Pane spacer

Abstract

 A spacer assembly comprising a first sidewall 1 and a second sidewall 2 and a first bridge 3 and a second bridge 4. The first bridge 3 and second bridge 4 and the first sidewall 1 and the second sidewall 2 are separate members joined permanently to form a spacer preferably by welding. The bridge 3 and/or 4 have reduced thickness to reduce the heat loss and employ substantially high strength metal material. The bridge 3,4 and sidewall 1,2 may also employ different metal materials.

Description

[0001] The exemplary and non-limiting embodiments of this invention relate generally to an insulated window pane spacer.

Background

[0002] Windows, doors or buildings may have insulated windows where two or more panes are separated by a spacer. The spacer has a structural function supporting the panes and the spacer also seals the space between the panes.

[0003] US5439716 shows an insulated window spacer. In particular figure 6 shows an interior wall 60 which is joined to the U shaped spacer body by welding. The spacer has a thickness of 0,13 mm (0,005 inches).

[0004] US5630306 shows bridge members made of a synthetic resin or composite material. In each case, it is preferred that the outermost dimension of the insulating spacer, provided by the synthetic resin or composite material bridge member, and no metal, contacts the inner and outer panes of the window unit.

[0005] DE10226269 also shows a spacer with bridges (called legs) made of plastic material. The bridges are connected to metal side members by use of forks.

Summary

[0006] It would be desirable to provide a spacer with reduced heat loss while maintaining a high reliability. Insulated glass units employing new technology and materials may have a higher risk of leaking and failing. Accordingly well proven materials and solutions may be more desirable if the draw backs regarding heat loss can be reduced.

[0007] According a first non-limiting exemplary aspect there has been provided a spacer for an insulated glass unit comprising at least: a first sidewall and a second sidewall and a first bridge and a second bridge, the first and second sidewall are opposed and each comprise an engagement portion configured to be attached to confronting surfaces of panes, the first bridge and the second bridge transversally space apart the first sidewall and the second sidewall,
the first sidewall and the second sidewall and the first bridge and the second bridge are separate members joined permanently together to form a spacer assembly, and
wherein at least the first bridge and/or the second bridge are substantially thinner than the sidewall
and/or
wherein at least one bridge has a thickness of 0,08 mm or less, preferably 0,05 mm or less.

[0008] Favourable embodiments are defined in the dependent claims.

[0009] It would be advantageous to provide a spacer that reduces the heat loss, e.g. heat conduction.

[0010] The disclosed aspects further provide a number of advantages, for example the material used to produce the spacer is reduced.

[0011] For example an advantage is that the production roll forming process is eliminated or at least simplified because the profile shaping is less complex.

[0012] For example an advantage is that the bridges enable easy modification of the spacer width. The spacer joined from separate parts enables flexible production and less storing etc. because the spacer shape and spacer properties can easy be changed by replacing the spacer parts instead of having to set up a new forming tool.

[0013] For example an advantage is that the bridge and sidewall may be from different materials providing properties favourable to the bridge and sidewall respectively.

[0014] Another advantage is that the spacer may be gas tight to enhance the sealing properties.

[0015] Other objectives, features and advantages of the present invention will appear from the following detailed disclosure, from the attached dependent claims as well as from the drawings.

[0016] Generally, all terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to "a/an/the [device, element, means, etc]" are to be interpreted openly as referring to at least one instance of the device, element, means, step, etc., unless explicitly stated otherwise. Where only one item is intended, the term "one" or similar language is used.

[0017] It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Brief Description of the Drawings

[0018] The aspects of the present disclosure will now be described in more detail, reference being made to the enclosed drawings, in which certain examples are shown. These disclosed aspects may, however be embodied in many different forms and should not be construed as limited; rather, these aspects are provided by way of example so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosed aspects to those skilled in the art. Like numbers refer to like elements throughout. For clarity the drawings schematically show a small gap between the parts, but it will be appreciated that this need not be the case in reality. Cross section and transversal is understood as the direction between the panes.

Fig. 1 shows two examples of a spacer.

Fig. 2 is an example of a spacer used in an insulated glass unit.

Figs. 3-5 show various details of a spacer.

Fig. 6 shows an example of an undulating spacer bridge.

Fig. 7-8 show spacer sealing design.

Fig. 9-12 show examples of spacer profiles.

Detailed Description of Embodiments

[0019] Typically insulated windows include panes which are spaced apart by spacers installed between the panes at the pane edge portions.

[0020] The spacer must fulfil several requirements including: strength to hold panes during production, transport, installation. Withstand years of aging and thermal expansion/contraction. Minimize the thermal conduction e.g. heat loss through the spacer.

[0021] Some window constructions benefit from better insulation. Window insulation performance is a result of tradeoffs in the construction. For example insulation may be improved by using different filling gas, pane coatings, layers of panes and pane material etc. And in some cases it may be advantageous to use a particular spacer for reduced heat loss.

[0022] The present disclosure employs slim bridges configured to have lower heat loss. Slim bridge members may have sufficient strength if they for example employ high strength metal or employ a rolling and/or corrugating process which hardens the bridges. Further when the spacer is welded from separate members the welding may further increase the strength by hardening.

[0023] Fig. 1 shows a cross section example of a spacer profile comprising a first sidewall 1 and a second sidewall 2. The sidewalls are connected and spaced apart by a first bridge 3 and a second bridge 4. The sidewalls comprise an engagement portion 1 a configured to be adhered to confronting surfaces of panes and optionally a tapering portion 1b configured to hold sealing/adhesive material.

[0024] In this example the first bridge 3 is associated with the sidewall 1,2 upper part and second bridge 4 is associated with the sidewall 1,2 lower part. The spacer has a substantially tubular cross section. This provides good strength and efficient production. The tubular cross section may also contain desiccant, foam or reinforcement insert or combinations thereof.

[0025] In this example the spacer is substantially rectangular. The first bridge 3 is associated with the spacer top (facing the interior of the glass unit when installed). And the second bridge 4 is associated with the spacer bottom (facing the exterior of the glass unit when installed). The first and second sidewalls 1,2 are associated with the respective sides of the spacer facing the panes when installed. The first and second sidewalls 1,2 substantially extend between the first bridge 3 and the second bridge 4. The rectangular spacer parts may be joined near the 4 respective corners.

[0026] The first sidewall 1 and the second sidewall 2 and the first bridge 3 and the second bridge 4 each are separate members joined together to form an assembly. The first sidewall 1 and the second sidewall 2 and the first bridge 3 and the second bridge 4 are joined together by assembly means. The first bridge and second bridge extend transversely between the first and second sidewall. The first and second bridge 3,4 extend in substantially a co-planar relationship. In one example both the first bridge 3 and the second bridge 4 have similar cross section.

[0027] The present disclosure employs slim bridges 3,4 with low thermal conductivity. In particular the bridge members may be worked such as rolled and/or corrugated to provide slim and yet strong bridge members. Further when the spacer is welded from separate members the welding may further increase the strength. Optionally the spacer bridge 3,4 is from metal and 0,1 mm thick or less. In one example the spacer bridge 3,4 is from metal and has thickness between 0,08 mm or less, preferably 0,05 mm or less. In one example at least the two bridges 3,4 are from metal and have thickness between 0,08 mm or less, preferably 0,05 mm or less. Hereby an enhanced assembly is provided with low heat loss. The first bridge 3 and/or the second bridge 4 are substantially thinner than the first sidewall 1 and/or the second sidewall 2. By thinner is understood that the thickness of one bridge e.g. sheet/profile thickness generally is lower than the thickness of one sidewall sheet/profile. By and/or is understood that either the first bridge is thinner than the sidewall or the second bridge is thinner than the sidewall or both bridges are thinner than the sidewall.

[0028] In one example the spacer e.g. sidewalls 1,2 and bridge 3,4 consists of separate joined metal parts only.

[0029] Optionally at least one bridge 3,4 is undulated along the longitudinal direction to provide enhanced strength and stability. Preferably both the first bridge 3 and the second bridge 4 are undulated in the longitudinal direction in which the spacer profile extends. Hereby the spacer strength is enhanced and the undulated shape may help to absorb thermal expansion in the longitudinal direction if the bridge 3,4 has thermal expansion different from the panes. The bridge 3,4 may be configured for increased transversal strength, for example by employing undulated shape, corrugated shape, honeycomb strip, sandwiched configuration or punched sheet pattern etc.

[0030] The bridge 3,4 optionally is from different metal material than the sidewalls 1,2 e.g. the first and second bridges 3,4 are from a first metal material and the sidewalls 1,2 are from a second metal material.. By first and second metal material is understood a material with different properties like heat conduction, heat expansion, strength, rigidity, seal material adhesion, forming ability etc.

[0031] For example the sidewalls 1,2 are based on ductile metal material and the bridges 3,4 are based on high strength metal material. Hereby the sidewalls 1,2 are configured for forming and the bridges 3,4 are configured for less heat transfer.

[0032] Generally by strength is understood material stress e.g. stronger material can withstands more stress.

[0033] For example a first and second metal material may be a stronger material, so the bridge 3,4 is from a metal material comprising higher strength than the material of the sidewalls 1,2. Hereby the assembly has the advantage that for example the bridge first metal material 3,4 has enhanced strength while the sidewall 1,2 second metal material has enhanced forming properties.

[0034] For example a first and second metal material may be a material configured to adhere seal material. Hereby the assembly has the advantage that for example the sidewalls 1,2 are from a second metal material having a surface configured for enhanced adhering of seal material. For example steel based materials have good long lasting adhering properties.

[0035] For example a first and second metal material may be a material configured to have a thermal expansion adapted to better match the thermal expansion the pane. Hereby the assembly has the advantage that for example the sidewalls 1,2 are from a second metal material having thermal expansion more suitable to the panes. The bridge 3,4 members may also be shaped or made from material to compensate the thermal expansion effect of the insulated glass unit.

[0036] For example a first and second metal material may be a material configured to have enhanced transversal compressive strength. The bridge 3,4 may be of a first metal material configured to have enhanced transversal compressive strength. Hereby enabling slim dimensions and low heat conduction.

[0037] The bridge 3,4 members extend between the sidewalls 1,2 are configured to provide reduced heat transfer compared to the sidewall 1,2 members. E.g. heat transfer transversely through the members.

[0038] Fig. 2 shows an example of an installed spacer. The sidewalls 1,2 comprise an upper engagement portion 1 a configured to be adhered to confronting surfaces of panes 5,6 and a lower tapering portion 1 b configured to be adhered with sealing material. The first and second sidewall 1,2 comprise an engagement portion 1 a which is perpendicular to the transverse direction of the bridge 3,4 and a tapering portion 1 b which slopes from the engagement portion 1 a towards the centre of the spacer. The first bridge 3 when in use faces the interior space of the insulated glass unit and the second bridge 4 when in use faces the exterior. The engagement portion 1 a is towards the interior and the tapering portion 1 b is towards the exterior.

[0039] The spacer is installed between two spaced apart panes 5,6 and the engagement portion 1 a is adhered to the pane 6 with a strip 7 or sealant, foam etc. while the tapering portion 1 b is adhered to the pane with sealant 8. The sealant 8 optionally covers the whole spacer facing the exterior as illustrated by 8b. Hereby providing enhanced sealing of the insulated glass unit which may be advantageous for example when the second bridge 4 is undulated and/or spot welded.

[0040] The engagement portion 1 a is adhered to the pane 6 by primary seal means like a strip 7 or adhesive, sealant, foam etc. The engagement portion 1 a is substantially orthogonal to the bridge and faces the pane when in use. In one example the engagement portion 1a is substantially planar. The engagement portion 1 a optionally is concave to provide a cavity towards the pane. The engagement portion 1 a optionally has a shape adapted to minimize contact to the pane and thereby configured to reduce the heat transfer. The tapering portion 1 b is configured for secondary attachment. The tapering portion 1 b is optionally a cavity configured to contain seal material 8.

[0041] Fig. 3 illustrates how the sidewall 1 assembly means 9,10,12,13 may be configured to join the bridge 3,4 parts to the sidewalls 1,2. The sidewall 1 has an upper end and lower end (e.g. when viewing a cross section) linked by an intermediate central portion. The assembly means may be an attachment ledge 9 provided at the upper end and lower end of the sidewall 1,2. Optionally an attachment ledge is associated with a protruding fold over 11. Hereby the bridge 3,4 is ensured a better fit because the fold 11 provides enhanced stability and guidance. The assembly means optionally are tab portions extending towards the bridge. The assembly means optionally are folds, so the bridge terminal end is folded around the sidewall end or vice versa.

[0042] Optionally the first sidewall 1 and the second sidewall 2 are joined to the first bridge 3 and the second bridge 5 by welding. Preferably at least 4 spot welding tracks in the longitudinal direction of the spacer profile. The welds may be provided at overlapping portions of the bridges 3,4 and sidewalls 1,2. The welds are preferably at ledge/tab portions overlapped by the bridge members 3,4. There are at least four overlapped portions to join the separate bridges 3,4 and sidewalls1,2.

[0043] On the left part of fig. 3 the assembly means illustrate how the bridge 3,4 may rest on the ledge 9,10. On the right part of fig. 3 the assembly means illustrate how the bridge 3,4 may be overlapped by the ledge 12,13.

[0044] Figs. 4a-4c show examples of a protruding fold over 11 which is folded 180 degrees and extends substantially perpendicular to the bridge. The fold over 11 extends beyond the ledge 9 and/or 10. The fold over 11 may be associated with both ends of the sidewall as seen in fig 4a. The fold over may be associated with the lower end of the sidewall only as seen in fig 4b. The fold over may be associated with the upper end of the sidewall only as seen in fig 4c. The fold over 11 may enhance the assembly of the spacer and help to position and join the parts.

[0045] Figs. 5a-5c show an enhancement of the sidewall tapering portion 1 b. The tapering portion 1 b when in use creates a cavity configured to hold sealant material 8. The sidewall tapering portion 1 b is formed with steps or waves to provide an enhanced attachment to the sealant material. The steps are illustrated as orthogonal, but the steps / waves may also be tilted. The stepped/waved tapering portion 1 b enhances the application and bonding of the seal material. The stepped tapering portion 1 b is compatible with the fold 11 described. And the stepped tapering portion 1 b may employ a fold at the upper and lower end (fig 5a), employ a fold 11 at the lower end (fig 5b) or employ a fold 11 at the upper end (fig 5c).

[0046] Fig. 6a shows a bridge 3,4 with an undulating or corrugated shape in the transversal direction. Fig. 6b shows a bridge 3,4 with an undulating or corrugated shape in the longitudinal direction. By longitudinal direction is understood that the bridge is undulating along the pane edge e.g. along the spacer. Hereby the spacer has more stability and/or the bridge thickness may be reduced. This among other advantages enhances the thermal properties of the spacer. The undulating or corrugated shape may also enhance the strength due to work hardening (and thereby further reduce the thickness and heat loss). The undulating or corrugated shape may also enhance the elasticity so the spacer may adapt to expanding and contracting panes.

[0047] The first bridge 3 and/or second bridge 4 may be provided as a band strip (flat, corrugated, perforated etc.). A bridge based on a band strip enables advanced bridge geometry with good strength and compressive strength and low heat conduction while providing easier production.

[0048] Fig. 7 shows an example of a spacer and illustrates the sidewall 1,2 comprises a primary seal face P and secondary seal face S which correspond to the engagement portion 1 a and the tapering portion 1 b. The primary seal face P provides a impermeable seal and the secondary seal face S provides the structural strength. The engagement portion 1 a is configured to be attached to confronting surfaces of panes by the primary seal. The primary seal for example is 2-5 mm in height P. The tapering portion 1 b is configured to be attached to the confronting marginal surfaces of panes by the secondary seal face S. The secondary seal for example is 2-5 mm in height S. The combined height P+S is for example 4-10 mm. Optionally the secondary seal S is larger than the primary seal P e.g. S>P. Hereby a stronger structural adhesion is provided and the strain caused by the thermal expansion of the pane may be improved.

[0049] Fig. 8 shows an example of a spacer and illustrates the details of the tapering portion 1 b used for the secondary seal. The tapering portion 1 b has an offset O from the engagement portion 1 a. The tapering portion 1 b has an angle A from the pane. The tapering portion does not need to be straight (may employ steps etc.) but is shown straight in this example for sake of simplicity. Depending on the seal material used the offset O and angle A are formed. The tapering portion 1 b is configured for enhanced application of the seal material, so the seal material may be injected and properly fill the cavity between the tapering portion 1 b and the pane. The tapering portion 1 b is configured for forming the seal so the seal can withstand thermal expansion/contraction of the insulated glass unit. Depending on the seal material the angle A may be selected between 1-45 degrees. Preferably about 5-15 degrees. Hereby the application of the sealant is enhanced and the seal has enhanced withstand of thermal expansion. The offset O and/or the tapering portion 1 b reduce the tension/stress on the seal material caused by the thermal expansion of the pane.

[0050] Fig. 9 illustrates another arrangement of the sidewall 1,2 and bridge 3,4 according to this disclosure. The sidewall 1,2 has an upstanding portion extending beyond the first bridge 3 (e.g upper bridge). The attachment ledge is provided by the offset O.

[0051] Fig. 9 also illustrates that the bridge 3,4 may be sandwiched from for example two bridge members to enhance the strength. If one or more of the bridge members 3,4 is corrugated or undulated and then sandwiched a honeycomb like configuration may be provided.

[0052] Fig. 10 illustrates another arrangement of the sidewall 1,2 and bridge 3,4 according to this disclosure. The first and second bridge 3,4 are attached to the same attachment ledge on each respective side. The first and second bridge 3,4 are provided at the bottom of the sidewalls 1,2 (e.g. towards the exterior of the insulated glass unit). A third bridge (not shown) for example associated with the top is also possible. This example could also employ one bridge only. In this example the engagement portion is provided by the sidewall 1,2.

[0053] Fig. 11 illustrates another arrangement of the sidewall 1,2 and bridge 3,4 according to this disclosure. The attachment ledge 10 may be provided by a fold 11 at the sidewall 1,2. The attachment ledge may be integral with the sidewall 1,2 or bridge 3,4. In this example the engagement portion is constituted by the sidewall 1,2.

[0054] Fig. 12 illustrates another arrangement of the sidewall 1,2 and bridge 3,4 according to this disclosure. Here the assembly means 9,10 are provided by the bridge 3,4 having an upstanding or down standing edge or tabs configured for attachment to the sidewall 1,2.

[0055] The spacer assembly may be joined by welding, preferably spot welding in the longitudinal direction of the spacer. The spacer sidewall 1,2 and/or preferably the bridge 3,4 may be from metals like steel, stainless steel, high strength steel including steel with wolfram, cobalt, titanium, vanadium or niobium etc. Alloys are understood to comprise a material if comprising more than 0,1 % of said material. The bridge 3,4 may be from steel comprising at least one of wolfram, cobalt, vanadium, niobium or titanium. Conventional aluminium or aluminium alloys may also be employed. Also alloys with nickel may be employed. Nickel may among other properties reduce the thermal expansion.

[0056] The disclosure has mainly been described above with reference to a few aspects. However, as is readily appreciated by a person skilled in the art, other aspects than the ones disclosed above are equally possible within the scope of the disclosure and as further explained below:

[0057] The aspects of this disclosure are not limited to particular bonding/sealing. Mentioned adhesive or seal is not limited to particular function and any material may be used, for example based on butyl, polyisobutyl, silicone, polyurethane, polysulfide, two component compositions, acrylic, hot melt etc.

[0058] For example the sidewalls and the first and second bridge may each be constructed from more parts. Different materials may also be employed.

[0059] For example a bridge may be intermittent or continuously interrupted to provide lower heat conduction properties and better expansion/contraction properties. For example the first bridge may be adapted to hold an additional pane/sheet located inside the insulated glass e.g. between the two panes. The first bridge 3 may be adapted to hold a mutin bar.

[0060] For example the first and second bridge 3,4 could be interconnected.

[0061] For example parts of the spacer may be covered by film or insulating material.

[0062] All though some aspects above refer to roll forming or welding, the advantages of the disclosure may be applicable to other non metal type of spacer material like for example plastics, ceramics and composites.

[0063] The hollow spacer interior may contain a supply of desiccant material configured to remove moisture from the interpane space. The first bridge 3 and second bridge 4 may enclose the desiccant. The first bridge 3 may be perforated etc. so the desiccant may communicate with the insulated glass unit interior.

[0064] Pane is to be understood as a window pane or a window glass, which may be laminated, coated etc.

Claims

1. A spacer for an insulated glass unit comprising at least:

a first sidewall 1 and a second sidewall 2 and a first bridge 3 and a second bridge 4,

the first and second sidewall 1,2 are opposed and each comprise an engagement portion configured to be attached to confronting surfaces of panes,

the first bridge 3 and the second bridge 4 transversally space apart the first sidewall 1 and the second sidewall 2,

characterized in that
the first sidewall 1 and the second sidewall 2 and the first bridge 3 and the second bridge 4 are separate members joined permanently together to form a spacer assembly, and
wherein at least the first bridge 3 and/or the second bridge 4 are substantially thinner than the sidewall 1,2
and/or
wherein at least one bridge 3,4 has a thickness of 0,08 mm or less, preferably 0,05 mm or less.

2. A spacer according to previous claim, wherein the first bridge 3 is associated with the sidewall 1,2 upper part and the second bridge 4 is associated with the sidewall 1,2 lower part providing a substantially tubular cross section.

3. A spacer according to any previous claims, wherein the first sidewall 1 and the second sidewall 2 and the first bridge 3 and the second bridge 4 are from metal and joined permanently by welding.

4. A spacer according to any previous claims, wherein the first bridge 3 and/or the second bridge 4 is undulated or corrugated.

5. A spacer according to any previous claims, wherein the first bridge and the second bridge in general have a thickness of less than 80 percent compared to the general thickness of the first and second sidewall.

6. A spacer according to any previous claims, wherein the bridge 3,4 members extending between the sidewalls 1,2 are configured to provide reduced heat transfer compared to the sidewall 1,2 member heat transfer.

7. A spacer according to any previous claims, wherein at least the first bridge 3 and the second bridge 4 are substantially thinner than the sidewalls 1,2 and wherein at least bridges 3,4 have a thickness of 0,08 mm or less, preferably 0,05 mm or less.

8. A spacer according to any previous claims, wherein at least one bridge 3,4 is from a first metal material and the sidewall 1,2 is from a second metal material wherein the first and second metal material comprise different properties like heat conduction, heat expansion, strength, rigidity, seal material adhesion or forming ability.

9. A spacer according to any previous claims, wherein bridge 3,4 is based on ductile metal material and the bridges 3,4 are based on high strength metal material.

10. A spacer according to any previous claims, wherein the bridge 3,4 is from a stronger material than the material of the sidewalls 1,2.

11. A spacer according to any previous claims, wherein the bridge 3,4 comprises high strength steel.

12. A spacer according to any previous claims, wherein the sidewalls 1,2 are from a material having thermal expansion adapted to substantially match the thermal expansion of the panes.

13. A spacer according to any previous claims, wherein the spacer comprises a tapering portion 1 b, preferably a stepped tapering portion 1 b.

14. A spacer according to any previous claims, wherein the first bridge 3 and/or the second bridge 4 is undulated in the longitudinal direction e.g. along the pane edge.

15. A spacer according to any previous claims, wherein the first sidewall 1 and the second sidewall 2 and the first bridge 3 and the second bridge 4 are joined together by means of attachment ledges 9,10 which preferably are associated with at least one protruding fold over 11.

Drawing