Patent Publication Number: US-9845635-B2

Title: Window frame system for vacuum insulated glass unit

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 14/717,318 filed on May 20, 2015, which claims the benefit of U.S. Provisional Application No. 62/003,158 filed on May 27, 2014. The entire disclosure of each of the above applications is incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates to a window frame system, and more particularly, to a window frame system for a vacuum insulated glass unit. 
     BACKGROUND 
     This section provides background information related to the present disclosure and is not necessarily prior art. 
     Advancements in glass technology continue to increase the insulation values of windows for buildings or homes, for example. Such advancements continue to reduce the amount of heat transfer through the glass units. These high-performing glass units, however, create new problems for the existing window frame and/or glazing technologies. In order for the window assembly, as a whole, to perform at a high level, there is a need for these high-performing glass units to be installed in high-performance window frame systems. Installing high-performing glass units in high-performing window frame systems can yield the synergetic effect of drastically increasing the R-value (thermal resistance) of the window assembly, as a whole, and drastically improving the energy efficiency of the building or home. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     A window assembly may include a vacuum insulated glass unit and a frame assembly. The vacuum insulated glass unit may include first and second glass substrates defining a space therebetween that is at a pressure lower than atmospheric pressure. One of the first and second glass substrates may include a vacuum port extending outward therefrom. The vacuum port may define a passage in communication with the space. The frame assembly supports the glass unit and may include a base member and a glazing member. The base member and the glazing member cooperate to define a slot in which an edge portion of the glass unit is received. One of the base member or the glazing member may include a cavity receiving the vacuum port. The glazing member and the base member may define a plurality of pockets that reduce or hinder thermal conductivity through the frame assembly. 
     In some embodiments, the glazing member includes a tab that snaps into engagement with the base member. 
     In some embodiments, the base member includes embedded reinforcement members. 
     In some embodiments, at least one of the base member and the glazing member include embedded additives that reduce thermal conductivity thereof. 
     In some embodiments, the base member includes a recess adjacent the slot that receives a portion of the glass unit when the glass unit is in a distorted condition. 
     In some embodiments, the recess includes an insulative barrier received therein to absorb energy associated with distortion of the glass unit. 
     In some embodiments, the glazing member structurally supports the glass unit. 
     In some embodiments, the glazing member bears at least a portion of a load of the glass unit. 
     In some embodiments, the glazing member and the base member cooperate to bear the load of the glass unit. 
     In some embodiments, the cavity that receives the vacuum port is filled with an insulative material. 
     In some embodiments, at least one of the pockets is filled with air. 
     In some embodiments, at least one of the pockets is filled with foam. 
     In some embodiments, the edge portion of the glass unit is inserted into the slot to a bite depth of at least 1.25 inches. 
     In another form, the present disclosure provides a window assembly that includes a vacuum insulated glass unit and a frame assembly. The glass unit may include first and second glass substrates defining a space therebetween that is at a pressure lower than atmospheric pressure. The frame assembly may support the glass unit and may include a base member and a glazing member. The base member and the glazing member may cooperate to define a slot in which an edge portion of the glass unit is received. One of the base member or the glazing member may include a recess adjacent the slot that receives a portion of the glass unit when the glass unit is in a distorted condition. 
     In some embodiments, one of the first and second glass substrates may include a vacuum port extending outward therefrom, the vacuum port defining a passage in communication with the space, and one of the base member or the glazing member includes a cavity receiving the vacuum port. 
     In some embodiments, the cavity that receives the vacuum port is filled with an insulative material. 
     In some embodiments, the glazing member and the base member define a plurality of pockets that reduce thermal conductivity through the frame assembly. 
     In some embodiments, at least one of the pockets is filled with air. 
     In some embodiments, at least one of the pockets is filled with foam. 
     In some embodiments, the glazing member includes a tab that snaps into engagement with the base member. 
     In some embodiments, the base member includes embedded reinforcement members. 
     In some embodiments, at least one of the base member and the glazing member include embedded additives that reduce thermal conductivity thereof. 
     In some embodiments, the recess includes an insulative barrier received therein to absorb energy associated with distortion of the glass unit. 
     In some embodiments, the glazing member structurally supports the glass unit. 
     In some embodiments, the edge portion of the glass unit is inserted into the slot to a bite depth of greater than or equal to 1.25 inches. 
     In some embodiments, the glazing member bears at least a portion of a load of the glass unit. 
     In some embodiments, the glazing member and the base member cooperate to bear the load of the glass unit. 
     In another form, the present disclosure provides a window assembly that may include a plurality of vacuum insulated glass units and a frame assembly. Each of the vacuum insulated glass units may include first and second glass substrates defining a space therebetween that is at a pressure lower than atmospheric pressure, one of the first and second glass substrates including a vacuum port extending outward therefrom, the vacuum port defining a passage extending through one of the first and second glass substrates and in communication with the space. The frame assembly may support the vacuum insulated glass units and may include a base member and a glazing member. The base member and the glazing member may cooperate to define a first slot in which a portion of a first one of the vacuum insulated glass units is received. One of the base member or the glazing member may include a cavity receiving the vacuum port of the first one of the vacuum insulated glass units. The base member may define a second slot receiving a portion of a second one of the vacuum insulated glass units. 
     In another form, the present disclosure provides a window assembly that may include a vacuum insulated glass unit, a third glass substrate, and a frame assembly. The vacuum insulated glass unit may include first and second glass substrates defining a space therebetween that is at a pressure lower than atmospheric pressure. One of the first and second glass substrates may include a vacuum port extending outward therefrom. The vacuum port may define a passage extending through one of the first and second glass substrates and in communication with the space. The frame assembly may support the vacuum insulated glass unit and the third glass substrate and may include a base member and a glazing member. The base member and the glazing member may cooperate to define a first slot in which a portion of the vacuum insulated glass unit is received. One of the base member or the glazing member may include a cavity receiving the vacuum port of the vacuum insulated glass unit. The base member may define a second slot receiving a portion of the third glass substrate. 
     In another form, the present disclosure provides a window assembly that may include a plurality of vacuum insulated glass units and a frame assembly. Each of the vacuum insulated glass units may include first and second glass substrates defining a space therebetween that is at a pressure lower than atmospheric pressure. The frame assembly may support the vacuum insulated glass units and may include a base member and a glazing member. The base member and the glazing member may cooperate to define a first slot in which a portion of a first one of the vacuum insulated glass units is received. The base member may define a second slot receiving a portion of a second one of the vacuum insulated glass units. One of the base member or the glazing member may include a recess adjacent the first slot that receives a portion of the first one of the vacuum insulated glass units when the first one of the vacuum insulated glass units is in a distorted condition. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
         FIG. 1  is a schematic representation of a window assembly according to the principles of the present disclosure; 
         FIG. 2  is a cross-sectional view of a glass unit installed in a window frame system of the window assembly of  FIG. 1 ; 
         FIG. 3  is a cross-sectional view of the glass unit and window frame system of  FIG. 2  in a distorted condition; 
         FIG. 4  is a perspective view of a glass unit and a coupler according to the principles of the present disclosure; 
         FIG. 5  is a perspective view of the glass unit and coupler installed in a frame assembly; 
         FIG. 6  is a cross-sectional view of the window frame system with of  FIG. 2  with the glass unit and another glass substrate installed therein; and 
         FIG. 7  is a cross-sectional view of the window frame system with of  FIG. 2  with a plurality of glass units installed therein. 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. 
     The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
     When an element or layer is referred to as being “on,” “engaged to,” “connected to,” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
     Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     With reference to  FIGS. 1-3 , an exemplary window assembly  10  is provided that includes an insulated glass unit and in particular a vacuum insulated glass (VIG) unit  12  and a frame assembly  14 . The window assembly  10  can be installed in a wall  16  ( FIG. 1 ) of a building or home, for example. As shown in  FIG. 2 , the VIG unit  12  may include first and second glass substrates  18 ,  20  that cooperate to define a space  22  therebetween. The space  22  may be at a pressure that is less than atmospheric pressure. The second glass substrate  20  is the interior substrate (i.e., the substrate that is exposed to the interior of the building or home) and includes a vacuum port or tube  24  (shown schematically in  FIGS. 2 and 3 ) defining a passage  25  that is in communication with the space  22 . Gas within the space  22  can be evacuated through the vacuum port  24  prior to or after installation of the VIG unit  12  in the frame assembly  14 . 
     As shown in  FIG. 1 , the frame assembly  14  may include a head portion  26 , a sill portion  28  and a pair of jamb portions  30 . The head, sill and jamb portions  26 ,  28 ,  30  may cooperate to support the VIG unit  12 . The head, sill and jamb portions  26 ,  28 ,  30  may be wood, vinyl, aluminum or any suitable structural material having a desirable thermal conductivity. The head, sill and jamb portions  26 ,  28 ,  30  may include certain additives that lower thermal conductivity. For example, when vinyl is chosen as the material, the material can include embedded microspheres. Embedded microspheres may include, for example, expanding microspheres. The head, sill and jamb portions  26 ,  28 ,  30  may be generally similar or identical, and therefore, only the sill portion  28  will be described in detail below. 
     As shown in  FIG. 2 , the sill portion  28  may include a base member  32  and a glazing member  34 . The glazing member  34  may be disposed on the interior side of the VIG unit  12  (i.e., the glazing member  34  may be disposed in the interior of the building or home) and may engage the base member  32  to define a slot  36  therebetween that receives some or all of an edge portion  37  of the VIG unit  12 . The edge portion  37  is defined as extending approximately 2.5 inches from a distal edge  33  of the VIG unit  12 . In some embodiments, a gasket  35  may be provided between the VIG unit  12  and the base member  32  and/or between the VIG unit  12  and the glazing member  34  to restrict or prevent fluid from entering the slot  36 . 
     In some configurations, the edge portion  37  of the VIG unit  12  may extend into the slot  36  to a bite depth D of greater than or equal to 1.25 inches. In some variations, the bite depth D could be between about 0.75 and 5 inches or between about 0.75 and 3 inches, for example. The VIG unit  12  tends to have higher thermal conductivity at the distal edge  33  due to the edge seal between the first and second glass substrates  18 ,  20  at the distal edge  33 . Therefore, the large bite depth lengthens the path that thermal energy (heat or cold) must travel to conduct between interior and exterior sides of the VIG unit  12 , thereby improving the thermal performance of the window assembly  10 . 
     The surface temperatures of the first and second glass substrates  18 ,  20  remain relatively constant from the center of the glass substrates  18 ,  20  until reaching the edge portion  37 , i.e., approximately 2.5 inches from the distal edge  33 , whereat the surface temperatures transition along a steep temperature gradient to the distal edge  33 , which is unique to high performing VIG units. The surface temperature of the first glass substrate  18  transitions towards the surface temperature of the second glass substrate  20  while the surface temperature of the second glass substrate  20  transitions towards the surface temperature of the first glass substrate  18 . The large bite depth prevents the accumulation of condensation on the second glass substrate  20  by affecting the surface temperature of the second glass substrate  20  that is exposed to the environmental conditions (e.g., relative humidity) of the interior of the building or home. Where the VIG unit  12  meets the frame assembly  14  defines a sight line S. The bite depth D is selected such that the surface temperature of the second glass substrate  20  at the sight line S will be above a target temperature throughout a range of interior and exterior environmental conditions in order to prevent condensation. 
     The distal edge  33  of the VIG unit  12  is seated on one or more glazing blocks  47  at the bottom of the slot  36 . The glazing blocks  47  may comprise a rubber or similar polymer material and are used to support the VIG unit  12  during assembly of the window assembly  10 . There may be a plurality of glazing blocks  47  spaced apart along the bottom of the slot  36 . The glazing blocks  47  may be spaced apart to allow moisture that enters the slot  36  to drain out through weeping holes (not shown) in the bottom of the slot  36 . 
     The base member  32  may be extruded, pultruded or injection molded from a polymeric or composite material, for example, and may include a plurality of support members or ribs  39  that cooperate to form one or more pockets  38 . The pockets  38  may serve to reduce or hinder thermal conductivity through the base member  32 . A lower end of the base member  32  may include one or more tabs  41  that engage the wall  16  of the building or home. One or more of the pockets  38  may be filled with air  42  and/or other gasses and one or more of the pockets  38  may be filled with an insulation material  44  to reduce the thermal conductivity of the frame assembly  14 . The insulation material  44  can include foam, rubber, glass microspheres, perlite, aerogel, fused silica, and/or inert-gas-filled foam, for example. It will be appreciated that in some variations, all of the pockets  38  could be filled with air and/or other gases, or all of the pockets  38  could be filled with the insulation material  44 . Any combination of such insulating gases or materials may be employed in the same or different pockets  38 . In some embodiments, one or more of the ribs  39  may include reinforcement members  46  to provide additional rigidity and strength to the frame assembly  14  to reinforce the frame assembly  14  against forces caused by distortion of the VIG unit  12 , for example. The reinforcement members  46  can be formed from any suitable material and can be embedded, co-extruded, co-pultruded or incorporated into the frame assembly  14  in any suitable manner. The reinforcement members  46  may have any suitable cross-section such as circular, rectangular, or square. In addition, there may be one or more reinforcement members  46  in each of the ribs  39 . A first lateral surface  49  of the base member  32  may contact the first glass substrate  18  and cooperates with the glazing member  34  to securely retain the VIG unit  12  in the frame assembly  14 . In some configurations, a two-sided adhesive glazing tape  51  or silicone or silicone-like product is disposed between the first lateral surface  49  and the first glass substrate  18 . 
     In some embodiments, the base member  32  may include a recess  48  adjacent the slot  36 . As shown in  FIG. 3 , the recess  48  is designed to accommodate distortion of the VIG unit  12  rather than constraining the VIG unit  12  at the distal edge  33 . Constraining at the distal edge  33  may introduce significant additional stresses into the VIG unit  12 . The base member  32  and the glazing member  34  may be designed to constrain the VIG unit  12  adjacent the sight line S, thereby preventing or minimizing distortion of the VIG unit  12 . Constraining the VIG unit  12  adjacent the sight line S introduces less stress into the VIG unit  12  than would be introduced if the VIG unit  12  is constrained at the distal edge  33 . In addition, the glazing member  34  may be designed to flex or pivot towards the interior of the building or home in response to distortion of the VIG unit  12 . A primary cause of distortion of the VIG unit  12  is differences in thermal expansion and contraction as a result of exposure to large differences between outdoor and indoor temperatures which due to the rigid edge seal of the VIG unit  12  causes the first and second glass substrates  18 ,  20  to distort together in the same direction. Such thermal distortion of the first and second substrates  18 ,  20  together tends to be an issue that arises for VIG units, but not for conventional IG or other window units. Thus, the ability for the edge portion  37  of the VIG unit  12  to experience thermal distortion into the recess  48  prevents potential mechanical stress or failure of the VIG unit  12  or frame assembly  14  over long-term use. Distortion of the VIG unit  12  may also be caused by wind loads or the like. In some embodiments, a thermally insulative barrier  50  may be located in the recess  48 . An adhesive may bond the insulative barrier  50  to the VIG unit  12  and/or to the base member  32 . For example, the insulative barrier  50  could include silicone or a polystyrene tape. In some configurations, the insulative barrier  50  could be approximately five millimeters thick or thicker. The insulative barrier  50  may structurally adhere the base member  32  to the VIG unit  12  and absorb and displace energy associated with the distortion of the VIG unit  12 . It will be appreciated that, in some embodiments, the recess  48  could be open (e.g., filled with gas or air rather than the insulative barrier  50 ). 
     In some embodiments, one or more of the ribs  39  of the base member  32  may be trimmed or removed so that one or more of the pockets  38  may define another slot for receiving other glass substrate(s) or a second VIG unit. For example, in the configuration illustrated in  FIG. 2 , first and second ribs  52 ,  54  may be trimmed or removed so that first and second pockets  56 ,  58  can function as a slot for receiving another glass substrate  13  (as shown in  FIG. 6 ) or a second VIG unit  15  (as shown in  FIG. 7 ). One or both of the first and second ribs  52 ,  54  may include one or more notches  60  that facilitate the cutting or breaking of the first and second ribs  52 ,  54  to allow for the insertion of glass substrate  13  or the second VIG unit  15  as well as insulation material (e.g., foam, rubber, glass microspheres, perlite, aerogel, fused silica, and/or inert-gas-filled foam) to surround the glass substrate  13  or the second VIG unit  15 . 
     The glazing member  34  may comprise a polymeric material or a polymeric composite comprising a reinforcement phase. The glazing member  34  may be formed via extruding, pultruding or injection molding such a polymeric or composite material, for example, and may include a plurality of support members or ribs  62  that cooperate to form pockets  64 . One or more of the pockets  64  may be filled with air, other gases and/or insulation material  66  to reduce the thermal conductivity of the frame assembly  14 . The insulation material  66  can include foam, rubber, glass microspheres, perlite, aerogel, fused silica, and/or inert-gas-filled foam, for example. In some embodiments, one or more of the ribs  62  may include reinforcement members  46  to provide additional rigidity and strength to the frame assembly  14 . First and second lateral surfaces  68 ,  70  of the glazing member  34  may contact the second glass substrate  20  and cooperate with the base member  32  to securely retain the VIG unit  12  in the frame assembly  14 . In some configurations, two-sided adhesive glazing tape  51  or silicone or silicone-like product is disposed between the first and/or second lateral surfaces  68 ,  70  and the second glass substrate  20 . 
     A lower end of the glazing member  34  may include one or more resiliently flexible tabs  72  that snap into engagement with the base member  32 . The tabs  72  may allow the glazing member  34  to pivot to accommodate distortion of the VIG unit  12  and/or provide for removal of the glazing member  34 . In this manner, the glazing member  34  may be repeatedly snapped into and out of the window assembly  10  on demand, even after the window assembly  10  has been installed into the wall  16  of the building or home. 
     The glazing member  34  may also include a recess (or cavity)  74  formed between the first and second lateral surfaces  68 ,  70 . The recess  74  may receive the vacuum port  24  of the VIG unit  12  and may protect the vacuum port  24  from being damaged. The recess  74  is designed to accommodate distortion of the VIG unit  12  without damaging the vacuum port  24 , or more importantly, without causing the VIG unit  12  to lose its vacuum. The recess  74  may be filled with an insulative material  76  that surrounds the vacuum port  24 . The insulative material  76  can include foam, rubber, glass microspheres, perlite, aerogel, fused silica, and/or inert-gas-filled foam, for example. The insulative material  76  may be compliant enough to allow for relative movement between the vacuum port  24  and the glazing member  34  without damaging the vacuum port  24 , or more importantly, without causing the VIG unit  12  to lose its vacuum. In an alternative embodiment, the second lateral surface  70  of the glazing member  34  does not contact the second glass substrate  20 . Rather, the recess  74  extends from the first lateral surface  68  to the bottom of the slot  36 . As shown in  FIG. 7 , in some configurations, another recess or cavity  75  (similar to the recess  74 ) may be formed in the base member  32  that may receive a vacuum port  25  of the second VIG unit  15 . While the figures show the VIG units  12 ,  15  having outwardly protruding vacuum ports  24 ,  25 , in some configurations, the vacuum ports  24 ,  25  may be substantially flush to the surface of the glass substrate of the VIG unit  12 ,  15 . In other configurations, the VIG units  12 ,  15  may not include the vacuum ports  24 ,  25  at all. Additionally or alternatively, either or both of the first and second glass substrates  18 ,  20  of either or both of the VIG units  12 ,  15  could be laminated substrates (e.g., substrates with laminated layers of glass with a layer of polyvinyl butyral (PVB) between the glass layers). 
     In some warmer climates (such as the southern United States), it is anticipated that the glazing member  34  may be disposed on the exterior side of the VIG unit  12  (i.e., the glazing member  34  may be disposed on the exterior of the building or home) to accommodate distortion of the VIG unit  12  in a direction opposite to what would be experienced in colder climates (such as the northern United States). 
     With reference to  FIGS. 4 and 5 , a coupler  80  is provided that may be used to adapt the VIG unit  12  to a standard window frame assembly  82 . The coupler  80  may include features similar or identical to the frame assembly  14 , such as the recess  48  and the recess  74  to accommodate distortion of the VIG unit  12 . Like the frame assembly  14 , the coupler  80  provides a large bite depth to hinder heat transfer between the first and second substrates  18 ,  20  and prevent the accumulation of condensation on the second glass substrate  20 . As shown in  FIG. 5 , the coupler  80  may be received in or otherwise attached to the frame assembly  82 . Like the frame assembly  14 , walls of the coupler  80  may include reinforcement members, like reinforcement members  46  described above. Insulative gases or materials may fill one or more cavities  84  between ribs  86  of the coupler  80 . 
     The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.