1. Technical Field
The disclosure generally relates to insulating glazing units and, more particularly, to a flexible spacer that is used to form thermal insulating laminates such as insulating glazing units which are used commercially as windows and doors or as parts of windows and doors.
2. Background Information
The procedure for assembling an insulating glazing unit generally involves spacing two sheets of glazing structures with a desiccated perimeter spacer that may be disposed inwardly from the outer edges of the glazing structures to define a channel that receives sealant. The glazed structures are typically glass sheets, but can also be plastic or other such suitable materials. One flexible spacer that is sold in the marketplace under the Federally Registered trademark SUPER SPACER includes a foam body, a foil moisture vapor barrier, and an acrylic adhesive disposed on its opposed sidewalls. The acrylic adhesive is used to connect the spacer to the glazing structures. A sealant material having a low moisture vapor transmission rate (MVTR) is arranged between the spacer and glazing structures to prevent or minimize the ingress of water vapor into the insulating chamber defined inwardly of the spacer and between the glazing structures. The primary sealant can be made from any self adhering material that has low gas and moisture permeability including polyisobutylene, saran, and epoxy adhesives.
An exemplary prior art insulating glazing unit is shown in
Spacer assembly 4 includes at least a spacer body 10 and a primary sealant 12. Spacer body 10 typically, but optionally, carries a desiccant. Spacer body 10 is a flexible or semi-rigid foam material manufactured from thermoplastic or thermosetting plastics. Suitable thermosetting plastics include silicone and polyurethane. Silicone foam rubber is a common material for spacer body 10. Suitable thermoplastic materials include thermoplastic elastomers. The advantages of the silicone foam rubber include: good durability, minimal outgassing, low compression set, good resilience, high temperature stability and cold temperature flexibility. A further advantage of the silicone foam rubber is that the material is moisture permeable and so moisture vapor can easily reach the desiccant material within the foam. Spacer body 10 also may be made from cellular material which may be synthetic or naturally occurring. In the instance where the cellular material is composed of a naturally occurring material, cork and sponge may be suitable examples and in the synthetic version, suitable polymers including, but not limited to polyvinyl chlorides, polysilicone, polyurethane, polystyrene among others are suitable examples. Cellular material is desirable because such materials, while providing structural integrity additionally provide a high degree of interstices or voids between the material. In this manner, a high volume of air is included in the structure and when this is combined with an overall insulating material, the air voids complement the effectiveness of the insulation. When the choice of material is not cellular, any number of the high insulating materials known to have utility for the subject matter herein may be selected.
In the context of this application, the primary sealant is the material primarily responsible for preventing moisture vapor from entering chamber 8 between spacer body 10 and glazing structures 6 and preventing gas within chamber 8 from escaping. In this prior art example, spacer body 10 includes a moisture vapor barrier 14 so that primary sealant 12 is only required to seal the area where spacer body 10 is joined to glazing structures 6. Barrier 14 can be a metallic foil, a metallized polymer, or a polymer film having a low MVTR. Spacer assembly 4 optionally includes a secondary sealant 16. The gap between barrier 14 and the inner surface of each glazing structure 6 is sealed with primary sealant 12.
In the exemplary prior art configuration depicted in
The disclosure provides a flexible spacer body which may be in strip form. The spacer body has two opposing faces adapted to be adhered to the inner surfaces of glazing structures to define an insulating glazing unit. The spacer body may be a thermoplastic or elastomeric foam and may contain a desiccant. The spacer body may be a silicone foam rubber or EPDM. An adhesive capable of bonding the spacer body to the glazing structure is carried by the opposing faces. The adhesive may be from about 0.050 mm (0.002 inches) to about 1.524 mm (0.060 inches) thick. The adhesive material also has the properties of low argon gas and low moisture permeability. The adhesive comprises polymers where butyl rubber and/or polyisobutylene polymers together or alone make up the majority of the polymers. The adhesive may also comprise other materials as needed to make it pressure sensitive and to impart a water resistant bond to glass glazing structures. The adhesive can elongate and stretch without significantly changing in permeability to argon gas or moisture. The strip or spacer body plus the two adhesive layers together form the strip assembly or spacer assembly.
The flexible spacer body is typically extruded and the adhesive may be applied to the two opposing faces immediately downstream or in a subsequent operation. The adhesive may be applied during the manufacture of the spacer assembly or during the manufacture of the insulating glazing unit. The spacer assembly may be coiled for storage. The spacer assembly also may be formed in equipment designed to apply the spacer assembly to the glazing structures with the adhesive layers being applied after the strip is moving through the automated equipment.
The foam spacer body may be covered by a thin skin which is not foam. The skin is thin relative to the dimensions of the spacer body and may be less than 20 percent of the height or width of the spacer body.
When the spacer body is silicone foam rubber, a primer may be used between the adhesive and the spacer body to secure the adhesive to the spacer body. Exemplary primers include Primer 94 by 3M, Chemlok AP-133 by Lord, and Chemlok 607 by Lord.
The spacer assembly may include a layer of acrylic adhesive between the adhesive and the spacer body.
The spacer assembly may include an adhesive tie layer between the adhesive and the spacer body.
The spacer assembly may include a release liner or liners applied to one or both adhesive layers.
The spacer assembly may include a moisture vapor barrier applied to the outwardly-facing surface of the spacer body and opposing faces or portions of the opposing faces of the spacer body such that the barrier extends between the opposing faces.
In one configuration, the spacer assembly is disposed between two parallel glass sheets along the perimeter of said glass sheets such that the adhesive on each opposed face of the spacer body is adhered to one of the glass sheets. The glass sheets with the spacer assembly applied to the perimeter encloses an insulating chamber between the glass sheets. The corners of the spacer assembly may be bent to form corners or notched to facilitate bending at the corners. An additional material which may be a sealant may be applied in the channel formed by the spacer assembly and the edges of the parallel glass sheets.
In another configuration, the adhesive may comprise reactive materials which can react with moisture after application to the glass to increase the modulus of the adhesive or to increase the adhesive force to the glass.
The spacer body is generally more rigid and less deformable than the adhesive. The opposed faces of the spacer body may not be exactly parallel and may be 1 to 10 degrees out of parallel due to manufacturing variances. The adhesive can be applied in non-uniform layer thickness to compensate for the variation in the spacer body such that the outwardly-facing surfaces of the opposing adhesive layers will be closer to parallel than the opposed faces of the spacer body to which they are applied. Adhesive having a thickness of about 0.254 mm (0.010 inches) to about 1.524 mm (0.060 inches) thick provides this compensation ability. This can improve the application of the spacer assembly to the glass sheets. The adhesive also may be used to compensate for geometry variations along the longitudinal length of the spacer body. In these situations, the adhesive is applied to the opposing faces of the spacer body and then passed through a die or a pair of knives to fix the width of the adhesive and square the spacer assembly.
Similar numbers refer to similar elements throughout the specification. The drawings are not to scale with the thicknesses of the different layers being exaggerated for clarity.
Exemplary spacer assembly configurations are depicted in
Spacer body 104 typically, but optionally, carries a desiccant. Spacer body 104 is a flexible or semi-rigid foam material manufactured from thermoplastic or thermosetting plastics in the form of an elongated strip. Spacer body also may be a solid material or a foam with a solid skin 110. Suitable thermosetting plastics include silicone and polyurethane. Silicone foam rubber is a common material for spacer body 104. Suitable thermoplastic materials include thermoplastic elastomers. The advantages of the silicone foam rubber include: good durability, minimal outgassing, low compression set, good resilience, high temperature stability and cold temperature flexibility. A further advantage of the silicone foam rubber is that the material is moisture permeable and so moisture vapor can easily reach the desiccant material within the foam. Spacer body 104 also may be made from cellular material which may be synthetic or naturally occurring. In the instance where the cellular material is composed of a naturally occurring material, cork and sponge may be suitable examples and in the synthetic version, suitable polymers including, but not limited to polyvinyl chlorides, polysilicone, polyurethane, polypropylene, polyethylene, polystyrene among others are suitable examples.
Each spacer body 104 depicted in the drawings is a flexible strip having a generally rectangular cross section. Spacer body 104 can have a height that is less than its width with the width defining the space between the inner surfaces of the glazing structures. Right angled corners and constant dimensions along its length are desired although variations can be compensated for by primary adhesive 102 as described above. Each spacer body 104 includes opposed faces (top and bottom surfaces of spacer body 104 in the drawings) that are adhered to the inner surfaces of the glazing structures. The opposed faces may come into direct contact with the inner surface of the glazing surfaces or may be spaced from these surfaces by a layer of adhesive. Each spacer body 104 has an inner face (right side surface of spacer body 104 in the drawings) that is exposed to the inner insulating chamber of the insulating glazing unit when spacer assembly 100 is used to form an insulating glazing unit in the manner shown in
In each of these spacer assembly configurations, the disclosure provides one configuration wherein the surface to which adhesive is applied is coated with a layer of primer 106 that improves the adhesion of adhesive 102. Exemplary primers are Primer 94 (3M, St. Paul, Minn.), Chemlok® AP-133 (Lord Corporation, PA), and Chemlok® 607 (Lord Corporation, PA). Primer 106 may be used in each location of adhesive 102 described below. Primer 106 may promote the adhesion of primary adhesive 102 to spacer body 104 or to barrier 14. Although
In each of these spacer assembly configurations, the disclosure also provides an alternative wherein an adhesive tie layer 108 is provided under adhesive 102. Tie layer 108 can be used with or without primer layer 106. When primer 106 is used, adhesive tie layer 108 is disposed between primer layer 106 and adhesive 102. Tie layer 108 is used when spacer body 104 is a silicone and primary adhesive 102 does not readily adhere to silicone. Tie layer 108 is provided in thicknesses from about 0.050 mm (0.002 inches) to about 1.524 mm (0.060 inches). An adhesive tie layer 108 that is believed to be useful for improving the adhesion of adhesive 102 to a silicone spacer body 104 includes a mixture of a silicone functional amorphous polyalphaolefin (APAO), a hydrocarbon resin, a paraffinic process oil, and an epoxy-functional silane. Filler such as carbon black may be added.
In one example, adhesive tie layer 108 includes:
1. 40% Vestoplast 206V—Silicone Functional APAO (Evonik)
2. 25% Escorez 1302—Hydrocarbon Resin (ExxonMobil)
3. 10% Sunpar 2280—Paraffinic Process Oil (Holly Refining & Marketing)
4. 24% Raven 890—Carbon Black (Columbian Chemicals)
5. 01% Silquest A-187—Epoxy-functional silane (Momentive)
Each of these embodiments includes a spacer body 104 and an adhesive 102 as described above. Some of the embodiments use a moisture vapor barrier 14 secured to spacer body 104 with an adhesive 18 (such as an acrylic adhesive) as described with respect to
In the exemplary configurations of
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In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the above description and attached illustrations are an example and the invention is not limited to the exact details shown or described. Throughout the description and claims of this specification the words “comprise” and “include” as well as variations of those words, such as “comprises,” “includes,” “comprising,” and “including” are not intended to exclude additives, components, integers, or steps.
This application is a United States National Stage Patent Application filed under 35 U.S.C. §371 claiming priority to PCT/US2013/043124 having an international filing date of May 29, 2013. This application claims the benefit of U.S. Provisional Patent Application 61/652,823 filed May 29, 2012.
Filing Document | Filing Date | Country | Kind |
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PCT/US2013/043124 | 5/29/2013 | WO | 00 |
Publishing Document | Publishing Date | Country | Kind |
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WO2013/181257 | 12/5/2013 | WO | A |
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61652823 | May 2012 | US |