Patent Description:
insulating glass units (also known as insulating glazing units or "IGUs" or "IGs") and vacuum insulating glass units (also known as vacuum insulating glazing units or "VIGUs" or "VIGs") are known. They comprise two or more parallel but spaced-apart sheets, or panes, of glass attached and/or sealed to one another around their respective peripheries. The gap between each pair of sheets or panes of glass (also known as "lites") defines a cavity. In IGUs, the cavity is filled with air and/or other gasses such as argon, krypton or xenon, whereas in VIGUs, the gap is "filled" with or contains a reduced-pressure atmosphere or a vacuum. Spacers (also known as "stand-offs" or "suspenders") are typically disposed within the gap of IGUs and VIGUs to maintain the gap between the opposing panes. In the case of VIGUs, spacers are particularly necessary in order to support the panes of glass against the pressure of the outside air, which otherwise might distort or damage the glass, or cause the two panes of glass to come in contact with each other so as to produce a thermal "short circuit," which can undesirably provide a thermally conductive path directly through the panes of glass.

Using vacuum to increase the insulating performance of window glazing components is known, and in fact many innovative approaches have been taught in the literature over the last <NUM> years. It is, however, readily observed by skilled practitioners of the art that the majority of the prior work relates to low-to medium-vacuum levels, i.e., vacuum levels within the range from about <NUM> torr (<NUM> atmosphere of pressure at sea level) to about <NUM>-<NUM> torr. For purposes of this application, a "higher" level of vacuum is understood to correspond to a lower absolute pressure, e.g., a vacuum level of <NUM>-<NUM> torr is a higher vacuum than <NUM>-<NUM> torr. While the literature makes infrequent reference to the measured vacuum levels in glazing components, in many cases the maintainable vacuum level must be interpreted from careful evaluation of the materials exposed to the vacuum enclosure, the methods used to create the vacuum seal and the methods used to produce/maintain the vacuum condition in the enclosed space.

While the literature describing vacuum insulating window glazing components may not rigorously define the vacuum levels, literature from other industries, such as the electronics industry, defines different vacuum levels and the types of materials and processing methods required to achieve and maintain those specified vacuum levels. The common distinction between medium and high vacuum devices is a vacuum level of <NUM>-<NUM> torr. In other words, the range of high vacuum levels begins at about <NUM>-<NUM> torr and goes higher, i.e., in the direction toward and/or past <NUM>-<NUM> torr. In the case of vacuum insulating glass units ("VIGUs" or "VIGs") for windows, doors and other components, where it is desirable for the VIGs to retain a prescribed minimum vacuum level for an extended operating lifetime (e.g., <NUM> years), a vacuum containment system capable of initially maintaining a higher level of vacuum (e.g., <NUM>-<NUM> torr to <NUM>-<NUM> torr), may be necessary for the VIG to maintain a desired degree of thermal resistance over its lifetime, i.e., as the contained vacuum degrades.

One purpose of high vacuum insulating glass units ("HVIGUs") is to provide lower levels of heat losses between temperature controlled spaces and non-temperature-controlled spaces, or between different temperature controlled spaces, that are separated by this glazing unit (i.e., compared to VIGUs with low or medium vacuum levels). In such cases, providing this desired lower level of heat transfer over a long period of time is desirable. Since the ambient conditions in the uncontrolled space, most commonly the external atmospheric environment, produce a variety of stresses including thermal, pressure and mechanical vibration, and since, to a lesser extent, this also happens in the conditioned space, various embodiments of the HVIGU will be more or less capable of surviving the applied stresses while maintaining the desired minimum vacuum level. Thus, the design lifetime, i.e., the period of time that the HVIGU will maintain its desired level of performance, is one of the performance features of the HVIGU.

As previously described, IGUs, VIGUs and HVIGUs are typically constructed using at least two spaced-apart sheets or panes of glass, each of some prescribed thickness. The gap between two adjacent glass sheets or panes defines a cavity. In IGUs, the cavity is filled with air or other gasses such as argon, krypton or xenon, whereas in VIGUs and HVIGUs, the gap is "filled" with a reduced pressure atmosphere or a vacuum. Spacers (also known as "stand-offs" or "pillars") are typically disposed within the gap of IGUs, VIGUs and HVIGUs to maintain the gap. In the case of VIGUs and HVIGUs, spacers are particularly necessary in order to support the sheets against the pressure of the outside air, which otherwise might distort or damage the glass, or cause the two panes of glass to come in contact with each other so as to produce an undesirable thermal short circuit.

Conventionally, these glass panes are then sealed, typically along the edges, using some arrangement of sealing elements which are intended to isolate the evacuated volume from the surrounding atmospheric pressure. Since the primary objective of the VIGU or HVIGU is to provide a low thermally-conductive barrier between environmental spaces, each of which may have a higher or lower temperature with respect to the other, it is obvious to skilled practitioners of the art that the two panes of glass may reach temperature levels which vary distinctly from each other. In fact, for a given space-to-space temperature differential, the pane-to-pane temperature differential will typically increase as a function of reduced thermal conductivity of the VIGU or HVIGU. As a result of the temperature differential between the panes of glass, the panes may expand and contract differentially. This may also introduce differential movement of the spacers relative to one or both panes of glass.

Vacuum insulated glass units (VIGUs/HVIGUs) are of interest for window applications and particularly greenhouse window systems because of their extremely high insulating properties, with center-of-glass insulating or thermal resistance R values as high as R- <NUM> or more, expressed in US units of British Thermal Units as ft<NUM> F hr/Btu, which equals to an R value of <NUM>,<NUM>*m<NUM>/W expressed in SI units (conductive U-Values or U-Factors of <NUM> or lower, expressed in US units of BTU/(hr F ft<NUM>), which equals to <NUM>,<NUM> W/(m<NUM>*K) expressed in SI units).

For these and other reasons, there is a need to provide a dynamic multi-pane insulating assembly with center-of-glass insulating or thermal resistance R values as high as R- <NUM> or more with improved dynamic maintenance of the thermal resistance R values at a desired high level over the course of the lifetime of the installation of the assembly in view of the ever changing internal and external environmental factors.

<CIT> discloses a vacuum insulating glass unit with two panes assembled in a spaced-apart configuration so as to have a between-pane space located between them. The between-pane space has a high vacuum. The vacuum insulating glass unit also includes a bleed chamber filled with an insulative gas at a pressure higher than atmospheric pressure and configured such that over time insulative gas from the bleed chamber diffuses into the between-pane space. In particular, document <CIT> discloses a dynamic multi-pane assembly comprising an interior pane that is gas permeable; a first exterior pane spaced from a first side of the interior pane and defining an evacuated gap between the first side of the interior pane and the first exterior pane, the evacuated gap having a predetermined thickness within which a vacuum is drawn; a second exterior pane spaced from a second side of the interior pane and defining a pressurized gap between the second side of the interior pane and the second exterior pane; a vacuum source in communication with the evacuated gap; a source of pressurized gas in communication with the pressurized gap; wherein the source of pressurized gas is pressurized at a set level that is greater than the pressure within the evacuated gap, and wherein gas from the pressurized gap permeates through the interior pane and into communication with the evacuated gap.

Further developments are given in the dependent claims.

The present system provides, among other things, a dynamic multi-pane insulating assembly and system including methods for dynamically maintaining the thermal resistance value of the assembly and system. In one embodiment, the dynamic multi-pane insulating assembly and system comprises:
an interior pane; a first exterior pane; a second exterior pane; a vacuum source; and a source of pressurized gas. In this aspect, an evacuated gap having a predetermined thickness is defined between the interior pane and the first exterior pane into which a vacuum can be drawn. Similarly, the second exterior pane is spaced from the interior pane and defines a pressurized gap between the interior pane and the second exterior pane.

In operation, the vacuum source is placed into communication with the evacuated gap to maintain the vacuum present in the evacuated gap at a desired vacuum level. The source of pressurized gas is placed in communication with the respective pressurized gap to pressurize the gas within the pressurized gap to a desired set level, which is greater than or equal to a barometric pressure of the environment that is external to the dynamic multi-pane insulating assembly and system. Thus, in the closed system, pressurized gas from the pressurized gap permeates through the interior pane, which is gas permeable, and into communication with the vacuum present in the evacuated gap.

In another aspect, the dynamic multi-pane insulating assembly and system further comprises a control assembly that includes a processor that is in communication with the source of vacuum and the source of pressurized gas. A first and second pressure sensor are provided. In this aspect, the first pressure sensor is in communication with the processor and the evacuated gap and the second pressure sensor is in communication with the processor and the pressurized gap. In operation, the processor, in response to sensed pressure from at least one of the first and second pressure sensors, is configured to selectively actuate at least one of the source of vacuum and the source of pressurized gas to maintain a set level of vacuum within the evacuated gap at a desired level.

The control assembly can further comprise a third pressure sensor that is in in communication with the external environment. In this aspect, the processor, in response to sensed pressure from the third pressure sensor and at least one of the first and second pressure sensors can be configured to selectively actuate at least one of the source of vacuum and the source of pressurized gas to maintain the set level of vacuum within the evacuated gap and the set level of pressure within the pressurized gaps at the desired level.

The control assembly can further comprise a fourth pressure sensor that is in in communication with the environment enclosed by the dynamic multi-pane insulating assembly. In this aspect, the processor, in response to sensed pressure from the fourth pressure sensor and at least one of the first, second, and third pressure sensors can be configured to selectively actuate at least one of the source of vacuum and the source of pressurized gas to maintain the set level of vacuum within the evacuated gap and the set level of pressure within the pressurized gaps at the desired level.

Various implementations described in the present disclosure can include additional systems, methods, features, and advantages, which can not necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings.

The features and components of the following figures are illustrated to emphasize the general principles of the present disclosure. Corresponding features and components throughout the figures can be designated by matching reference characters for the sake of consistency and clarity.

The following description of the invention is provided as an enabling teaching of the invention in its best, currently known embodiment.

The present methods and systems can be understood more readily by reference to the following detailed description of preferred embodiments and the examples included therein and to the Figures and their previous and following description.

The present system provides, among other things, a dynamic multi-pane insulating assembly and system <NUM> including methods for dynamically maintaining the thermal resistance value of the assembly and system. In one embodiment, the dynamic multi-pane insulating assembly and system <NUM> comprises an interior pane <NUM>, which is gas permeable; a first exterior pane <NUM>; a second exterior pane <NUM>; a vacuum source <NUM>; and a source of pressurized gas <NUM>. In this aspect, the first exterior pane <NUM> is spaced from a first side <NUM> of the interior pane <NUM> and defines an evacuated gap <NUM> having a predetermined thickness between the interior pane <NUM> and the first exterior pane <NUM> into which a vacuum is drawn. The second exterior pane <NUM> is spaced from a second side <NUM> of the interior pane <NUM> and defines a pressurized gap <NUM> between the interior pane <NUM> and the second exterior pane <NUM>.

Various embodiments of this invention relate to vacuum systems and pressurization systems comprising, without limitation, a plurality of dynamic multi-pane insulating assemblies whose vacuum spaces are connected to one another by ducts or conduits and to one or more vacuum pumps and whose pressurized spaces are connected to one another by ducts or conduits and one or more pressure pumps that operate during the service lives of the plurality of dynamic multi-pane insulating assemblies. A duct or conduit herein is any enclosure capable of allowing gas flow. By way of example only, and without limitation, a duct or conduit may comprise tubing, pipes, valves, pumps, and interconnections and fittings such as tees, flanges, and manifolds. The vacuum and pressurization pumps maintain most of the vacuum spaces and pressurized spaces at service pressures for a time period of indefinite duration or for an indefinite number of time periods of indefinite duration for the purpose of reducing heat conduction and convection through the residual gasses in the vacuum spaces.

In operation, the vacuum source <NUM> is placed into communication with the evacuated gap <NUM> to maintain the vacuum present in the evacuated gap <NUM> at a desired vacuum level. The source of pressurized gas <NUM> is placed in communication with the pressurized gap <NUM> to pressurize the gas within the pressurized gap <NUM> to a desired set level. In one aspect, the set level for the pressurized gap is greater than or equal to a barometric pressure of environment that is external to the dynamic multi-pane insulating assembly and system <NUM>. The set level for the pressurized gap is greater than the pressure existing within the evacuated gap. Thus, in the closed system, pressurized gas from the pressurized gap <NUM> permeates through the respective permeable interior pane <NUM> and into communication with the vacuum present in the evacuated gap <NUM>. As one skilled in the art can appreciate, the vacuum within the evacuated gap <NUM> can be a partial vacuum. In a further operational aspect, the vacuum level within the evacuated gap <NUM> is selectively configured to maintain the thermal resistance of the assembly at a desired level. It is contemplated that there may be some gas losses from the pressurized gap <NUM> to the evacuated gap <NUM> through the gaskets and the like that are used to seal the respective pane of the dynamic multi-pane insulating assembly and system <NUM>, but those gasket losses are minor compared to the gas passage through the gas permeable interior pane <NUM>.

The dynamic multi-pane insulating assembly and system <NUM> theoretically permits heat transfer via visible light while minimizing convective and conductive heat transfer. In the case of convective and conductive heat transfer, the dynamic multi-pane insulating assembly and system <NUM> acts as an insulator. As described herein, the dynamic multi-pane insulating assembly defines an evacuated gap <NUM> between the first exterior pane and the interior pane into which a vacuum can be drawn and the interior pane and the second exterior pane define the pressurized gap <NUM>. In one aspect, it is desired that the evacuated gap <NUM> be sized to create a sufficiently large vacuum chamber volume in order to allow for the desired level of molecular diffusion throughout the vacuum chamber towards the low pressure region or vacuum pump inlet.

In operation, it is contemplated that the relative thickness of the pressurized gap <NUM> can affect the convective heat transfer taking place between the inner face of second exterior pane <NUM> and the second side <NUM> of the interior pane <NUM> in the air regime. In a further aspect, a decrease in the thickness of the pressurized gap <NUM> can result in lower coefficients of convection under a certain threshold thickness.

Increasing the predetermined distance between the inside surface of the interior pane <NUM> and the first exterior pane <NUM> can increase the total thermal resistance (R) by increasing Ivc , as calculated by: <MAT> where,
<IMG>.

In a further aspect, it is contemplated that the pressurized gap <NUM> can be selectively pressurized with dry (i.e., low humidity air as described herein) to an operating pressure level sufficient to negate the water vapor pressure in the surrounding (exterior) environment. For example, assuming ideal gas behavior (valid for P atm< <NUM> atm), the operating pressure level required to negate the water vapor pressure is equal to the external atmospheric pressure. In operation, it is contemplated that pressure source can provide above atmospheric pressure, for example and without limitation, between about <NUM>-<NUM> to about <NUM>-<NUM> ATM gauge pressure, or between about <NUM>-<NUM> to about <NUM>-<NUM> ATM gauge pressure. It is desired to minimize moisture in the system as moisture can degrade the performance and/or structural integrity of the system, especially in those aspects in which the gas permeable pane comprises polymer materials. Thus, it is preferred that the relative humidity of the gas within the system is low as described in more detail herein.

Optionally, in an embodiment in which the set level for the pressurized gap is set to exceed or be greater than the pressure existing within the evacuated gap, it is contemplated that the set level can be less than the exterior barometric level. In this exemplary aspect, the set level of the pressurized gap can range from a negative vacuum pressure to a positive pressure that is greater than or equal to a barometric pressure of environment. In operation, it is contemplated that pressure source can provide gas pressurized between about -<NUM> ATM gauge pressure to about <NUM>-<NUM> ATM gauge pressure.

Service pressure for the evacuated gap <NUM> can mean, without limitation. any gas pressure that significantly reduces heat conduction and convection through a gas or a mixture of gases such as air within the evacuated gap <NUM> and can depend on the dimensions of the vacuum space, which may include, without limitation, the dimensions between the first exterior pane <NUM> and the first side <NUM> of the interior pane <NUM> of the dynamic multi-pane system and/or the elements of a spacer assembly defining the evacuated gap <NUM>. It is contemplated that the gas load for the evacuated gap <NUM> can have multiple sources that may include, without limitation, gas permeation through the gas permeable interior pane <NUM> from the pressurized gases present in the pressurized gap <NUM>; outgassing of gases that have been absorbed in the materials surrounding the evacuated gap <NUM> or materials in communication with the evacuated gap <NUM>; and evolution of gas species and materials generated by the interior panes <NUM>. It is contemplated that the largest source of gas loading for the evacuated gap <NUM> will comprise gas permeation through the gas permeable interior pane <NUM> from the pressurized gases present in the adjoining pressurized gap <NUM>. It is further contemplated that the outgassing from the materials forming the interior pane <NUM> will be negligibly small and thus may not be a factor.

The vacuum source <NUM> can comprise, without limitation, valves, frit screens, temperature sensors, pressure sensors, air compressors, compressed air lines and pneumatically actuated devices, pressure switches, pressure manifolds, relays, solenoids, electrical cable, batteries, electric power generators, pumps, backup pumps, automated control systems, pump controllers, active and passive noise reduction systems, computers, computer cables, and computer programs. In part, and without limitation, it is contemplated that a vacuum source <NUM> can contribute to maintaining the vacuum pressures within the evacuated gap <NUM> of the dynamic multi-pane insulating assemblies by removing gases and gas species that permeate from the pressurized gap <NUM> into the evacuated gap through the materials forming the gas permeable interior pane. In part, and without limitation, it is contemplated that the vacuum source <NUM> can contribute to maintaining the vacuum pressures within the evacuated gap of the dynamic multi-pane insulating assemblies by removing gases and gas species that enter the evacuated gap through leaks or less than perfect seals. In some embodiments, the vacuum source <NUM> comprises at least <NUM>-<NUM> ATM. This includes embodiments in which the vacuum source <NUM> comprises at least <NUM>-<NUM> ATM, at least <NUM>-<NUM> ATM, at least <NUM>-<NUM> ATM, at least <NUM>-<NUM> ATM, or at least <NUM>-<NUM> ATM. In a further optional aspect, the vacuum source <NUM> can comprise between about <NUM>-<NUM> ATM to about <NUM>-<NUM> ATM.

Similarly, it is contemplated that the source of pressurized gas <NUM> can comprise, without limitation, valves, frit screens, temperature sensors, pressure sensors, air compressors, compressed air lines and pneumatically actuated devices, relays, solenoids, electrical cable, batteries, electric power generators, pumps, backup pumps, automated control systems, pump controllers, active and passive noise reduction systems, computers, computer cables, and computer programs. In part, and without limitation, it is contemplated that the source of pressurized gas <NUM> can contribute to maintaining the gas pressure within the pressurized gap <NUM> of the dynamic multi-pane insulating assemblies at a desired level to ensure that the gases can permeate into the evacuated gap. In some embodiments, the source of pressurized gas <NUM> comprises providing pressurized gas at a set level greater than <NUM> atmosphere (ATM). This includes embodiments in which the source of pressurized gas <NUM> provides pressurized gas at a set level between about <NUM> ATM to about <NUM> ATM (about <NUM> pascals to about <NUM> pascals, and preferably between about <NUM> ATM to about <NUM> ATM (about <NUM>,<NUM> pascals to about <NUM>,<NUM> pascals).

In one aspect, the pressurized gas can comprise, without limitation, one or more of: air, nitrogen, argon, krypton, xenon and the like. If the pressurized gas comprises air, it is contemplated that the pressurized air supplied to the pressurized gaps <NUM> will comprise air having a relatively low humidity. For this disclosure, relatively low humidity is defined as a humidity of less than about <NUM>%, preferably, less than about <NUM>%, more preferably less than about <NUM>%, and still more preferred, less than about <NUM>%. In another aspect, relatively low humidity can be defined as a humidity of between about <NUM> to <NUM> %. Optionally, it is contemplated that pressurized air entering the pressurized gap <NUM> can pass through a conventional desiccant device to ensure that the relative humidity of the pressurized gas entering the respective first and second pressurized gaps has the desired relatively low humidity value.

In one aspect, the interior pane <NUM> can be formed of a substantially transparent material that is formed into a sheet. In one non-limiting example, it is contemplated that the interior pane <NUM> can comprise a polymer material, such as acrylic, polycarbonate, and the like. The polymer material can also comprise polymer materials containing low concentrations of strength enhancing particles or, optionally, composite systems containing the aforementioned exemplary polymer materials positioned in alternate layers with polyethylene terephthalate and the like. The sheet forming the interior pane <NUM> can comprise, without limitation, any polymeric material that is preponderantly flat with a substantially even thickness but which may also have raised or contoured areas in regions that may function to maintain a space and separation between the otherwise flat and even thickness regions of the interior pane <NUM> and the first exterior pane <NUM>.

Optionally, as shown in <FIG>, the sheet forming the interior pane <NUM> can comprise, without limitation, any polymeric material that has a convex shape in cross-section (with the apex of the convex portion being positioned closer to the second exterior pane <NUM> than the first exterior pane <NUM> in a static, un-loaded position) with a substantially even thickness but which may also function to maintain a space and separation between the otherwise flat and even thickness regions of the interior pane <NUM> and the first exterior pane <NUM>. In this aspect, it is contemplated that the application of pressure in the pressurized gap <NUM> and vacuum to the evacuated gap <NUM> will urge the interior pane to bias inwardly toward the first exterior pane <NUM>. In one preferred aspect and as shown in the loaded condition in <FIG>, the application of pressure in the pressurized gap <NUM> and vacuum to the evacuated gap <NUM> will urge the interior pane <NUM> to bias inwardly toward the first exterior pane <NUM> such that the interior pane <NUM> is substantially planer. In another preferred aspect, the application of pressure in the pressurized gap <NUM> and vacuum to the evacuated gap <NUM> will urge the interior pane <NUM> to bias inwardly toward the first exterior pane <NUM> such that the interior pane <NUM> is spaced from and maintains separation between the otherwise flat and even thickness regions of the interior pane <NUM> and the first exterior pane <NUM>.

It is contemplated that a sheet forming the gas permeable pane can have coatings and/or films applied thereto all or respective portions of the sheet. Such coatings and/or films can include, without limitation light diffusing, Ultraviolet, and/or infrared coatings and/or films. Optionally, the permeable interior pane can have active and or passive devices or components imbedded within it or attached to a surface.

Optionally, it is contemplated that the interior pane <NUM> can be formed of glass material that can comprise, without limitation, comprise tempered glass; laminated glass, such as, for example, glass sheets bonded together by a polymer, electrochromic glass, photochromic glass, and the like.

In one aspect, the interior pane <NUM> has a predetermined thickness (GPPt). In some embodiments, the predetermined thickness of the interior pane <NUM> can comprise at least <NUM> millimeters. This includes embodiments in which predetermined thickness of the interior pane <NUM> comprises at least <NUM> millimeters, at least <NUM> millimeters, or at least <NUM> millimeters. Alternatively, it is contemplated that the predetermined thickness of the interior pane <NUM> can be between about <NUM> millimeters to about <NUM> millimeters, preferably between about <NUM> millimeters to about <NUM> millimeters, and more preferred between about <NUM> millimeters to about <NUM> millimeters.

In another aspect, the respective first and second exterior panes <NUM>, <NUM> can be formed of a substantially transparent material. In one non-limiting example, it is contemplated that the first and second the first and second exterior panes <NUM>, <NUM> can comprise a glass material formed into a glass sheet. The glass material can, without limitation, comprise tempered glass; laminated glass, such as, for example, glass sheets bonded together by a polymer, electrochromic glass, photochromic glass, and the like. The respective glass sheets forming the first and second exterior panes <NUM>, <NUM> can comprises, without limitation, any glass material that is preponderantly flat with substantially even thickness but which may also have raised or contoured areas in regions that may function to maintain a space and separation between the otherwise flat and even thickness regions of the first and second exterior panes <NUM>, <NUM> and the flat and even thickness regions of the respective first and second side <NUM>, <NUM> of the adjacent interior pane <NUM>. It is contemplated that a glass sheet can have coatings applied thereto all or respective portions of the sheet. It is also contemplated that the glass sheet can have active and or passive devices or components imbedded within it or attached to a surface.

Optionally, like the previously described interior pane <NUM>, it is contemplated that at least one of the first and second exterior panes <NUM>, <NUM> can comprise a polymer material, such as acrylic, polycarbonate, and the like, that is formed into a sheet. For example, and not meant to be limiting, it is contemplated that the first exterior pane <NUM> can comprise a glass material formed into a glass sheet and the second exterior pane <NUM> can comprise a polymer material, such as acrylic, polycarbonate, and the like, that is formed into a sheet. In a further example, the first exterior pane <NUM> can comprise a polymeric material such as polycarbonate, polymethyl methacrylate, or polyethylene terephthalate. In this exemplary aspect, the first exterior pane <NUM> can have a substantially greater thickness than the gas permeable interior pane <NUM> in order to substantially decrease the amount of air permeation through the first exterior pane <NUM> relative to internal pane <NUM>.

In these exemplary aspects, the glass material that can comprise, without limitation, tempered glass; laminated glass, such as, for example, glass sheets bonded together by a polymer, electrochromic glass, photochromic glass, and the like, and the polymer material can comprise polymer materials containing low concentrations of strength enhancing particles or, optionally, composite systems containing the aforementioned exemplary polymer materials positioned in alternate layers with polyethylene terephthalate and the like.

Each of the respective first and second gas exterior panes has a predetermined thickness (EXPt). Optionally, the respective first and second exterior panes <NUM>, <NUM> can have the same or different predetermined thicknesses. In some embodiments, the predetermined thickness of the first and second exterior panes comprises at least <NUM> millimeter. This includes embodiments in which predetermined thickness of the first and second exterior panes <NUM>, <NUM> comprises at least <NUM> millimeters, at least <NUM> millimeters, or at least <NUM> millimeters. Alternatively, it is contemplated that the predetermined thickness of the first and second exterior panes can be between about <NUM> millimeter to about <NUM> millimeters, preferably between about <NUM> millimeters to about <NUM> millimeters, and more preferred between about <NUM> millimeters to about <NUM> millimeters.

In various optional aspects, the predetermined thickness (EGt) of the evacuated gap <NUM> can be between about <NUM> to about <NUM> millimeters; between about <NUM> to about <NUM> millimeters; between about <NUM> to about <NUM> millimeters, and preferably between about <NUM> to about <NUM> millimeters. In another aspect, the predetermined thickness (EGt) of the evacuated gap <NUM> can be between about <NUM> to about <NUM> millimeters.

Similarly, it is contemplated that the pressurized gap <NUM> can have a predetermined thickness (PGt) of between about <NUM> to about <NUM> millimeters; between about <NUM> to about <NUM> millimeters between about <NUM> to about <NUM> millimeters; and preferably between about <NUM> to about <NUM> millimeters. Further, the predetermined thickness of the evacuated gap <NUM> can be substantially the same or differ from the predetermined thickness of the pressurized gap <NUM>.

In an optional aspect, the dynamic multi-pane assembly can further comprise a spacer assembly disposed between the first exterior pane <NUM> and the first side <NUM> of the interior pane <NUM> for maintaining the desired predetermined thickness of the evacuated gap <NUM>. In one aspect, it is contemplated that the spacer assembly can be configured to float with respect to the interior pane <NUM>. The spacer assembly can comprise, without limitation, any physical element or number of elements that contribute to resisting the collapse of the evacuated gap <NUM> under the total or partial compressive load of the applied vacuum. For example, and without limitation, the spacer assembly can comprise discrete spacers of any size or shape arranged in any pattern in between the first exterior pane <NUM> and the first side <NUM> of the interior pane <NUM>, which can be totally or partially optically clear. In a further aspect, discrete spacers for dynamic multi-pane assembly can include any portion of a spacer assembly comprising individual spacers that, excluding any connections to a gas permeable pane, are unconnected and that are arranged in some pattern in between the first exterior pane <NUM> and the first side <NUM> of the interior pane <NUM>.

In another aspect, the dynamic multi-pane insulating assembly and system <NUM> further comprises a control assembly <NUM> that includes a processor <NUM> that is in communication with the vacuum source <NUM> and the source of pressurized gas <NUM>. The vacuum source <NUM> and/or the source of pressurized gas <NUM> are configured to be controlled to operate continuously or under active control to maintain vacuum pressure within the evacuated gap <NUM> at a desired level and/or the pressures within the pressurized gap <NUM> at a desired set level.

The dynamic multi-pane insulating assembly and system <NUM> further comprises a first and second pressure sensor <NUM>, <NUM>. In this aspect, the first pressure sensor <NUM> is in communication with the processor and the evacuated gap <NUM> and the second pressure sensor <NUM> is in communication with the processor and the pressurized gap <NUM>. In operation, the processor <NUM>, in response to sensed pressure from at least one of the first and second pressure sensors, is configured to selectively actuate at least one of the vacuum source <NUM> and the source of pressurized gas <NUM> to maintain a set level of vacuum within the evacuated gap <NUM> and a set level of pressure within the pressurized gap <NUM> at desired levels.

The control assembly <NUM> can further comprise a third pressure sensor <NUM> that is in in communication with the external environment. In this aspect, the processor <NUM>, in response to sensed pressure from the third pressure sensor <NUM> and at least one of the first and second pressure sensors can be configured to selectively actuate at least one of the vacuum source <NUM> and the source of pressurized gas <NUM> to maintain the set level of vacuum within the evacuated gap <NUM> and a set level of pressure within the pressurized gas <NUM> at the desired levels.

The control assembly <NUM> can further comprise a fourth pressure sensor <NUM> that is in in communication with the environment enclosed by the dynamic multi-pane insulating assembly <NUM>. In this aspect, the processor <NUM>, in response to sensed pressure from the fourth pressure sensor <NUM> and at least one of the first, second, and third pressure sensors can be configured to selectively actuate at least one of the vacuum source <NUM> and the source of pressurized gas <NUM> to maintain the set level of vacuum within the evacuated gap <NUM> and a set level of pressure within the pressurized gap <NUM> at the desired levels.

The dynamic multi-pane assembly <NUM> further comprises a frame <NUM> into which the interior pane <NUM> and the respective first and second exterior panes <NUM>, <NUM> are spaceably and sealably mounted. It is further contemplated that the sheets of the interior pane <NUM> and the respective first and second exterior panes <NUM>, <NUM> can be hermetically sealed with respect to the frame <NUM> via conventional IGUs, VIGUs and HVIGUs construction methodologies and materials. By way of example only, and without limitation, an edge seal for hermetically sealing the respective sheets of the interior pane <NUM> and the respective first and second exterior panes <NUM>, <NUM> to the frame can comprise a polymer that can further include any of the edge seal technologies currently used for inert gas filled insulating glass units and may include composite, foam, and thermoplastic types of hermitical seals.

In various optional aspects it is contemplated that the interior pane <NUM> and the respective first and second exterior panes <NUM>, <NUM> can be spaceably and sealably mounted within the dynamic multi-pane assembly <NUM> by use of manufacturing processes such as, without limitation, glass pack methodologies; extrusion; and floating gasket methodologies (to form the floating gasket configuration illustrated in <FIG>). Using glass pack manufacturing processes, the interior pane <NUM> and the respective first and second exterior panes <NUM>, <NUM>, which comprise three polymeric sheets, can be attached to polymeric frame spacers in a stacking process to create a composite sash that holds the three polymer sheets together. Similarly, an extruded manufacturing process provides for a cross section that is similar to the formed glass pack composite sash configuration and the resulting formed dynamic multi-pane assembly <NUM> can include the extruded lengths of the polymeric interior pane <NUM> and the respective polymeric first and second exterior panes <NUM>, <NUM> that are capped on the respective ends to seal the evacuated gap <NUM> and the pressurized gap <NUM>. In another exemplary method, float gasket manufacturing processes can form a dynamic multi-pane assembly <NUM> in which respective polymeric interior pane <NUM> and the respective first and second exterior panes <NUM>, <NUM>, which are formed from glass, are mounted in a frame using gaskets in order to compensate for the thermal expansion differences between the polymer interior pane <NUM> and the glass sheets (first and second exterior panes <NUM>, <NUM>).

In one aspect, and as schematically illustrated in <FIG>, a thermal resistant system <NUM> can further comprise a plurality of dynamic multi-pane assemblies <NUM>. In this aspect, the thermal resistant system can further comprise at least one vacuum duct <NUM> in communication with the vacuum source <NUM> and the evacuated gaps <NUM> of the plurality of dynamic multi-pane assemblies and at least one pressure duct <NUM> in communication with the source of pressurized gas <NUM> and the pressurized gaps <NUM> of the plurality of dynamic multi-pane assemblies.

In one example, and not meant to be limiting, the at least one vacuum duct <NUM> can be connected to a vacuum pump or multiple vacuum pumps. It is contemplated that one or more vacuum valves can be provided within the at least one vacuum duct, which can be selectively closed to isolate the vacuum ducts of the coupled dynamic multi-pane assemblies from the atmosphere. In this aspect, closing the vacuum valves allows for the maintenance of vacuum pressures in the evacuated gaps of the coupled dynamic multi-pane assemblies for some period of time, allowing the coupled pump(s) to be turned off for service or removed for replacement. Additional vacuum valves can be provided that can be configured to be selectively closed as a safety measure if there is a likelihood of a power failure. For example, and without limitation, it is contemplated that the vacuum valves can be selectively closed if there is a likelihood of a power failure or of damage to any of the dynamic multi-pane assemblies, if service needs to be performed on the thermal resistant system, there is a system failure, an anticipated or increased likelihood of a system failure, an event that could precipitate a system failure, or an anticipated event that could precipitate a system failure.

It is contemplated that the at least one vacuum valve can be remotely controlled via the processor. For example, and without limitation, the at least one vacuum valves can comprise conventional vacuum valves that are configured to the actuated to selectively close and or open manually, using compressed air, electrical energy (solenoid, motor), spring, or combination of these methods.

Optionally, at least one pressure sensor can be provided in the at least one vacuum duct, which is in communication with the processor, that is configured to initiate a signal to close the vacuum valve if the pressure begins to rise faster than a set rate or exceeds a set value.

Similarly, without limitation, the at least one pressure duct <NUM> can be connected to a pressure pump or multiple pressure pumps. It is contemplated that one or more pressure valves can be provided within the at least one pressure duct, which can be selectively closed to isolate the pressure ducts of the coupled dynamic multi-pane assemblies from the atmosphere. In this aspect, closing the pressure valves allows for the maintenance of gas pressures in the pressurized gaps of the coupled dynamic multi-pane assemblies for some period of time, allowing the coupled pressure pump(s) to be turned off for service or removed for replacement. Additional pressure valves can be provided that can be configured to be selectively closed as a safety measure if there is a likelihood of a power failure. For example, and without limitation, it is contemplated that the pressure valves can be selectively closed if there is a likelihood of a power failure or of damage to any of the dynamic multi-pane assemblies, if service needs to be performed on the thermal resistant system, there is a system failure, an anticipated or increased likelihood of a system failure, an event that could precipitate a system failure, or an anticipated event that could precipitate a system failure.

It is contemplated that the at least one pressure valve can be remotely controlled via the processor. For example, and without limitation, the at least one pressure valves can comprise conventional pressure valves that are configured to the actuated to selectively close and or open manually, using compressed air, electrical energy (solenoid, motor), spring, or combination of these methods.

Optionally, at least one pressure sensor can be provided in the at least one pressure duct, which is in communication with the processor, that is configured to initiate a signal to close the pressure valve if the pressure begins to fall faster than a set rate or exceeds a set value.

Any valve within the thermal resistant system can be independently open or closed while other valves in the thermal resistant system remain open or closed as desired. Thus, it is contemplated that number or combination of vacuum/pressure valves within the thermal resistant system can be selectively closed while others remain selectively open. Further, any vacuum/pressure valve within the thermal resistant system may be actuated to selectively close or open manually, remotely, or automatically as desired or according to some system parameter such as vacuum pressure, gas pressure, temperature, and the like.

The vacuum/pressure valve within the thermal resistant system <NUM> can be any commercially available vacuum valve or valve known in the art. Further, it is contemplated that any technologies, any processes, or any methods any of which are known in the art of vacuum/pressure engineering and vacuum/pressure systems can be employed in a thermal resistant system of the present invention that comprises a plurality of dynamic multi-pane assemblies.

The thermal resistant system <NUM> can provide a means for isolating one or more dynamic multi-pane assemblies in the event that affected dynamic multi-pane assembly's vacuum chamber is compromised. The means for isolating one or more dynamic multi-pane assemblies can comprise a tee valve that is placed in fluid communication with each dynamic multi-pane assembly <NUM>. The tee valve can be electrically coupled to and selectively controlled via the control assembly <NUM> so that the thermal resistant system <NUM> can selectively isolate the failed dynamic multi-pane assembly <NUM> from the system. Optionally, it is contemplated that selectively controlled tee valves can be assigned to pluralities of dynamic multi-pane assemblies <NUM>, such as, for example and without limitation, to one of every ten panels, or one of every twenty panels, or one of every thirty panels, and the like, so that potentially failed dynamic multi-pane assemblies <NUM> can be identified by the thermal resistant system <NUM> by the identification and isolation of the respective section of the system. It is further contemplated that the control assembly be programmed or otherwise configured to use sorting algorithms to isolate the section of the thermal resistant system <NUM> containing the failed dynamic multi-pane assemblies <NUM>.

In a further optional aspect, the thermal resistant system <NUM> can further comprise a means for removing and/or reducing accumulation of snow thereon the respective exterior panes of the dynamic multi-pane assemblies <NUM> that form the thermal resistant system <NUM>. As one will appreciate, in substantially non-vertical applications, such as for skylights, greenhouses, and the like, the transparent exterior panes of the dynamic multi-pane assemblies <NUM> can accumulate significant amounts of snow in certain environments due to the high R-value of the dynamic multi-pane assemblies <NUM> forming the thermal resistant system <NUM>, which can pose both structural and operational problems. Structurally, allowing large amounts of snow to accumulate increases the weight or load on the underlying structure and the respective dynamic multi-pane assemblies <NUM> and operationally, resting snow can block the desired passage of adequate sunlight from passing through the dynamic multi-pane assemblies <NUM> and into the formed enclosure. The means for removing and/or reducing accumulation of snow provides the application of warm air from the interior volume of the enclosed structure to be selectively placed into fluid communication with the respective exterior pressurized gaps of the affected dynamic multi-pane assemblies <NUM>. Operationally, the means for removing and/or reducing accumulation of snow can comprise the steps of turning on the compressor, and opening a pressurized air source shut-off valve as well as a pressurized chamber release valve. Optionally, heating elements can be integrated into the external pressurized air plumbing network to ensure that the warm air being supplied to the pressurized gaps of the affected dynamic multi-pane assemblies <NUM> is heated to a desired temperature.

It is contemplated that the high R-value of the dynamic multi-pane assemblies <NUM> forming the thermal resistant system <NUM>, as shown in the exemplary test data provided below, can be attributed to the vacuum provided in the evacuated gap <NUM>. It is further contemplated that the maintenance of a higher level of vacuum in the evacuated gap <NUM> can provide greater resistance to heat transfer across the multi-pane assembly.

Referring now to <FIG>, it is anticipated that moisture may leak into the system or permeate through the external pane. In this aspect, the control assembly of the multi-pane insulating assembly can include a humidity and/or moisture sensor capable of providing an input signal for a feedback control to affect the rate of dry gas passing into and through the pressurized gap. In this aspect, the control assembly can be configured to receive at least one signal from a moisture sensing circuit and at least one signal from a pressure sensing circuit. The signal outputs can include a signal sent to the pressurized air source shut-off valve, pressurized chamber release valve, and/or a signal to power the compressor. In operation, if moisture is sensed in the system beyond a desired threshold, the pressurized air source shut-off valve will open, the pressurized chamber release valve will open, and a signal will turn the compressor's power on. Subsequently, once the moisture within the system is sensed within the desired range, the pressurized air source shut-off valve will close, the pressurized chamber release valve will close, and a signal will turn the compressor's power off. It is contemplated that the purge process will be used intermittently to insure desired moisture levels are present within the pressurized gap.

Claim 1:
A dynamic multi-pane assembly (<NUM>) comprising:
an interior pane (<NUM>) that is gas permeable;
a first exterior pane (<NUM>) spaced from a first side (<NUM>) of the interior pane (<NUM>) and defining an evacuated gap (<NUM>) between the first side (<NUM>) of the interior pane (<NUM>) and the first exterior pane (<NUM>), the evacuated gap (<NUM>) having a predetermined thickness within which a vacuum is drawn;
a second exterior pane (<NUM>) spaced from a second side (<NUM>) of the interior pane (<NUM>) and defining a pressurized gap (<NUM>) between the second side (<NUM>) of the interior pane (<NUM>) and the second exterior pane (<NUM>);
a vacuum source (<NUM>) in communication with the evacuated gap (<NUM>);
a source of pressurized gas (<NUM>) in communication with the pressurized gap (<NUM>);
a control assembly (<NUM>) comprising:
a processor (<NUM>) in communication with the source of vacuum (<NUM>) and the source of pressurized gas (<NUM>);
a first pressure sensor (<NUM>) in communication with the processor (<NUM>) and the evacuated gap (<NUM>); and
a second pressure sensor (<NUM>) in communication with the processor (<NUM>) and the pressurized gap (<NUM>),
wherein the processor (<NUM>), in response to sensed pressure from at least one of the first and second pressure sensors (<NUM>; <NUM>), is adapted to selectively actuate at least one of the source of vacuum (<NUM>) and the source of pressurized gas (<NUM>) to maintain a set level of vacuum within the evacuated gap (<NUM>) and a set level of pressure within the pressurized gap (<NUM>) of the dynamic multi-pane assembly (<NUM>) at respective desired levels, wherein the source of pressurized gas (<NUM>) is pressurized at a set level that is greater than the pressure within the evacuated gap (<NUM>), and wherein gas from the pressurized gap (<NUM>) permeates through the interior pane (<NUM>) and into communication with the evacuated gap (<NUM>).