can be removed. It will be appreciated that this can be performed in various ways as described before. Excess adhesive composition5410can be removed before or after it has cured.FIG.56shows a gap5602between the adhesive composition5410and the secondary sealant5408. However, it will be appreciated that in some embodiments a sufficient amount of adhesive composition5410can be used to partially or completely eliminate gap5602.

It will be appreciated that various operations herein related to attaching retention members to insulating glazing units can be performed at the same time as insulating glazing unit assembly (“in-line”) or after the insulating glazing unit has already been assembled as part of a separate process (“off-line”). Referring now toFIG.57, a schematic view is shown illustrating assembly of an insulating glazing unit and, as a separate process, attachment of a retention member to the insulating glazing unit in accordance with various embodiments herein. Various operations can be performed as part of a process of assembling an insulating glazing unit.FIG.57shows a process wherein a spacer unit5406is placed between glass panes (only one pane5404is shown in this view). A spacer placement device5710and be used to place the spacer unit5406(as withdrawn from a roll5712) onto the first or second panes5402,5404and then the other pane (not shown in this view) can be placed onto the spacer unit5406forming an insulating glazing unit. In some embodiments, a secondary sealant can be applied around a perimeter of the insulating glazing unit after the spacer unit5406is placed between the two panes.

Then, in a separate operation, the retention member5412can be mounted onto the insulating glazing unit5400. For example, the retention member5412can be withdrawn off of a roll5714and the adhesive composition can be pumped to a mounting device5752through a supply conduit5716. The mounting device5752can proceed to perform one or more of various operations described herein such as applying the adhesive composition, shaping the adhesive composition, mounting the retention member, applying pressure to the retention member, removing excess adhesive composition, cutting the retention member, and the like.

In some embodiments, the mounting device5752(or another component herein) can include a device to facilitate cutting of the retention member such as a shears, knife, rotary cutter, punch, or a similar device. In some embodiments, a linear encoder or a rotary encoder can be included as part of the system in order to keep track of the length of the retention member in order to know when to execute a cutting operation. In some embodiments, the mounting device5752(or another component herein) can include sensors to detect the position of the insulating glazing unit and/or the retention member such as proximity sensors, optical sensors, load sensors, electrical field sensors, and the like. In some embodiments, sensors can be used to locate the perimeter edges of at least one of the first pane and the second pane and align the position of the retention member. In some embodiments, sensors can be used to locate a corner of at least one of the first pane and the second pane and align the position of the retention member to be within 0.25 inches of the corner (or another specific distance as described with respect toFIG.63herein).

In some embodiments, the insulating glazing unit5400can remain substantially stationary during this process and the mounting device5752can be moved. In some embodiments, the insulating glazing unit5400can move and the mounting device5752can be substantially stationary. In some embodiments, both the insulating glazing unit5400and the mounting device5752can both move. In some embodiments, the mounting device5752can proceed around the insulating glazing unit5400side by side. In some embodiments, the insulating glazing unit5400can be rotated before or after the retention member is applied to each side of the insulating glazing unit5400. In some embodiments, multiple mounting devices5752can be used so that multiple sides of the insulating glazing unit5400can be processed simultaneously.

In some embodiments, the operation of mounting the retention member onto perimeter edges of the first pane and the second pane occurs while the secondary sealant can still bond to other components (e.g., the secondary sealant is still tacky, still within open time, not fully cured, etc.). For example, in some embodiments, the operation of mounting the retention member onto the perimeter of the insulating glazing unit occurs less than 10 minutes after the operation of applying a secondary sealant around a perimeter of the insulating glazing unit. It will be appreciated, however, that in some cases, such as with a hot-melt adhesive, the secondary sealant can be reheated in order to render it tacky or otherwise capable of bonding.

In some embodiments, the operation of mounting the retention member onto the perimeter of the insulating glazing unit occurs after the secondary sealant is no longer tacky, or otherwise can no longer bond with other components. Thus, for example, in some embodiments the operation of applying the retention member to the perimeter edge occurs greater than 60 minutes after the operation of applying a secondary sealant around a perimeter of the insulating glazing unit. In still other embodiments, there is no separate application of a secondary sealant followed (directly or indirectly) by the application of an adhesive composition. Rather, in such embodiments, the secondary sealant can serve as the adhesive composition, or conversely, the adhesive composition can serve as the secondary sealant.

As referenced above, in some embodiments operations herein related to attaching retention members to insulating glazing units can be performed at the same time as insulating glazing unit assembly (“in-line”), after insulating glazing unit assembly (“off-line”), and/or during later window assembly operations (“in-assembly”), amongst other times. Referring now toFIG.58, a schematic view is shown illustrating assembly of attachment of a retention member to an insulating glazing unit in accordance with various embodiments herein. In this view, an adhesive delivery unit5850is applying an adhesive composition from a supply conduit5716. In some embodiments, the adhesive delivery unit5850is simultaneously depositing what serves as a secondary sealant and an adhesive composition. Then, a mounting device5752performs one or more of various operations described herein such as mounting the retention member, applying pressure to the retention member, removing excess adhesive composition, cutting the retention member, and the like

It will be appreciated that in some embodiments a single device performs multiple functions. However, in some embodiments, different functions are performed by different devices. In some embodiments, a device can be used to ensure that a desirable amount of adhesive composition is applied and, in some cases, shape or remove excess adhesive composition. Referring now toFIG.59, a schematic view is shown illustrating attachment of a retention member to an insulating glazing unit in accordance with various embodiments herein.FIG.59is generally similar toFIG.58. However,FIG.59also shows a regulating device5900that can regulate the thickness of the adhesive composition on the insulating glazing unit.

Referring now toFIG.60, a cross-sectional view is shown of a regulating device6002for applying adhesive as taken along line60-60′ ofFIG.59in accordance with various embodiments herein. The regulating device6002can include a first body portion6004and a second body portion6006that are held together with a first fastener6008and a second fastener6010. Fasteners6008and6010can be anchored to the first body portion6004, but allow the second body portion6006to move along a shaft of the fasteners such that the distance between the first body portion6004and the second body portion6006can be changed to allow for an open position (such as to facilitate insertion of an insulating glazing unit) and a closed position (such as for use when regulating the amount/thickness of the adhesive composition).

FIG.60shows the regulating device6002in an open position. In some embodiments springs6012can be included such that the regulating device6002is biased into the open position. However, in some embodiments, the regulating device6002can also be biased into the closed position. A track6020into which the insulating glazing unit can fit can be defined by the first body portion6004, the second body portion6006, and a compressible member6022disposed between the two. In some embodiments, a first slide6024and a second slide6026can be included to provide for direct contact with surfaces of the panes of insulating glazing units. In some embodiments, one or both of the first body portion6004and the second body portion6006can include a stop6028or lip in order to limit how far an insulating glazing unit can be inserted into the track6020and to define a thickness of adhesive composition to be applied.

Referring now toFIG.61, a cross-sectional view is shown of a regulating device6002for applying adhesive as taken along line60-60′ ofFIG.59in accordance with various embodiments herein.FIG.61shows the regulating device6002in a closed position, with the compressible member6022being compressed and an insulating glazing unit5400inserted into the track6020so that the perimeter edges of the panes of the insulating glazing unit5400are contacting the stop6028and the faces of the panes are contacting the slides6024,6026.FIG.61shows an adhesive composition5410at a specific thickness6104as controlled by the configuration of the track6020at a point beyond the stop6028.

Referring now toFIG.62, a schematic cross-sectional view is shown of an insulating glazing unit with a retention member attached thereto in accordance with various embodiments herein. The insulating glazing unit can include a first pane5402, a second pane5404, a spacer unit5406disposed between the first pane5402and the second pane5404, and a secondary sealant5408between the first pane5402and the second pane5404. A retention member5412can be mounted onto perimeter edges of at least one of the first pane5402and the second pane5404. In specific, an adhesive composition5410can be used to mount the retention member5412.

FIG.63shows a schematic cross-sectional view of a portion6202of the insulating glazing unit with retention member shown inFIG.62.FIG.63shows many of the components inFIG.62. However, as described elsewhere herein, the retention member5412can include various components.FIG.63shows an example of a retention member5412that includes a layer of a fibrous support structure6304along with layers6302,6306of a polymeric composition, which could be any of the materials described herein with respect to an adhesive composition or a secondary sealant.

As described above, the position of the retention member5412can be controlled so that a shortest distance6320between the fibrous support structure6304of the retention member5412and an outer peripheral edge6322of the first and second panes5402,5404(e.g., a distance between an adjacent side6324of the fibrous support structure6304of the retention member5412and an outer peripheral edge6322of the first and second panes5402,5404) is a specific distance. For example, the distance6320can be about 0.01, 0.02, 0.04, 0.04, 0.05, 0.07, 0.1, 0.12, 0.14, 0.16, 0.18, 0.2, 0.3, 0.5 inches or more, or an amount falling within a range between any of the foregoing. In some embodiments, the distance6320can be approximately 0.04 to 0.16 inches.

Various techniques can be used to achieve a precise and consistent distance6320. By way of illustration,FIG.64shows a schematic cross-sectional view of a portion of an insulating glazing unit with a retention member attached thereto in accordance with various embodiments herein. In this embodiment, the retention member5412is pushed into the adhesive composition5410sufficiently far for the retention member5412to contact a standoff structure6402. The standoff structure6402can be a variety of different shapes. In some embodiments, the standoff structure6402can be substantially continuous along the perimeter of the insulating glazing unit and in other embodiments the standoff structure6402can be only in discrete places. In some embodiments, the standoff structure can be formed as a part of another component and in other embodiments the standoff structure can be formed separately and later attached. In some embodiments, the standoff structure6402can be mounted on or otherwise attached to an edge of at least one of the first and second panes. In some embodiments, the standoff structure6402can be mounted on or otherwise attached to the retention member5412. In some embodiments, the standoff structure6402can be mounted on or otherwise attached to another structure. As another example,FIG.65(which is generally similar toFIG.64) shows that the adhesive composition can include particulate matter6502(such as polymeric or glass beads, spheres, cubes, or other shapes) that can assist in setting/maintaining a desired adhesive composition thickness.

It will be appreciated that many different configurations of retention members are contemplated herein, a number of which are described above. In some embodiments, the retention member may simply include a fibrous support structure and not include any separate layer of a polymeric composition. For example, referring now toFIG.66, a schematic cross-sectional view is shown of a portion of an insulating glazing unit with a retention member5412attached thereto in accordance with various embodiments herein. In this example, the retention member5412includes a fibrous support structure6304, but omits separate polymeric layers.

In various embodiments, the retention member5412can be bonded to perimeter edges of the first pane5402and the second pane5404using an adhesive composition. However, in some embodiments, the retention member5412may only bond to the perimeter edges of one pane. Referring now toFIG.67is a schematic cross-sectional view is shown of a portion of an insulating glazing unit with a retention member5412attached thereto in accordance with various embodiments herein. In this example, the retention member5412is bonded to the perimeter edge6504of the first pane5402, but not to the perimeter edge6702of the second pane5404leaving a gap6704. While in some cases gap6704can remain after complete window assembly, in other cases gap6704may be filled with a bed glazing or other materials during later window assembly operations such as when the insulating glazing unit is bed glazed into a window assembly.

In some cases, the secondary sealant and the adhesive composition can be the same component (e.g., the secondary sealant can serve as the adhesive composition or the adhesive composition can serve as the secondary sealant). Referring now toFIG.68is a schematic cross-sectional view is shown of a portion of an insulating glazing unit with a retention member5412attached thereto in accordance with various embodiments herein. In this embodiment, the adhesive composition5410serves as (and physically takes the place of) the secondary sealant that may otherwise be present.

While in many embodiments at least one of the panes is a laminate glass as described elsewhere herein. However, in some embodiments, both panes can be non-laminates. Referring now toFIG.69is a schematic cross-sectional view is shown of a portion of an insulating glazing unit with a retention member attached thereto in accordance with various embodiments herein. In this view, both the first pane5402and the second pane5404are non-laminates, while in other embodiments one or both of the first pane5402and the second pane can be laminates.

As described elsewhere herein, in some embodiments the retention member can be cut into distinct pieces and in other embodiments can exist as a unitary piece disposed around the outer perimeter of the insulating glazing unit. While not intending to be bound by theory, it is believed that there can be some advantages associated with cutting the retention member into distinct pieces or at least cutting notches or slits at or near corners. For example, cutting the retention member can allow better conformance and/or prevent bulges or additional volume at the corners of the insulating glazing unit that may hinder later operations including insertion of the insulating glazing unit into a frame structure during later window assembly.

Referring now toFIG.70, a schematic view is shown of an insulating glazing unit5400and a pane5404thereof with a retention member5412mounted around the perimeter thereof in accordance with various embodiments herein. In this example, the retention member5412is unitary at the corner7004of the insulating glazing unit5400. Depending on various factors such as the maximum radius of curvature that can be achieved by the retention member5412, this can result in the formation of a bulge7002. Referring now toFIG.71, a schematic view is shown of an insulating glazing unit with a retention member attached thereto in accordance with various embodiments herein.FIG.71stands in contrast toFIG.70because inFIG.70the retention member5412has been cut such that it has cut edges7102at the corner7004preventing the formation of a bulge. In some embodiments, the cut edges are less than 1, 0.75, 0.5, 0.35, 0.25, 0.2, 0.15, 0.1, 0.05, or 0.025 inches away from the corner7004, or a distance falling within a range between any of the foregoing. In some embodiments, the retention member5412remains continuous about the perimeter of the insulating glass unit, but has excess material removed at the corners in the form of notches or purposeful slits to allow conformance of the retention member about the perimeter of the insulating glass unit.

It will be appreciated that many different configurations are contemplated herein beyond those illustrated above. As yet another example, in some cases where the amount of adhesive composition used does not completely fill the channel, a gap can be left underneath the retention member. Referring now toFIG.72, a cross-sectional view is shown illustrating a retention member5412mounted on an insulating glazing unit5400in accordance with various embodiments herein. The insulating glazing unit5400can include a first pane5402, a second pane5404, and a spacer unit5406disposed between the first pane5402and the second pane5404. The insulating glazing unit5400can also include a secondary sealant5408between the first pane5402and the second pane5404. The insulating glazing unit5400can include a channel that is bounded by the first pane5402, the second pane5404, the secondary sealant5408(if present—otherwise by the spacer unit5406), and the perimeter edge of the first pane5402and the second pane5404. An adhesive composition5410can be disposed within the channel and specifically can be between the retention member5412and the perimeter edges of the first pane5402and the second pane5404so as to facilitate attachment of the retention member5412to the first pane5402and the second pane5404. However, in this example, the adhesive composition5410does not completely fill the channel. Rather, there is a gap7202underneath the retention member5412.

FIG.72illustrates the retention member, after mounting the retention member onto perimeter edges of the first pane and the second pane, as substantially planar in a direction perpendicular to a face of the first pane and second pane. However, it will be appreciated that the retention member, after mounting the retention member onto perimeter edges of the first pane and the second pane, can also be nonplanar in a direction perpendicular to a face of the first pane and second pane. In some embodiments, the retention member5412may have sufficient flexibility such that it readily conforms with profile of the adhesive composition5410and thus assumes an inward contour. In some embodiments, a roller or other device (including one having a contour) could be passed over the retention member effectively having it be at least partially pushed into the gap7202shown inFIG.72.

In some embodiments, certain components can be omitted. By way of example, in some embodiments, the secondary sealant as a distinct structure can be omitted. Referring now toFIG.73, a cross-sectional view is shown illustrating a retention member5412mounted on an insulating glazing unit5400in accordance with various embodiments herein. In this example, the secondary sealant has been omitted. Rather, the adhesive composition5410can be applied in sufficient volume and contacting both the first pane5402and the second pane5404to provide for the functionality normally provided by the secondary sealant. By way of example, the adhesive composition5410can provide the structural integrity to the insulating glazing unit5400that is normally provided by the secondary sealant.

FIG.73shows a gap7302between the spacer unit5406and the adhesive composition5410. However, this gap7302is shown primarily by way of emphasizing that the secondary sealant is missing in this configuration. While a gap7302could be present, in various embodiments the space where the gap7302is displayed may be filled by the adhesive composition5410(which could be acting as the secondary sealant as described elsewhere herein) or a filler material or structure that is less costly than the adhesive composition5410could be places wherein the secondary sealant would otherwise go.

Many different devices can be used to apply and/or shape adhesive compositions. As one specific example, referring now toFIG.74, a schematic perspective view of an adhesive applicator7400in accordance with various embodiments herein. The adhesive applicator7400can include a supply port7402(where adhesive composition can be received by the applicator), a handle7404, a body member7406, and an upper jaw7408. The body member7406and upper jaw7408can define a track6020through which an insulating glazing unit5400can pass in order for the application of an adhesive composition and/or shaping, trimming, or distributing the adhesive composition. The adhesive applicator7400can move relative to the insulating glazing unit5400, such as in the direction of arrow7420(or could move in the opposite direction). Referring now toFIG.75, a schematic perspective view of the adhesive applicator7400ofFIG.74is shown from a different angle.

Adhesive applicators/shapers herein can include various components. Referring now toFIG.76, a schematic perspective view is shown of an adhesive applicator7400in accordance with various embodiments herein. As before, the adhesive applicator7400can include a supply port7402(where adhesive composition can be received by the applicator), a handle7404, a body member7406, and an upper jaw7408, which the size of the upper jaw7408substantially attenuated in comparison to the embodiment shown inFIG.74. In some embodiments, the upper jaw7408can float or otherwise move to accommodate various offsets of perimeter edges of5402and5404. As one example, this can be accomplished by disposing a spring in the upper jaw7408that allows the upper jaw to be offset from lower jaw7410to maintain a consistent adhesive composition thickness on both panes. In some embodiments, a portion of the upper jaw7408can be disposed on or within a track or guide that allows for the upper jaw7408to float or move.

In this example, the adhesive applicator7400can also include a lower jaw7710as shown inFIG.77. Together, the body member7406, upper jaw7408, and lower jaw7710can define a track6020through which an insulating glazing unit5400can pass in order for the application of an adhesive composition and/or shaping, trimming, or distributing the adhesive composition.

Referring now toFIG.78, a schematic perspective view is shown of another adhesive applicator7400in accordance with various embodiments herein. The adhesive applicator7400can include a supply port7402, a body member7406, and an upper jaw7408, and a lower jaw7410. Together, the body member7406, upper jaw7408, and lower jaw7710can define a track6020through which an insulating glazing unit5400can pass in order for the application of an adhesive composition and/or shaping, trimming, or distributing the adhesive composition.

In some embodiments, the lower jaw7410can float or move to accommodate various insulating glazing unit thicknesses (such as the distance between faces of5402and5404). This can be accomplished in various ways. In some embodiments, a pivoting hinge or other pivot point7802can be disposed between the upper jaw7408and the lower jaw7710in order to facilitate such movement. Referring now toFIG.79, a schematic perspective view of the adhesive applicator7400ofFIG.78is shown from a different angle.

Referring now toFIG.80, a schematic perspective view is shown of another adhesive applicator7400in accordance with various embodiments herein. The adhesive applicator7400can include a supply port7402, a body member7406, and an upper jaw7408, and a lower jaw7410. Together, the body member7406, upper jaw7408, and lower jaw7710can define a track6020through which an insulating glazing unit5400can pass in order for the application of an adhesive composition and/or shaping, trimming, or distributing the adhesive composition. Referring now toFIG.81, a schematic perspective view of the adhesive applicator7400ofFIG.80is shown from a different angle. InFIG.81, an adhesive nozzle8102can be seen disposed within the track6020. The adhesive composition can enter the track6020and then be applied to an insulating glazing unit as the insulating glazing unit moves relative to the adhesive applicator.

It will be appreciated that various types of devices can be used for shaping or troweling operations herein.FIG.82is a schematic cross-sectional view of a troweling tool8200in accordance with various embodiments herein. The troweling tool8200includes a body member8202defining a track8206through which an insulating glazing unit can be slid. In some embodiments, one or more squeegees8204can be disposed within the track8206to aid in distributing adhesive composition and allowing the insulating glazing unit to slide through. However, in some embodiments the squeegees8204can be omitted.FIG.83is a schematic cross-sectional view showing the troweling tool ofFIG.82, with an insulating glazing unit5400disposed therein and an adhesive composition5410that is being shaped or troweled using the tool.

It will be appreciated that for any of the applicators or equipment included herein that movement of the applicator/equipment with respect to insulating glazing units (IGU), windows, or specific components can be relative in the sense that in some cases the applicator/equipment can move while the IGU can be static, in some cases the IGU can move while the applicator/equipment can be static, and in some cases both the IGU and the applicator/equipment can move.

It will be appreciated that operations described herein can be performed as part of manual processes, semi-automated processes, or fully automated processes. In some embodiments, it will be appreciated that equipment illustrated herein and/or operations described herein can be integrated with other pieces of equipment for manufacturing windows and other fenestrations. For example, equipment and/or operations herein can be integrated with various pieces of fenestration manufacturing equipment including, but not limited to, glazers and secondary sealant applicators (auto, hand-assist, gantry style, fixed head, manual, robotic, and the like), rolling applicators (bead rollers, weather strip applicators, etc.), spacer applicators (auto, hand-assist, gantry style, fixed head, manual, robotic, and the like), integrated insulating glazing unit assembly lines, robotic assemblers, laminating equipment, tape or film applicators, and the like.

It should be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. Thus, for example, reference to a composition containing “a polymer” includes a mixture of two or more polymers. It should also be noted that the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise.

As used herein, the recitation of numerical ranges by endpoints shall include all numbers subsumed within that range (e.g., 2 to 8 includes 2.1, 2.8, 5.3, 7, etc.).

The headings used herein are provided for consistency with suggestions under 37 CFR 1.77 or otherwise to provide organizational cues. These headings shall not be viewed to limit or characterize the invention(s) set out in any claims that may issue from this disclosure. As an example, although the headings refer to a “Field,” such claims should not be limited by the language chosen under this heading to describe the so-called technical field. Further, a description of a technology in the “Background” is not an admission that technology is prior art to any invention(s) in this disclosure. Neither is the “Summary” to be considered as a characterization of the invention(s) set forth in issued claims.