Source: http://www.google.com/patents/US5819499?dq=5,960,411
Timestamp: 2017-11-24 14:29:29
Document Index: 627580894

Matched Legal Cases: ['art.\n12', 'art 82', 'art 86', 'art 94', 'art 98', 'art 98', 'arts 86', 'arts 94', 'arts 86', 'art 94']

Patent US5819499 - Insulating units - Google Patents
A sealed insulating unit including two parallel opposed panes with a spacing and sealing system therebetween defining, with said panes, a sealed gas spaced between them, said spacing and sealing system comprising a spacer frame with a primary seal between each side of the spacer frame and the opposing...http://www.google.com/patents/US5819499?utm_source=gb-gplus-sharePatent US5819499 - Insulating units
Publication number US5819499 A
Application number US 08/570,346
Also published as CA2104818A1, CA2104818C, DE69317340D1, DE69317340T2, EP0586121A1, EP0586121B1, US6370838
Publication number 08570346, 570346, US 5819499 A, US 5819499A, US-A-5819499, US5819499 A, US5819499A
Inventors John Evason, Mervyn John Davies, Kenneth John Pearson
Original Assignee Pilkington Glass Ltd
Patent Citations (46), Non-Patent Citations (11), Referenced by (19), Classifications (9), Legal Events (5)
US 5819499 A
A sealed insulating unit including two parallel opposed panes with a spacing and sealing system therebetween defining, with said panes, a sealed gas spaced between them, said spacing and sealing system comprising a spacer frame with a primary seal between each side of the spacer frame and the opposing pane face and a secondary seal extending between the panes outside the outer peripheral face of the spacer frame characterised in that each primary seal is greater than 0.4 mm thick on construction of the unit and comprises at least 7 grams of sealant material on each side of the spacer frame per metre of the spacer frame length. There is also provided a method of producing a sealed insulating unit including the steps of providing a spacer frame of required size, applying primary sealant to each side face of the spacer frame, assembling the spacer frame with and between two opposed parallel panes so that the spacer frame with the panes defines a gas space therebetween, and, with a primary seal thickness of greater than 0.4 mm on each side of the spacer frame, applying a secondary sealant into a channel between the panes outside the outer peripheral face of the spacer frame and curing said secondary sealant in situ between the panes. There is further provided a spacer for a sealed insulating unit in which in the side walls of the spacer are defined elongate recesses, the dimensions of the recesses being selected such that sufficient primary sealant can be accomodated therein to provide in the sealed insulating unit opposed primary seals each at least 0.4 mm thick.
1. A sealed insulation unit comprising two parallel opposed panes with a spacing and sealing system therebetween, the spacing and sealing system and panes defining a sealed gas spaced, said spacing and sealing system comprising:
a spacer frame comprising an elongate hollow metal member having opposed outer and inner walls connected together by two opposed sides walls, the side walls each defining therein an elongate recess having a section in the form of a trapezium,
a primary seal interposed between each side wall of the spacer frame and the opposing pane, and
a secondary seal extending between the panes outside the outer peripheral face of the spacer frame,
wherein each primary seal is greater than 0.4 mm thick on construction of the unit and comprises at least 7 grams of sealant material on each side of the spacer frame per meter of the spacer frame length.
2. A sealed insulating unit according to claim 1 wherein the trapezium is a regular trapezium.
3. A sealed insulating unit according to claim 2 wherein the trapezium is defined between two inclined wall parts and a central straight wall part having a length shorter than the open side of the recess.
4. A sealed insulating unit according to claim 3 wherein the inclined wall parts are each inclined to the straight wall part at an angle of around 110°.
5. A sealed insulating unit according to claim 4, further comprising in each side wall a laterally outwardly inclined wall connecting between the outer wall and one of the inclined wall parts.
6. A sealed insulating unit according to claim 1 wherein the recess is around 1.5 mm wide.
7. A sealed insulating unit according to claim 1 wherein each recess is located between two side wall edge faces which are substantially laterally level.
8. A spacer for a sealed insulating unit comprising two parallel opposed panes with a spacing and sealing system therebetween, the spacer comprising an elongate hollow metal member having opposed outer and inner walls connected together by two opposed side walls, the side walls each defining therein an elongate recess having a section in the form of a trapezium, the dimensions of the recess being selected so that sufficient primary sealant can be accommodated therein to provide in the sealed insulating unit opposed primary seals each at least 0.4 mm thick.
9. A spacer according to claim 8 wherein the trapezium is a regular trapezium.
10. A spacer according to claim 8 wherein the trapezium is defined between two inclined wall parts and a central straight wall part having a length shorter than the open side of the recess.
11. A spacer according to claim 10 wherein the inclined wall parts are each equally inclined to the straight wall part.
12. A spacer according to claim 11 wherein the inclined wall parts are each inclined to the straight wall part at an angle of around 110°.
13. A spacer according to claim 10 further comprising in each side wall a laterally outwardly inclined wall connecting between the outer wall and one of the inclined wall parts.
14. A spacer according to claim 8 wherein the recess is around 1.5 mm wide.
This application is a continuation of application Ser. No. 08/111,955, filed Aug. 26, 1993 now abandoned.
The present invention relates to sealed insulating units, especially but not exclusively sealed double glazing units, and, in particular, to a form of construction of sealed insulating units which provides an assured long lifetime, to a method of constructing sealed insulating units to achieve an assured long lifetime, and to the use of a thick primary seal to achieve such a lifetime. The present invention also relates to spacer frame constructions for such units.
In a well known form of construction, a sealed double glazing unit comprises two parallel opposed panes of transparent or translucent glazing material, usually but not necessarily glass, with a spacing and sealing system therebetween defining, with the panes, a sealed gas space. The space usually contains air, but selected other gases may be used in place of air to enhance the thermal or acoustic insulating properties of the unit. The spacing and sealing system may comprise a spacer frame, commonly lengths of hollow section spacer, for example of aluminum alloy or plastics, joined by right angled corner keys to form a rectangular frame (or a single length of such hollow section spacer bent to form a rectangular with the free ends joined by a key), a primary seal and a secondary seal. The primary seal is composed of a non setting extrudable thermoplastic material with good adhesion to the spacer frame and panes, an a low moisture vapour transmission, such as polyisobutylene, incorporated between the side walls of the spacer frame and the opposing faces of the panes. The primary seal serves to prevent ingress of moisture vapour between the spacer frame and the panes, and may also assists in the assembly of the unit by securing the spacer frame in position between the panes while the secondary sealant is applied end cured. The secondary sealant is usually a two component material which is initially extruded into a channel defined by the outer peripheral face of the spacer frame and the adjacent faces of the opposing panes, but cures in situ to bond the panes and spacer frame together. The secondary sealant, which is typically of polysulphide, polyurethane or silicone, commonly has good adhesive properties and forms a strong bond to both spacer frame and glass; however, the moisture vapour transmissions of the materials used are generally significantly higher than those of the primary sealants. Thus the gas space of the unit may be better protected from moisture ingress (and consequent condensation on the interior surfaces of the panes defining the gas space) by the use of the additional primary seals as described above between the spacer and the panes.
This form of construction is widely used and gives good results. A drying agent, usually of the kind described as a molecular sieve, may be incorporated within the body of the hollow section spacer constituting the spacer frame and be in communication with the gas space between the panes through orifices in the inner peripheral wall of the spacer. This drying agent absorbs any moisture initially present in the gas in the sealed space between the panes, and is also available to absorb further moisture penetrating through or past the primary and secondary seals. Eventually however, the drying agents become saturated and unable to absorb further moisture so that the moisture content of the gas between the panes increases and water vapour condenses on an internal pane surface; such condensation detracts from ,he appearance of the unit generally being regarded as amounting to failure of the unit and requiring replacement of the unit.
Typical good quality units have a lifetime of at least 10 years to failure, and many are guaranteed for five or even ten years. There is demand for units with a longer lifetime, but manufacturers are reluctant to offer guarantees as they have bee unable to produce units which provide consistently longer lifetimes.
Hitherto, premature failures have generally been associated with poor unit construction, for example, insufficient or poorly mixed secondary sealant, or insufficiently cleaned pines resulting in poor adhesion to the glass, and attempts to provide more reliable and consistent unit Lifetimes have generally concentrated on avoiding such construction deficiences.
The present inventors have found, however, and the discovery forms the basis of the present invention, that a consistently long unit lifetime may be achieved for "twin seal" units of the kind described above by using a thicker primary seal than generally used hitherto or recommended by suppliers of the primary sealant material. Thus, for example, one typical sealant supplier recommends the use of 2.5 grams of primary sealant (on each side of the spacer) per meter of spacer frame length, and that the applied primary sealant strip should be compressed to a thickness of between 0.3 and 0.4 mm on assembly of the unit, the corresponding depth of the sealant strip being 4.5 mm. In practice, unit manufactured tend to use less of the primary sealant material to save cost. Moreover, since the only path for ingress of moisture vapour into the gas space of the unit is between the sides of the spacer and the opposing pane surfaces it has been considered chat a wider gap (corresponding to the thickness of the primary sealant) would lead to greater moisture ingress. The inventors have discovered, however, that the use of a sealant thickness greater than 0.4 mm, preferably at least 0.5 mm, enables a consistently longer unit life to be achieved before the dew point is reached and the unit fails, with a much lower risk of premature failure.
Although, as noted above, it has been usual to use a primary seal thickness of less them 0.4 mm, it has been proposed to use a spacer with pre-applied primary sealant on each side to form the spacer frame to avoid the need for applying the primary seal on tie double gluing production line, for example the VITROFORM (trade mark) insulated glass profile system. This included a spacer with recesses on the side walls thereof to facilitate pre-application of the primary seal material extending into the recesses: the spacer was designed to be bent in one process into a closed rectangular spacer frame avoiding the need for corner keys as described above, and the width of the primary sealant layer on the sides of the spacer was of the order of 1 mm or more before compression between panes. The thick primary seal, which incorporated a core of circular section of about 1 mm diameter, was used to provide thermal separation between the spacer and the glass unit with "surface damping" for improved sound insulation, but there was no suggestion that its use provided an extended unit lifetime. We have measured the amount of sealant material applied to the sidewalls of the VITROFORM spacer, and found an amount of 6.1 grams (excluding the core) on each side of the spacer per meter of spacer length.
Reverting to the present invention, it will be appreciated that the use of a wider seal than is normal, for a constant seal depth, implies the use of a greater amount or seal material, and in a preferred embodiment of the present invention at lease 7 grams of sealant material is used on each side of the spacer frame per meter of spacer length.
According to a second aspect of the invention, there is provided a method of producing a sealed insulating unit comprising providing a spacer frame of required size, applying primary sealant to each side face of the spacer frame, assembling the spacer frame with and between two opposed parallel panes so that the spacer frame with the panes defines a gas space therebetween and, with a primary seal thickness of greater then 0.4 mm, preferably greater than 0.5 mm, on each side of the spacer frame, applying a secondary sealant into a channel between the panes outside the outer peripheral face of the spacer frame and curing said secondary sealant in situ between the panes. The primary sealant will usually, but not necessarily, be used in an amount of at least 4 grams of sealant material on each side of the spacer frame per meter of spacer frame length.
According to a third aspect of the invention, there is provided the use, in a twin seal sealed insulating unit, of a primary seal between each side of a spacer frame and the adjacent opposing pane having a thickness of greater than 0.4 mm on construction of the unit, to extend the reliable lifetime of the unit. In these second and third aspects of the invention, the account of primary seal material is preferably, but not necessarily, at least 7 grams on each side of the spacer frame per meter of spacer length.
In each aspect of the invention, each primary seal preferably has a thickness of up to 1 mm on construction of the unit. Each primary seal preferably comprises 7 to 12 grams, especially 3 to 11 grams, of primary sealant material (more may be used but is not cost effective) on each side of the spacer frame per meter of spacer frame length. The opposite sides of the spacer frame facing the panes may be provided with recesses to accommodate at least part of the primary seal material, and ensure that a desired minimum thickness of primary seal material is retained in position when the unit is assembled.
The spacer configuration 30 shown in FIG. 6 provides the advantage that relatively large recesses 56,58 are provided, because they are semi-circular and initially have the centres of curvature thereof lying within the lateral extremeties of the spacer and so are relatively deep for their width. This means that a relatively large body of primary sealant material can initially be present in the recesses 56,58. This assists in ensuring that a minimum thickness of at least 0.4 mm of primary sealant material extends between the spacer 30 and the respective glass surface. In the regions where the spacer has been bent, the recess configuration is substantially symmetrical about a central common plane through the recesses 56,58 and this assists in ensuring a reproducibly thick seal of primary material.
Referring now to FIG. 7, there is shown an alternative embodiment of a spacer frame in accordance with the invention. The spacer 70 comprises an outer peripheral wall 72 and an inner wall 74 having a thinned portion 76 in a central region thereof through which holes (not shown) may be provided. The outer and inner walls 72,74 are connected by opposed side walls 78,80. Each side wall 78,80 consists, going from the outer peripheral wall 72 to the inner wall 74, of a laterally outwardly inclined part 82,84, a laterally inwardly inclined part 86,88, with there being a respective juncture 90,92 therebetween, a straight part 94,96 and an outward inclined part 98,100 to which respective ends 102,104 of the inner wall are connected. Each inclined part 98,100 has at its laterally outward edge a flat surface 106,108 which is laterally level with the respective juncture 90,92. In an alternative embodiment, the junctures 90,90 are disposed laterally inwardly of the flat surfaces 106,108 to provide gaps through which excess sealant may be hydraulically pumped if required. The inclined parts 86,98 and 88,100 are configured so as to define therebetween, and laterally outwardly of the respective straight parts 94,96, respective recesses 110,112. Each recess 110,112 has a section in the form of a regular trapezium. The inclined parts 86,88 and 98,100 are each inclined at an angle of around 110° to the respective straight part 94,96. Each recess 110,112 is around 1.5 mm wide and 3.8 mm deep.
The spacer 70 shown in FIG. 7 may be formed into a frame by connecting corner pieces, i.e. without being bent but alternatively the spacer 70 may be bent in the manner described hereinabove whilst holding the junctures 90,92 laterally level with the respective faces 106,108. Irrespective of which spacer frame configuration is employed, the spacer 70 is configured so that the recesses 110,112 can contain the desired weight of butyl material prior to pressing. After pressing, as a result of the symmetrical shape of the trapezium section recesses 110,112, any primary sealant which is extruded from the recesses is substantially uniformly extruded both inwardly and outwardly. The symmetrical construction of the recesses provides, during the pressing step, equal hydraulic bending or deforming forces acting on the spacer which tends to prevent bending or bowing of the spacer during the pressing step. Furthermore, the recesses, having a trapezium section, have a relatively deep area where the width of the recess is a maximum amount. This provides a relatively large area over which the primary sealant material is relatively thick in the recess relative to the remainder of the region of the spacer which is in contact with the primary seal. The spacer recess shape assists in ensuring reliable obtaining of a primary sealant thickness of at least 0.4 mm whilst substantially avoiding inadvertent deformation of the spacer during the formation of the double glazing unit.
As is discussed hereinabove, the use of a wider primary seal in accordance with the present invention provides unexpected advantages despite the technical prejudice that existed prior to the present invention against using wide primary seals. Although the primary seal material has good resistance to moisture vapour transmission, it was believed prior to the present invention that the primary seal should be made thin so as to reduce the surface area of the primary seal potentially available for water vapour transmission. However, the present inventors discovered surprisingly that the use of wider primary seals than in the prior art did not lead to increased unit failure compared to the known units as a result of water vapour transmission through the primary seal. In fact, the inventors discovered that by using a thicker seal, the lifetime of the units was increased due to a decrease in water vapour penetration. This is believed to result from a reduced incidence of cohesive failure in the flexible primary seal material as a result of repeated flexing of the unit as a result of pressure/temperature change in the environment to which the unit is subjected. It is believed that the thicker primary seal in accordance with the invention acts to absorb these flexing stresses at the glazing unit edge to a greater degree than the thinner primary seals of the prior art. In addition, the thicker primary seal tends to reduce the absorption of water therein which can lower the elastic modulus of the material which in turn can tend to cause failure of the primary seal.
In particular, when the glazing unit is subjected to an increase in temperature, this can cause an increase in the thickness of the unit at the sealed edge of the unit. This thickness increase results from an expansion of the secondary sealant when it is heated. Typical secondary sealant materials, when heated and subject to stretch, tend to remain stretched to some degree after cooling. The use of a thicker primary seal in accordance with the present invention provides that the primary seal is more likely to accomodate such stretching of the secondary material resulting in a thickness increase of the unit edge without causing a breakdown of the primary seal.
Two 6 mm clear, float glass panes each 510 mm×360 mm were washed and dried and assembled with the spaces frame bearing the primary seal material symmetrically disposed between them, and the opposed panes pressed together to an overall unit thickness of 23.4 mm thereby compressing the primary sealant layer to a thickness of 0.7 mm or greater over a depth of 4.5 mm. The resulting channel 20 defined between the outer face 13 of the spacer frame and the internal face of the opposed panes was filled with Dow Corning (trade mark) Q3-3332 two part silicone as secondary sealant and the sealant cured in situ between the panes at room temperature to produce a completed insulating unit. A batch of ten similar units was made up for testing, and subjected to the following weather test.
At approximately every 50 cycles, the dew point in every unit is measured. A lone life unit construction may be regarded as one where all 10 units of a batch retain dew points of equal to or less than, -40° C. at 500 cycles. In some cases, unit failure is a result of venting that can occur due to a faulty single unit rather than the particular construction.
______________________________________  No of units having dew points           -49° C.                   -39° C.                         -29° C.                               -19° C.                                     -9° C.No of           to      to    to    to    tocycles <-50° C.           -40° C.                   -30° C.                         -20° C.                               -10° C.                                     -1° C.______________________________________50     1098     10140    10195    10246    10293    10______________________________________
and all 10 units retained a dew point below -50° C. when testing was continued to over 1000 cycles.
The thickness measurements showed, surprisingly, an increase in the thickness of the units after the first fifty cycles. This increase was greatest (up to about 0.8 mm) at the corners but still significant (about 0.4 to 0.5 mm) at the centres of the edges, and tended to declines as the weathering tests continued. It is believed the invention operates by providing sufficient primary seal material to accommodate the unexpected expanded thickness while maintaining the integrity of the primary seal and its adhesion to the spacer and the glass.
The procedure of Example 1 was repeated except that the spacer used had a section of 7 mm×11.9 mm and the primacy seal material was extruded onto the opposed side walls at a rate of approximately 3.5 grams per meter of peripheral length of the spacer frame on each side thereon. The opposed panes were pressed together to an overall unit-thickness of 24.5 mm--thereby compressing the primary sealant layer to a minimum thickness of 0.3 mm. with a greater thickness where the primary sealant extends into the recess in the spacer. A batch of ten similar units was made up for testing and subject to the weather test as described above:
______________________________________No of units having dew pointsNo of        -49° C.                -39° C.                      -29° C.                            -19° C.                                  -9° C.cy-  <-50°        to      to    to    to    tocles C.      -40° C.                -30° C.                      -20° C.                            -10° C.                                  -1° C.                                        >0° C.______________________________________59   10110  8       1       1159  6       2       1                       1211  5       3       1                       1256  5       2       1                 1     1309  5       2             1                 2357  5       1             1           1     2403  5       1                   1           3480  3       2                   1           4528  3       1             1           1     4575  1       2             1                 6______________________________________
The results show a steady failure of the units on test until, after 575 cycles, 60% of the units had failed completely. This contrasts sharply with Example 1 (in accordance with invention) in which 100% of the units had maintained a dew point below -50° C. after 1000 cycles.
The procedure of Example 1 was reseated using PRC (trade mark) 469 two part polysulphide as secondary sealant in place of the Dow Corning silicone sealant. As in Example 1, all 10 units maintained a dew point below -50° C. for over 700 cycles. After 728 cycles, one unit was dropped and removed from test. After 868 cycles, the dew point of one unit had risen to a temperature in the range -49° C. to -40° C., the dew point of this unit increased to above 0° C. (unit failure) after 1004 cycles, with the remaining units maintaining dew points below -50° C. to 1004 cycles whereupon testing was terminated.
______________________________________No of units having dew pointsNo of        -49° C.                -39° C.                      -29° C.                            -19° C.                                  -9° C.cy-  <-50°        to      to    to    to    tocles C.      -40° C.                -30° C.                      -20° C.                            -10° C.                                  -1° C.                                        >0° C.______________________________________50   1098   10146  10195  10246  8       2293  8               1                 1341  7       1                               2398  7                                 1     2451  7                                       3506  5               1     1                 3555  4       1                         2     3606  3       1             1                 5650  2       1             1                 6728  2                                       8776  2                                       8825  2                                       8868  2                                       8916  2                                       81004 2                                       8______________________________________
This result, with only 20% of the units surviving to 1000 cycles, contrasts sharply with result of Example 2 in which 80% of the units maintained a dew point below -50° C. after over 1000 cycles (and one of the remaining 2 units failed because it was dropped).
The procedure of Example 2 was repeated using PRC (trade mark) 449 two part polysulphide as secondary sealant in place of the PRC 469 used in Example 2; the PRC 449 has a higher modulus than PRC 469. All 10 test units maintained a dew point below -50° C. or over 1000 cycles, when testing was terminated.
The thickness measurements again showed a geneses increase in thickness. Initially, this was greatest at the aid points of the long edges (around 1 mm after 150 cycles) and least at the mid points of the short edges (around 0.5 mm after 150 cycles) with an intermediate value at the corners. However, as the testing continued, the thickness increased to over 1 mm at the corners after approximately 800 cycles, with smaller, substantially equal, increases at the mid points of the long and short edges.
The procedure of Comparative Example 2 was repeated using PRC (trade mark) 449 too part polysulphide in place of the PRC 469 in Comparative Example 2. The results of the weather tests are set out below:
______________________________________No of units having dew pointsNo of        -49° C.                -39° C.                      -29° C.                            -19° C.                                  -9° C.cy-  <-50°        to      to    to    to    tocles C.      -40° C.                -30° C.                      -20° C.                            -10° C.                                  -1° C.                                        >0° C.______________________________________50   9                                       198   9                                       1146  9                                       1195  9                                       1246  9                                       1293  8                                       1341  9                                       1398  9                                       1451  9                                       1506  8       1                               1555  8               1                       1606  8                     1                 1650  8                                 1     1728  6       1       1                       2776  5       1       1                 1     2825  4       2                         1     3868  3       3                               4916  2       1       2     1                 4965  1       2       1     2                 41004         1       1           1           7______________________________________
One unit vented early in the test procedure; the reason for this was not known, but it may have been due to a flaw in the glass edge. The results contrast sharply with those of Example 3, with 7 units (including the one that had vented) having failed after 1004 cycles, and no units maintaining a dew point below -50° C. to this stage when the tests were terminated. Comparing the results after 650 cycles of Comparative Examples 2 and 3 it appears that, in the absence of the thick primary seal in accordance with the invention, the higher modulus PRC 449 gives a better performance than the lower modulus PRC 469. However, it is notable that, using the higher modulus material (without the thick primary seal), two units had maintained a dew point below -50° C. for over 1000 cycles, whereas no units using the lower modulus material maintained this dew point beyond 1000 cycles. In any event, it is clear that the choice of a particular secondary sealant is relatively unimportant provided a thick primary seal in accordance with the invention is used.
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U.S. Classification 52/788.1, 52/790.1
International Classification E06B3/66, C03C27/06, E06B3/663
Cooperative Classification E06B3/66342, E06B3/66352
European Classification E06B3/663B8R, E06B3/663B8