Patent Publication Number: US-2005136198-A1

Title: Insulating glass units with inserts and method of producing same

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S)  
      None.  
     FIELD OF THE INVENTION  
      The present invention relates to architectural insulating glass units.  
     BACKGROUND OF THE INVENTION  
      Architectural insulating glass units (IGU) are typically constructed of two glass facings and a perimeter edge seal. The perimeter edge seal holds the two glass facings in place, which are then sealed using a variety of sealants. If the IGUs are produced in accordance with the Insulating Glass Certification Council (IGCC) specifications, the seal will consist of a double silicone seal. In a conventional IGU the space between the glass facings in the center of the IGU is filled with air, and is therefore sometimes referred to as the airspace.  
      While commonly used in the architectural industry, conventional IGUs have some limitations associated with their use. Primary among them is their visual and heat conducting properties. As they are typically constructed of glass, conventional IGUs allow high amounts of sunlight and heat to penetrate into the interior of a building. This can have a significant effect on the amount of energy required to cool a building in warmer climates and typically tinted or reflective films or coatings are applied to mitigate the effects of solar heat.  
      Additionally, the visual characteristics of conventional IGUs are not desirable in all situations. Traditional IGUs typically provide complete visibility, in both directions, and therefore, offer no privacy from persons on the opposite side of the unit.  
      Traditional IGUs do not permit control over the visual characteristics of the IGUs. It would be desirable to have an IGU that allows better control of the visual. characteristics of the IGU. It would be desirable to have an IGU that allows better control over the degree of privacy and the amount of light penetrating the unit. It would also be desirable to have an IGU that better controlled the heat conduction into the interior of a building from sunlight.  
     SUMMARY OF THE INVENTION  
      An architectural insulating glass unit with an insert in the airspace is disclosed. The IGU comprises two glass facings; an open cell honeycomb insert sized to be positioned between the two glass facings in the insulating glass unit; and a perimeter spacer dimensioned to secure the two glass facings and the open cell honeycomb in the insulating glass unit, wherein the open cell honeycomb insert is between the two glass facings. In one embodiment, the open cell honeycomb insert is constructed from polycarbonate tubular honeycomb. In another embodiment, the open cell honeycomb insert is regular. In the preferred embodiment, the open cell honeycomb insert is constructed from regular polycarbonate tubular honeycomb. In one embodiment, the open cell honeycomb insert may be cut in a range of about +0.00″ to −0.04″ less in thickness and −0.00″ to +0.03″ less in length and width than the specified airspace of the IGU into which it is inserted. The open cell honeycomb insert may be prepared using a dust removal process producing a visual grade insert.  
      A method for preparing an insert for insertion into the airspace of an industrial glass unit is also disclosed. The method comprises the following steps: slicing a block of open cell tubular honeycomb into sheets of a thickness compatible with the thickness of the airspace of the insulating glass unit; cutting the sheets of open cell tubular honeycomb to a length and width compatible with length and with of the airspace of the insulating glass unit to form an insert; and cleaning the insert using high pressure air.  
      In one embodiment the slicing of a block of open cell tubular honeycomb is performed with a high speed rotating saw blade. In another embodiment, the dust generated by the high speed rotating saw blade is removed as much as possible from the core insert by a downdraft vacuum system.  
      In the method, cutting the sheets of open cell tubular honeycomb to a length and width is preferably performed using a computer numerically controlled saw and the sheets are cut in a range of about +0.03″ to −0.00″ less in length and width than the specified airspace of the IGU into which it will be inserted.  
      A method for constructing an architectural glass unit is also disclosed. The method comprises the following steps: adhering a first lite of glass to a perimeter spacer, placing an open cell honeycomb insert within the perimeter of the spacer adjacent to the first lite of glass; and, adhering a second lite of glass to the perimeter spacer, wherein the open cell honeycomb insert is sized to fit securely within the perimeter spacer between the first and second lite of glass. Optionally, the method further comprises the step of sealing the unit. In one embodiment the sealing of the unit is done with a double silicon seal. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The accompanying drawings are incorporated in and constitute a part of this specification and, together with the description, explain the advantages and principles of the invention. In the drawings,  
       FIG. 1  is an exploded perspective view of the components of an IGU of the present invention.  
       FIG. 2  is an assembled perspective view of an embodiment of an IGU of the present invention.  
       FIG. 3  is a cut-away sectional view of a portion of an assembled IGU of the present invention.  
       FIG. 4  is a diagram showing the relationship between the distance of the observer to the IGU and the observer&#39;s cone of vision through the unit.  
       FIG. 5  is a diagram showing the relationship between the angle of the observer to the IGU and the observer&#39;s cone of vision through the unit.  
       FIG. 6  is a diagram showing the relationship between the thickness of the IGU insert and the observer&#39;s cone of vision through the unit.  
       FIG. 7  is a diagram showing the relationship between the cell sizes of the IGU insert and the observer&#39;s cone of vision through the unit. 
    
    
     DETAILED DESCRIPTION  
      An architectural insulating glass unit (IGU) with an open cell honeycomb insert is disclosed. A method for constructing the IGU with the insert, as well as a method for preparing the insert for use is also disclosed.  
      Assembly of the IGU With Insert  
      Turning now to the drawings,  FIG. 1  illustrates an exploded view of the parts of an unassembled embodiment of an architectural IGU with a honeycomb insert.  FIG. 2  illustrates a perspective view of an assembled IGU  10 . Arrows indicate how the unassembled parts fit together to form the assembled IGU  10 .  
      The assembled IGU  10  has two glass facings  15   a  and  15   b,  also commonly referred to as glass lites, and herein the two terms are used interchangeably. As the two glass facings  15   a  and  15   b  are intended to be secured together as one unit, they have roughly the same length and width. Standard glass facings of the size and type commonly used in the industry are acceptable for use in the present invention and are specifically contemplated for use. Non-limiting examples of the types of glass commonly used include laminated, low-iron, heat-strengthened, annealed, float, or tempered glass. Custom colored PVB interlayer is also compatible with the present invention, as are, without limitation, glass finishes such as sand-blasting, acid-etching, ceramic frit, low-e, reflective or tinted coatings. The IGUs of the present invention are applicable to both indoor and outdoor use, therefore, the specific size and material used for the facing depends on the intended application. Although glass is overwhelmingly used in the industry and is preferred for use in the present invention, other types of facings may be used, for example plastic.  
      The two glass facings  15   a  and  15   b  are positioned together by a perimeter spacer  20 . The perimeter spacer  20  provides the framework for securing the two glass facings  15   a  and  15   b  as a unit and for creating the airspace  24  for the insertion of an insert  30 . The perimeter spacer  20  is preferably constructed from aluminum, although other materials may be used. Again, standard perimeter spacers of the size and type commonly used in the industry are acceptable for use in the present invention and are specifically contemplated for use. The perimeter spacer  20  has an outer edge  22  and walls  27   a  and  27   b  on either side of the outer edge  22  extending substantially perpendicular. The perimeter spacer  20  is sized to according to the size of the glass facings  15   a  and  15   b . In the preferred embodiment, the length and width of the outside edge of the perimeter spacer  20  are typically slightly smaller than that of the glass facings  15   a  and  15   b  so that when the unit  10  is assembled, the edges of the two glass facings  15   a  and  15   b  will extend slightly beyond the outer edge  22  of the perimeter spacer  20 . In an alternate design, the spacer can be placed all the way to the edge of the glass lites. The edges of the glass facings  15   l  and  15   b  typically are sized to extend about ¼ inch beyond the outer edge  22  of the perimeter spacer  20  created a shallow gap between the two glass lites at the outer edge. When the two glass facings  15   a  and  15   b  are positioned in this manner, an airspace  24  is created in the middle of the IGU  10 .  
      An insert  30  is positioned in the airspace  24  of the IGU  10  between the two glass facings  15   a  and  15   b  and within the perimeter spacer  20 . The preferred insert is made from open cell honeycomb, and more specifically regular polycarbonate tubular honeycomb is most preferred. The term regular refers to the size of the individual tubes of the honeycomb material, and indicates that the individual tubes are identical or nearly identical in size. The use of regular tubular honeycomb creates a unique visual effect. Preferred cell diameters are ⅛″, {fraction (3/16)} or  ¼′,″ however other sizes may be used. Additionally, the insert may be composed of other materials and m ay have alternate cellular shapes. The preparation of the insert is discussed more fully below.    
      To assemble the IGU  10 , a first glass panel  15   a  is adhered to the wall  27   a  of the perimeter spacer  20 . Typically, adhesive is applied to the wall  27   a  of the perimeter spacer  20  secure the glass lite  15   a  to the perimeter spacer  20 . The adhesive will create a seal between the glass lite  15   a  and the perimeter spacer  20 . The adhesive, also referred to as the primary sealant is preferably polyisobutylene (PIB), however, other sealants or adhesives may be used. Once in position, a space is created for the insert  30  to be positioned.  
      The insert  30  is placed in position followed by the second glass lite  15   b.  Again, adhesive is applied to the walls  27   a  and  27   b  of the perimeter spacing  20  to secure the second glass lite in position and to create a hermetic seal. Optionally, desiccant can be injected into the perimeter spacer, which is hollow to ensure that little or no moisture remains inside the airspace  24  of the assembled IGU  10 . The assembly is preferably completed with the application of a secondary sealant, applied to the outer edge  22  of the perimeter spacing  20 . Typically, this would be applied in the shallow gap at the outer edge between the glass lites. The preferred secondary sealant is a two-part silicone seal, which is IGCC-certified and CBA rated so that the unit can be approved by the architecture glazing industry.  
       FIG. 3  illustrates a cut-away sectional view of a portion of an assembled IGU of the present invention. The position of the primary sealant  32  and secondary sealant  34  is shown. Also shown is the preferred positioning of the optional desiccant  36 . As is common in the industry, the desiccant is injected into the hollow spacer before the spacer is properly positioned.  
      Also shown in  FIG. 3  are framing devices  40  used for securing the IGUs in place. As can be seen, framing devices  40  are standard frames used in the industry for securing IGUs. No special clamps or devices are required for installation of the IGUs of the present invention. The IGUs with inserts of the present invention function structurally as other IGUs but have the added benefits and advantages of the inserts. They are completely compatible with existing and standard equipment and intended to be used with such.  
      Preparation of the Insert  
      The type of insert is an important consideration as the cell size, core thickness, and cell wall opacity will affect the visual characteristics and heat transmitting qualities. Tubular Polycarbonate open-cell honeycomb is the preferred material for use as an insert. Typically tubular polycarbonate is produced in b lock form, by thermally fusing multiple identical extruded tubes of polycarbonate. The block can then be sliced to the specific thickness as required to fit into the airspace of an insulating glass unit. This method for the preparation of the insert is the preferred method, however other methods may be used. Methods such as molding, stamping, extruding, or other additional methods not described here can be used to prepare the insert.  
      In the preferred embodiment, to maximize the quality of the final IGU, the core blocks are cut or sliced such that no shavings, burrs, or other trace of the slicing of the cores is visible once the block has been sliced into multiple singular ‘inserts’. To achieve this type of cut, the preferred method of cutting employs a high speed rotating saw blade capable of achieving the necessary quality.  
      The preferred method of preparation also employs a vacuum system at this point in the tubular honeycomb insert production. The dust generated by the sawing is removed as much as possible from the core insert by a downdraft vacuum system. The cut honeycomb is placed on an open grid framework and the dust is vacuumed from below, but the dust traces outlining the grid support may remain on the core. Existing markets for tubular core honeycomb do not usually require visual-grade dust removal at this stage of production as other industries do not require a higher degree of cleanliness of the this material. The phrase “visual grade” means that the open cell insert should be as visually consistent as possible as it may be used in an architectural setting. A visual grade core has a very regular cell configuration and negligible levels of dust deposits, shavings, or other impurities or traces of the cutting or cleaning process. In general, the preferred core is as visually consistent as possible with no outstanding irregularities or imperfections.  
      In order to meet the high aesthetic requirements of the architectural market, preferably the tubular open-cell insert is cleaned by using the cleaning process described below. Alternate processes designed to achieve the desired cleanliness may also be used.  
      It is a standard practice in the architectural glazing industry to fabricate or install the structural framing members before specifying the exact size of and ordering the final IGUs so that the relationship between the unit and framing is precise and any unnecessary stresses on the system are avoided. Therefore, once the final IGU dimension has been determined, the sliced insert can be cut to the specified dimension, at which point it may be processed further so that the final assembled IGU with an open cell insert is as visually consistent as possible.  
      In order to achieve the best fit into the airspace of an IGU, inserts are preferably cut using a computer numerically controlled (CNC) saw. This provides the necessary ‘visual grade’ tolerance of the cut and ensures that the insert aligns properly with the perimeter spacer at the perimeter of the unit. It is important to cut the cores to the desired size before the final cleaning stage as described below. In keeping with the tolerances of both the insulating glass unit industry and tubular honeycomb core production, the honeycomb core insert is preferably sliced to a maximum of about 0.04″ less in thickness and +0.03″ to −0.00″ in length and width than the specified airspace of the intended IGU into which it will be inserted. Performance problems may arise as the result of improperly sized inserts. If the insert is too thick, it can prevent an accurate bond of the second glass lite to the perimeter spacer, which may compromise the weather seal and the overall integrity of the unit. If the insert is too thin, it can rattle in the airspace against the glass facings creating an unpleasant noise, which is undesirable in the architectural industry. In addition, the relationship between the insert thickness and the airspace is carefully determined to take into account the thermal expansion of the core by evaluating the coefficients of expansion and contraction of the core insert in relation to that of a typical insulating glass unit.  
      Because polycarbonate tubular honeycomb is not commonly used in an application requiring it to be visual grade, as the architectural IGU market requires, the dust removal process currently employed by most vendors does not sufficiently remove the dust from the insert. In the preferred embodiment, the cleaning system described below is utilized to clean the core to visual grade specifications. However, depending on the specific application of the IGU, this level of cleaning may not be required and other cleaning methods may be used.  
      The application of high pressure air using regularly spaced air nozzles sufficiently cleans the inserts to visual grade quality. The cores are placed on an open support structure with narrow supports (about ⅛″ wide or less) which allows the air from the nozzles to flow through the insert, thereby cleaning the cell wall through the entire depth of the insert.  
      The nozzles are connected to a hollow air flow tube in such a pattern as to allow maximum and even air distribution. The tube is connected to a large volume air compressor unit [recommended 120 psi/ with at least 300 scfm capacity]. Because the nozzles are fan shaped and the air tends to spread out once it leaves the nozzle, best results are achieved when the nozzles are staggered such that the air flow from one nozzle overlaps slightly the air flow from the contiguous nozzles. This ensures that there are only minimal gaps in air pressure over the surface of the insert and will result in the most consistent cleaning.  
      The cleaning steps above are preferably employed in a clean room environment with a negative air pressure and with a downdraft or cross-draft air circulation system such that air enters the enclosed booth from the top or side and is removed from the floor or opposite wall, as this enhances the effectiveness. This will ensure that the dust removed from the inserts does not float freely in the environment and possibly redeposit on the insert.  
      Air in the booth is preferably free of oil and moisture. The insert is preferably cleaned well on each side with a minimum of three passes, overlapping by at least 50% each pass. The first pass over the entire core insert is parallel to one side of the insert, the second pass is perpendicular to the first pass, and the third pass is at a 45 degree angle to the 2 nd  pass. If a fourth pass over the core is necessary, it should be performed perpendicular to the 3 rd  pass. The edges of the inserts are cleaned as well and all partially cut cell wall material should be removed. Cleaning is preferably performed in a well lit area to confirm that the entire insert is thoroughly cleaned and no streaks remain. Finally, cleaned inserts should be removed from the cleaning room to ensure that no dust will redeposit.  
      Once the cores are cut and cleaned as described above they are preferably stored with the use of anti-static films to avoid latent dust in the environment from being deposited back onto the cell walls.  
      Use and Benefits of IGU With Insert  
      The physical shape, plastic nature and light transmitting properties of the insert, and specifically the preferred tubular polycarbonate honeycomb, provide multiple benefits when inserted in the airspace of an IGU that is typically used in the architectural industry. Although the IGUs with inserts of the present invention are particularly suitable as a weather and insulation barrier between indoor and outdoor spaces, because of the thermal and sound insulating properties as well as visual and other properties afforded by the insert, the present invention can also be used to separate interior spaces.  
      One of the main benefits of the present invention is the ability to better manipulate and control the visual characteristics of the IGU. When the tubular honeycomb core is inserted into the airspace of an insulating glass unit, thereby putting this honeycomb into the sightlines of observers, the cell walls of the tubular honeycomb, which is sliced to fit into the airspace of the unit, restrict the sightlines of an observer depending upon the observer&#39;s position in relation to the panel.  
      The honeycomb depth is related to the depth of the airspace of the IGU, which typically has standard industry dimensions ranging from {fraction (5/16)}″ to ¾″ in depth. Other depths may be used, however depending on the application. The honeycomb cell walls restrict the lines of sight, or cone of vision, as the sight lines encounter the first cut surface and then the second cut surface of the honeycomb core.  
      Assuming a 90 degree [perpendicular] view, there is more visual transparency in the center of the observer&#39;s cone of vision and less as the sightlines are interrupted by the honeycomb cell walls. As the observer&#39;s distance from the panel increases, assuming an axis perpendicular to the face of the panel, the observer&#39;s cone of vision enlarges in relation to the face of the panel resulting in more visual transparency because fewer sightlines are being interrupted by the cell walls of the honeycomb (see  FIG. 4 ).  
      A direct result of this visual property is the ability to control the amount of privacy offered by the panel: the tubular nature of the honeycomb restricts the sight lines of an observer depending upon the proximity of that observer to the unit.  
      The degree of privacy also varies as the observer&#39;s angle of view towards the panel changes. The greatest degree of privacy is offered when the observer is at an oblique angle to the unit (see  FIG. 5 ). The 90° degree view angle offers the clearest vision and least amount of privacy. Because of the possibility to vary the light transmitting properties of the polycarbonate honeycomb—from transparent to opaque cells walls—more or less privacy can be offered depending upon the specification of the cell wall. The more transparent the polycarbonate, the less privacy can be expected.  
      The amount of privacy can also be controlled by the depth of the insert and associated airspace, and by the density of the insert. Assuming a constant distance from the observer to the IGU, the angle at which all sightlines are interrupted and there is no visibility through the panel is directly related to the thickness and cell size of the core insert.  
      Thinner inserts result in increased transparency and therefore decreased privacy because the sightlines encounter the second cut surface of the cell wall sooner, allowing the sight line to continue into the space beyond with less interruption by the cell wall itself (see  FIG. 6 ).  
      Varying the cell size of the tube core honeycomb will also affect the amount of privacy—smaller cells will restrict the sight lines more dramatically than larger cells because of the smaller diameter and thereby offer a greater degree of privacy (see  FIG. 7 ).  
      In a similar vein, the amount of light being transmitted through the panel can better be controlled by varying the properties of the insert. This is especially important with windows that are exposed to direct sunlight for large portions of the day. This control over privacy and light makes the IGU of the present invention equally suitable for interior applications. Additionally, different colors degrees of translucency/opacity of materials used for the insert may be used to further enhance these properties, as well as to offer greater design flexibility to the architect or specifier.  
      Another main benefit of the addition of the insert to the IGU is the increase in energy efficiency. The IGU with insert of the present invention limits the amount of direct sunlight that can penetrate the unit, thereby decreasing the amount of heat transmitted into the interior space of a building. The reduced heat in the interior space lessens the need for energy-dependent cooling systems, reducing the overall expenditure of energy in the building. In comparison to a typical IGU with no insert, the IGU with insert of the present invention achieves reduced Shading Coefficient and Solar Heat gain Coefficient values comparable to an IGU with a low-C coating. These low values are desirable in the fields of architecture and building. The IGU with insert of the present invention can also be produced with low-e coatings. The combined effect of the insert and the low-e coating achieves further reduced Shading Coefficient and Solar Heat gain Coefficient values.  
      Also, the insert occupying the airspace reduces convection of the air within the unit and correspondingly, the amount of heat transmitted into the interior spaces.  
      Variations of the Inserts  
      The type, shape and regularity of the basic insert may be varied. This is another way to achieve different visual effects. One variation is to have more than one individual insert in a single IGU. For example, 2 or more inserts may be sliced to fit together in the airspace and create an overlapping pattern.  
      Another variation is to vary the thickness of a single insert within an IGU. In the basic unit described above, the insert is sliced to be consistent thickness. However, the insert thickness may be manipulated for aesthetic or visual privacy purposes. For example the insert may be cut on an angle such that it is of standard thickness at the base of the unit and then tapers to gradually become thinner towards the top. A unit with this type of insert would be obscure at the base and allow clearer vision at eye-level. For another example, the insert could be of one thickness for the majority of the unit but have a decorative pattern milled into its thickness in various areas in the insert to create a three dimensional visual effect. Units prepared with thickness variations must be prepared without compromising the stability of the insert within the unit. Therefore a portion of the insert has to remain thick enough to keep the insert stable in the airspace within the unit.  
      One other variation is to have a variety o f different c ell sizes within a single insert. As mentioned above, the preferred embodiment utilizes regular open cell honeycomb as the insert material. However, multiple sized cells within a single insert may be used for a different visual effect. The insert would maintain similar functions in terms of the aesthetics, visibility, and thermal performance but offers another option to manipulate the visual characteristics both for esthetic and privacy.