Stock material or miscellaneous articles – Light transmissive sheets – with gas space therebetween and...
Reexamination Certificate
2002-05-28
2003-09-02
Loney, Donald J. (Department: 1772)
Stock material or miscellaneous articles
Light transmissive sheets, with gas space therebetween and...
C428S913000, C052S786130, C165S049000, C126S618000, C126S619000, C156S109000
Reexamination Certificate
active
06613404
ABSTRACT:
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention generally relates to stock material such as light transmissive sheets with gas space between and a sealed edge, such as a double glazed storm window. Similarly, the invention generally relates to static structures such as a composite prefabricated panel including adjunctive means. More specifically, the static structure may have a sandwich or hollow structure with sheet-like facing members, especially parallel transparent panes such as a double glass window panel. The invention also relates to an internal spacer between parallel transparent panes. The static structure may be a hermetically sealed opaque or transparent panel. In a further aspect, the invention generally relates to adhesive bonding and methods for surface bonding and assembly, especially for making a multi-pane glazing unit with air-spaced panes.
2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
Insulating glazing (“IG”) structures include double glazed windows and other multi-pane glazing units. These structures are ubiquitous in modern architectural construction, both residential and commercial, where they are commonly found as windows, glass walls, and doors. A primary technological problem faced by IG units is their low insulating value, relative to many other types of insulated panel and wall structures. In both hot and cold climate conditions, a low insulating value results in energy loss from a building that is either heated or cooled by an energy consuming system, such as a heating system or a cooling system that directly or indirectly consumes fuel. On a broad scale, the challenge presented by IG structures is to reduce energy loss through them and to reduce the resultant higher costs for basic utilities in the buildings using IG structures.
Typically, an IG unit is formed of two or more glass panes, spaced apart by a mechanical spacer to form a central air space or interlayer, and sealed at the peripheral edge of the panes to prevent entry of humidity. In substantially all commercial IG units, the central air space is a dead air space, because the IG unit is sealed as a static unit, with no opportunity for exchange of gas from this central space. Although terms such as “air” and “air space” are commonly used in connection with the internal central space of an IG unit, unless context dictates otherwise these terms do not imply that the gas is or should be limited to the mixture commonly referred to as air. As described below, one or more specific gasses other than ordinary air are used to fill the air space. Most commonly the construction of an IG unit is a hermetically sealed glazing assembly in which two similarly sized glass panels, which may be defined as interior and exterior panes, are bonded along their corresponding edges by structural sealants and moisture barriers to opposing surfaces of a central parametric spacer tube. The spacer often is about one-half inch (13 mm) by ⅜ inch (10 mm) thin wall metallic tube, which is perforated and contains a desiccant agent. The central air space is defined by the glass panels and the spacer tube. The central insulating air space is dried by exposure to beads of desiccant stored within the perimeter spacer tube. The tube is perforated and vented to the insulating central air space along its interior parametric surface.
Modifications to this basic design have focused on methods of improving insulating values of sealed glazing assemblies through 1) deposit of a transparently thin metal oxide coating on the surface of exterior glass panes to filter and trap radiant energy; 2) addition of a third glass panel and corresponding second parametric spacer and insulating air space to further constrain thermal conduction through the assembly; 3) introduction of low-conductive gases such as argon and krypton into the central insulating air space, replacing some or all of the normal air with the selected gas; 4) replacement of perforated metallic perimeter spacer tubes with a variety of alternative spacer configurations employing materials exhibiting low thermal conductivity, and 5) various combinations of these methodologies.
As a group, these modifications are passive in that their approach to improving insulating values of sealed glazing assemblies proceed from a common premise. Uniformly, they seek to provide more effective intervening barriers to conduction of temperature extremes through sealed glazing assemblies and into interior living and working quarters. Only the metal oxide coating provides a benefit other than lower thermal conduction rates. Coated glass also reflects certain wave lengths of light while passing other light through to the interior. Metal oxide coatings also create a spectrum of new problems, in that direct sunlight on these coatings causes excessive heating in exterior glass panes and contributes to thermally induced breakage of glass, failure of structural seals, failure of vapor barriers and disintegration of the glazing units due to differing rates of linear expansion of constituent components.
Edge seal systems are an area of considerable research. The spacer can have considerable variation in its design and material of construction. Spacers commonly are formed of aluminum, steel, or polyvinyl chloride. Spacer shapes can be tubular or an open-sided channel. In addition, spacers often contain a desiccant to reduce moisture content of the gas or air in the air space, thus preventing condensation within the IG unit or at least delaying the time period when condensation will occur. Various materials are used as the sealant, with considerable variation in success of keeping out air and humidity. Sometimes the glass panes are held in position by the sealant, while other designs employ an exterior channel or keeper to hold the panes in place.
Energy transmission through the edge portion of an IG unit is well known to be greater than through the dead air space at the center of the unit. The pathway through the edge seal and spacer tends to be much more conductive, with the result that as exterior temperature decreases, the interior surface temperature of an IG unit tends to be significantly lower at the edges. Thus, when moisture is present, condensation starts near the edges and spreads over an entire IG unit as exterior temperature decreases.
The study of energy transmission near the edge of an IG unit is such a significant area that it has gained special recognition as “warm-edge technology” or “WET.” The goal of WET is to enhance both condensation resistance and thermal resistance at the perimeter of the IG unit, particularly in the 63 mm (2.5 inches) above the sight line of the IG perimeter. While studies are concentrated on this perimeter area as the initially effected area, studies confirm that temperature changes begin at the edge of an IG unit and continue toward the center of the glass until the change reaches the center. Thus, the 63 mm perimeter is an area of primary concern, although the effects concern the entire IG unit.
Studies with spacer bars of different thermal conductivity have shown that the temperature of the glass surface on the warm side of an IG unit increases with the thermal resistance of the spacer bar material. Thus, many improvements in construction of IG units have focused upon the material and design of the spacer in order to increase thermal resistance.
Commercial, industry standard, dual pane insulated glazing units with metallic spacer tubes, as widely manufactured according to present practices, have predictable properties. This type of industry-standard product will be referred to as the conventional product. The conventional window provides thermal insulating properties that are sufficient for the intended use when exterior temperatures are of a moderate range, such as greater than 35° F. (1.67° C.) and less than 85° F. (29.44° C.). Relatively more extreme exterior temperatures, outside the defined moderate range, ov
Loney Donald J.
Rost Kyle W.
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