Stock material or miscellaneous articles – Light transmissive sheets – with gas space therebetween and...
Reexamination Certificate
1998-05-01
2001-12-11
Loney, Donald (Department: 1772)
Stock material or miscellaneous articles
Light transmissive sheets, with gas space therebetween and...
C428S081000, C428S192000, C156S107000, C156S109000, C052S786130
Reexamination Certificate
active
06329030
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to composite insulated glass assemblies, and more particularly to a method of improving the integrity and effectiveness of the seal between spaced apart substrates in a glass assembly, and to assemblies having the improved seal. The invention relates in particular to seals formed wholly of flexible polymers having insulative qualities, and to glass assemblies featuring a relatively simple fabrication process.
BACKGROUND OF THE INVENTION
The manufacture of composite insulated glass assemblies by applying a spacer between spaced glass substrates at the periphery of the substrates is well known. The majority of commercially available spacers comprise a rigid metal structure, which may also incorporate an insulating polymeric layer. Increasingly, spacers fabricated entirely of resilient flexible polymeric material are used for their improved insulating and sealing abilities. However, after application of the spacer, there may be a peripherally extending gap. A major problem can occur at corners and/or at the joints between the adjacent ends of the spacer, and in fact at any position where the cross section of the spacer is reduced. This problem has been addressed in the past by costly and labor-intensive solutions. For example, metal composite spacers typically feature a butt joint at each corner at the intersection between adjacent spacers. The abutting spacers are joined by means of an insert or a mating structure. This arrangement is subject to eventual leakage as the window shifts, and is labor-intensive to assemble. In a resilient flexible spacer, to provide for a relatively sharp corner at the window corners, the spacer can form separate lengths that join at one or more corners. Alternatively, the spacer may be cut partway through to permit the spacer to describe a sharp bend.
As is well known, any discontinuity in the spacer creates significant energy losses and results in a weak spot through which moisture can leak. Previously, it has been proposed that taping be used or alternatively simply applying a filler material which is not bonded to the spacer.
A further limitation of the prior art resides in the position of the spacer relative to the periphery of the glass substrates. Conventional polymeric spacers comprise a generally unitary body and it is difficult to maintain a gas impermeable seal between the spacer and the glass substrates. Conventionally, the seal is improved by maintaining a space between the periphery of the spacer and the periphery of the glass substrates, and applying a substantially impermeable backspace material within this gap, about the entire periphery of the assembly. Accordingly, it is desirable to provide a method for fabricating an assembly with a flexible polymeric, insulating spacer that eliminates the need to backfill the entire periphery of the glass assembly. This may be accomplished if the spacer includes an at least partial discontinuity at the corners, thus permitting a relatively sharp bend of the spacer and positioning of the spacer substantially adjacent to the periphery of the glass substrates. The discontinuity may be introduced if specific steps are taken to ensure that the thermal integrity of the spacer is not compromised at the discontinuity. As well, an improved spacer may be used in an assembly, wherein the spacer incorporates a substantially gas-impermeable vapour barrier membrane and is characterized by an improved seal. The use of such a spacer, permits the spacer to be positioned substantially adjacent to the periphery of the glass thus substantially eliminating the need to backfill about the entire periphery of the assembly.
SUMMARY OF THE INVENTION
It is a prime objective of the present invention to provide a method of positioning a sealant material capable of chemically fusing with the spacer material, at positions where the cross section of the spacer is reduced, or there exists a gap between spacer segments, and to provide assemblies embodying sealant material chemically fused to the spacer material.
A further object is to provide a method of assembling an insulating glass assembly featuring a polymeric insulating spacer whereby backfill between the periphery of the spacer and the periphery of the substrates is required only partway around the periphery of the structure.
In one aspect, the present invention comprises a method of forming an insulated glass assembly including a pair of substrates with corners, comprising the steps of:
positioning a continuous length of flexible insulating polymeric spacer between the substrates about the periphery of the substrates, said spacer defined by an exterior face and an interior face;
wherein the spacer is characterized by at least one at least partial discontinuity adjacent at least one corner;
providing a sealant material having a melting point lower than a melting point of the spacer, the sealant comprising a material chemically compatible with the spacer and capable of fusing therewith; and
introducing melted sealant material into contact with the spacer at corner substantially filling the discontinuity to form a generally integral one piece fused gas impervious junction between the spacer and the sealant material to restore the coefficient of thermal conductivity of the corner portions to substantially equal or exceed the coefficient of thermal conductivity of the continuous length of the spacer material. The spacer may be incised to create a Vee-shaped opening facing the exterior of the assembly at the corner of the assembly.
Conveniently, the spacer comprises a multicomponent structure featuring a first layer comprising a resilient insulating material and a second layer comprising a flexible substantially gas impervious layer. The spacer is positioned on the substrates such that the first layer faces the perimeter of the assembly and the second layer faces the interior of the assembly, with the discontinuity extending substantially through the first layer but not into the second layer.
Further, the spacer may remain substantially free from contact with the sealant except at one or more corners, where the sealant is applied to fill in discontinuities within the spacer.
In another aspect, the invention comprises a composite insulated glass assembly having corners and corner angles and comprising:
a pair of glass substrates in spaced relation, each defined by corners and an outer edge at the perimeter thereof;
an insulating spacer body between and spacing the substrates, the spacer body featuring an at least partial discontinuity therein generally adjacent at least one of said corners; and sealant material within said discontinuity in contact with and bonded to the spacer body. The spacer body is substantially free from contact with the sealant material except at the corners of the assembly.
It will be noted that the term “glass” as used herein includes substitutes such as Plexiglass™.
The invention will be fully understood by the description of certain embodiments, in conjunction with the accompanying drawings.
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Loney Donald
McFadden Fincham
LandOfFree
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