Note: Descriptions are shown in the official language in which they were submitted.
05
This inven-tion relates to insula-ting sealed units
and in particular -to sealed units rnade Erom glass plates.
It is well Icnown to construct a glass insulating
sealed unit made from two or more spaced-apart shee-ts of
glass with the glass plates being separated by spacers that
are made to act as vapour seals or combined with such
seals. The gas or air between the glass plates is made
vapour free and generally a dessicant material is provided
in or in the region of the spacers -to maintain the
moisture-free environment between the glass plates. It is
necessary to maintain a moisture-free condition between the
glass plates if the sealed unit is to be kept in a
condition where condensation does not form and the unit can
always brought -to a very clear, transparent condition.
Various arrangements are known at the present
time for mounting and supporting the sealed units in a
framework or mullion without exterior stops or caps. The
interior light or sheet of glass of the unit can be adhered
~o the structural mullion frame in situ or alternatively
this light can be adhered to a framework in a factor~ and
then the total combination can be clipped or bolted in
place. ~lthough it is preferable to adhere the inner light
to the adjoining framework, it is also possible to adhere
both the interior and exterior lights to the framework or
just the exterior light~ Generally a setting block is
placed between the inner surface of the edge portion of the
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li.gh-ts and the adjacent :Eramework.
When the interior light is adhered direc-tly to
the mullion frame, all the wind and gravity loads acting
on the unit pass through the adhesive sealant and, in the
even-t of fai.lure of this sealant, the whole unit can fall
out of -the frame. A further problem arises from the fact
-that there is no reliable method of determining whether -the
seal between the edges of the glass plates has failed.
Another problem with sealed units presently being
sold is that the air or gas enclosed and sealed between the
sheets of glass expands or contracts during the life of the
unit due to temperature change, atmospheric pressure
changes, outgassing of dessicant and/or environmental loads
such as those caused by wind or snow. This expansion or
contraction of the air in the unit can cause the glass to
deflect. The deflection in turn produces stresses on the
seals which can eventually result in their failure.
United States Patent No. 3,981,111 issued
September 21, 1976 to N.T.L. Berthagen describes and
illustrates an insulating unit wherein the glass plates are
sealingly joined together around their peripheral edges by
spacers which act as seals. The spacers are constructed to
permit a pivo-ting movement of one of the transparent plates
towards and away from the opposing plate, thereby to
increase or decrease the volume of the enclosed gas or air
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705
in response to temperature changes.
Recent U~S. Patent No. 4,348,435 issued September
7, 1982 to PPG Industries Inc. -teaches a multiple glazed
unit having an organic elastomer sealant about its
periphery. The unit is mounted into a curtainwall system
by first coating the exposed organic elastomer sealant with
a suitable primer before bonding the unit to the
curtainwall system with silicone elastomer adhesive.
The present invention provides an insulating
sealed unit that can be glazed without exterior stops or
caps and -that reduces the loads on the structural sealants
by 50% or, in some cases, considerably more.
In the glass insulating sealed unit disclosed
herein, at least one of the lights of glass will be
retained in place in the event of failure by the structural
sealant and this will in turn mainkain the integrity of the
building envelope provided by the glass units.
According to -the invention, a glass insulating
sealed unit suitable for a building exterior comprises at
least two spaced-apart glass plates and spacer means to
join and seal the edge portions of said glass plates
arranged about the entire periphery of said plates and
between said plates, said spacer means including at least
one connecting spacer device e~tending along at least one
side of said unit having a channel-shaped recess that i9
open along the edge of the unit. There are also connecting
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means Eor fastening saicl spacer clevice to an adjoining
support member, said connecting means having a flat end
portion. The sealed unit is Eastened to said support
member by insertion of said flat end portion into said
recess.
The connec-ting means can comprise a number oE
flat or L-shaped metal plates with the aforementioned flat
end portion being part of each metal plate. Each plate has
a hole -therein for passage of a threaded fastener.
According to a further aspect of the invention, a
glass insulating sealed unit comprises at least two
spaced-apart glass plates and spacer means to join and seal
the edge portions of said glass plates arranged about the
entire periphery of said plates and between said plates,
said spacer means including at least one connecting spacer
device extending along at least one side of said unit
having a channel-shaped recess that is open along the edge
of the unit, structural sealant on two opposite sides o~
said spacer device bonding each of said sides to an
adjacent inside surface of a respective glass plate, and an
elongate strip of compound capable of providing both a
dessicant and a vapour seal extending between the glass
plates and immediately adjacent to the surface of said
spacer device which faces towards the centre of the sealed
unit.
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According to s-ti.ll another aspec-t of the
inventio:n, a glass ;.nsulating sealed uni-t co~prises -two
spaced-apart glass plates and spacer means to join and seal
the edge portions oE said glass plates arranged about the
entire periphery of said plates and between sai.d plates,
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said spacer means inclucling spacer members extending along
each side of said unit and having a channel-shaped recess
that is open along the edge of the uni-t, and a separate
uniti~ed connecting frame for fastening said sealed unit by
means of the spacer members to adjoining supports, said
frame having a hook portion extending about its perimeter
on one side of said frame, wherein said hook portion has a
flat end section that projects into said recess on all
sides of said sealed unit.
Preferred embodiments of the invention will now
be described, by way of example, with reference to the
accompanying drawings.
In the drawings,
Figure l is a sectional detail illustrating one
prior art method of sealing a.nd supporting a glass sealed
unit, without the use of exterior caps or stops;
Figure 2 is another sectional detail illustrating
an alternative prior art method for sealing and supporting
a glass sealed unit, without the use of exterior caps or
stops;
Figure 3 is an outside view of several sealed
units constructed in accordanca with the invention and
mounted in place;
Figure 4 is a sectional detail taken along the
line IV-IV of Figure 3 showing details of a first
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embodiment oE the i.nvention and how i-t is connected to a
mullion frame;
Figure 5 is a plan view of the spacer device
shown in Figure 4, which view shows details of the joint at
the corner of the sealed unit;
Figure 6 is a view similar to Figure 4 showing
details oE a second embodiment of a sealed unit constructed
in accordance with the invention;
Figure 7 is a sectional view showing details of a
third embodiment;
Figures 8 to 11 are views similar to Figures 6
and 7 but showing further embodiments of the invention;
Figure 12 is a sectional detail showing a
triple-gazed sealed unit constructed in accordance with the
invention;
Figure 13 is a sectional detail of an embodiment
wherein the dessicant enclosing chamber is separate from
the structural spacer used to s~lpport the sealed unit;
Figure 14 is a sectional detail of a spacer
davice constructed i.n accordance with the invention, which
device is made up of two separate members;
Figure 15 is a sectional detail showing how two
sealed units can be connected to a support frame by means
of ~-shaped connectors;
Figure 16 is a perspective view of the H-shaped
connector shown in Figure 15;
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Fiyure L7 is a sec-tional detail showing how the
edges oE two sealed un:its can be connected by means of
connec-ting bars that extend between -the edges of the sealed
units and that are slide fitted at their ends into recesses
formed in the spacer devices;
Figure 18 is a perspective view of the connecting
bar used in the embodiment of Figure 17;
Figure 19 is a sectional detail of a spacer
device which permits the sealed units to be mounted to the
mullion frame from the inside of the building;
Figure 20 is a sectional detail showing how two
sealed units can be connected to a support frame from the
inside of the building using H-shaped connectors;
Figure 21 is a sectional detail showing how the
structural spacer of -the present invention can be employed
to support a spandrel glass panel;
: Figure 22 is a sectional detail of another sealed
unit joined by means of connecting bars that extend between
the edges of the sealed units:
Figure 23 is a sectional setail showing the
result o~ a ailure of a structural seal in an embodiment
similar to that shown in Figure 22;
Figure 24 is a sectional detail showing the edges
of sealed units connected to a unitized frame;
Figure 25 is a plan view of the unitized rame
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only which frame forms part of the embodiment of Figure 24;
and
Figure 2~ i9 a sectional detail oE yet another
embodiment oE a sealed unit which is connected to -the
mullion frame using special clips or connec-ting bars.
Figures 1 and 2 of the drawings illustrate
alternative rnethods now used for mounting a glass
insulating sealed unit without e~terior stops or caps.
Other methods are also known in the gla~ing industry but
none of -these rnethods employ the spacer itself to support
the sealed unit. In Figures 1 and 2 there are two,
separated glass plates or lights 10 and 12. These lights
are separated by a spacer 14, one of which extends along
each of the edges of the sealed unit. The spacer
preferably forms a substantially enclosed elongate cavity
for holding a dessicant 16. A gap 18 is formed in the
inner wall of the spacer so that the dessicant material can
remove moisture from the gas or air enclosed by the plates
10 and 12. Located between the edges of the glass plates
and about the outer side of the spacer 14 is unit sealing
material 20 which preferably is a one part or two part
silicone. As shown in Figures 1 and 2, the sides of the
spacer 14 adjacent the glass plates have an elongate recess
running along their length at 22 and 24. Located in these
recesses is a vapour seal which provides protection from
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S'705
molsture laderl air leaking into the space between the glass
plates. In the construction of Figure 1, the interio~
glass plate 12 is attached to a mullion frame 26 by means
of a structural seal 2~. A glass seat 30 is provided along
the edge o:E the structural seal ~urthest from the edge 32
of plate 12. It wlll thus be appreciated that the entire
glass unit is supported and held in place by t~e structural
seal 28 and the failure of this seal would resul-t in a
complete falling out of the sealed unit. In addition to
the aforementioned seals, there is provided an additional
weather seal 34 extending between the adjacent edges of the
exterior plates 10.
The sealed unit shown in Figure 2 is mounted to a
different type of mullion frame, which frame has an outward
extension 36 that projects to a point in the plane of the
exterior surface of plate lO o Extending between the edge
of the glass plate 10 and the extension 36 is a combination
weather and structural seal 38. In this embodiment the
interior light 12 is not bonded to the mullion. Instead
; 20 there is simply a glass seat 40 positioned between the
light 12 and the mullion. It will thus be appreciated that
the entire glass sealed unit is held in place by the
adhesive bond between the exterior light and the extension
36. A disadvantage of the prior art constructions shown in
Figures 1 and 2 is the fact tha-t there i9 a high stress
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placed on the structural seals 28 and 38. With -these
cons-tructions, there will be no warning to the user or to
the insta:Ller o:E seal failure and, if the seal Eails, the
entire sealed uni~ will fall out leaving an opening in the
building envelope. Another problem inherent in such
installations is that in order to obtain proper adhesion
~ith the structural seal, the rnullion must be properly
finished and it is sometimes difficult to ensure the
necessary quality control in this regard.
Turning now to the construction of sealed units
constructed in accordance with the present invention,
Figure 3 of the drawings shows several of such units 11
mounted on a suitable mullion frame (not shown). A gap is
formed between adjacent sides o the units 11 and this gap
is preferably closed by means of the weather seal 34. On
the right hand side of the figure, the weather seal has not
been put in place in order to i].lustrate the elongate
clamping bars 40 used to attach the sealed units to the
mullion frame. Bolts 42 or other suitable fasteners are
used to attach the clamping bar to the mullion frame.
These bolts 42 extend into holes in the mullion frame as
will be explained hereinafter with reference to Figure 4.
In Figure 4 the adjacent edges of two sealed
units 11 are shown, which edges are connected to the
mullion :Erame 45 by means of two connecting spacer devices
44. Each device 44 joins and seals the edge portions of
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the glass plates 10 and 12 and part thereoE is located
between -these glass plates. Each device 44 comprises a
first section 46 Eorming a substantially enclosed, elongate
cavity for 'nolding dessicant, w~ich section is positioned
be-tween the two glass plates 10 and 12 adjacent -the edges
~8 and 50 thereof. The spacer device also has a second
sec-tion 52 in the form of an integral extension of the
first section pro~ecting outwardly to a position 53 beyond
the adjacent edges 48 and 50 oE the glass plates.
Preferably the second section 52 is made from a thicker
metal than the major portion of the first section 46. The
spacer device is preferably constructed from aluminum and
the device is shaped as required by an extrusion process.
In the preferred spacer device 44 shown, there is
a third section 54 which is an integral extension of the
first section 46 and which projects outwardly away from the
center of the sealed unit to a location directly between
the adjacent edges 48 and S0 of the glass plates. It will
be noted that both the second and the third sections are
bonded to the glass plates by a structural sealant 56 which
preferably is a two part, fast cure silicone sealant. This
type of sealant does not break down under ultraviolet
light. Each of the two spacer devices 44 is clamped to the
end of -the mullion frame 45 by means of the clamping bar 40
and bolts 42. If necessary, a suitable cutout can be
provided on the outer end of the section 52 to permit
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passage oE the bolts 42. Threadecl holes 5~ are Eormed in
-the mullion ~rame -to receive the bolts 42. ~n optional
glass seat (not shown) can be provided between mullion
frame 45 and each plate 12 if desired.
In order that the air between the plates 10 and
12 can reach the dessicant material 16 there is the usual
gap 18 provided in the interior wall of the spacer device.
The preferred dessicant material is molecular sieve.
Instead of using dessicant material such as that shown, it
is possible to use a light gas such as argon or
argon-halocarbon mixture in the space between the glass
lights. Such a gas will not form condensation in the
interior of the unit. The use of such gases is w~ll known
in the art. Located in the elongate recesses formed in the
sides of the first section 46 adjacent the glass plates 10
and 12 there is moisture barrier sealant 62 (also called
the vapour seal). The preferred sealant 62 is
polyisobutylene which is a viscous material which remains
~iscous during the life o~ the sealed unit.
The silicone seals 56 and the structural spacer
devices 44 in this embodiment and those described
hereinafter should be constructed and arranged to minimize
the movement o~ the vapour seal 62. This can be
accomplished by making the hollow first section 46 slightly
flexible and by making each silicone seal 56 rela-tively
wide, preferably approximately 8 mm., and relatively thin
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in the direction perpendicular to the g:Lass plates,
preferaby approxima-tel~ 3 mm. ~he seals should have
parallel sides, should not be -thinner than 2.5 mm., and
should be made with a high modulus silicone. The overall
stress on the spacers in units constructed in accordance
with this invention are not significantly greater than
stresses in the spacers of typical "capped" units because
-temperature and pressure loads (i.e. inside loads) are
usually greater than wind suction loads (outside loads).
With structural spacers of this invention, it can
be advantageouæ to make the inner plate of glass thicker
than the outer plate because this will reduce the stress on
the outer seal under wind suction load conditions.
In the embodiment of Figure 6, the adjacent edges
of two sealed units are shown and these edges act as the
mullion frame. Each connecting spacer device 74 joins and
seals the edge portions of the two glass plates that make
up each unit. ~ach device 74 comprises a first section 76
that forms a cavity for holding dessicant in the same
manner as the first section 46 of the embodiment shown in
Figure 4. In Figure 6, the first section 76 extends to a
location directly between the edges of the glass plates.
The spacer device 74 also has a second section 78 in the
orm of an integral extension of the irst section 76 and
this second section comprises all of the portion of ~he
device 74 located outside the space between the two glass
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plates. Again the second section 78 is -thicker than the
ma-terial Eorming the f:irst section 76. The second 4ection
78 has first and second legs 82 and 84 with the second leg
being con~iderably longer than the first leg. The first
leg 82 extends from the first section 76 parallel to the
glass plates to a position located out from the adjacent
edges of the glass plates. The second leg 84 extends
perpendicularly from the first leg and past the adjacent
edye 80 of the inner light to a location beyond the plane
of the outer surface 86 of the inner light. In the
illustrated embodiment, the second section 78 also has a
third leg 88 that extends perpendicularly from the end of
the second leg that is furthest from the first le~ 82. If
desired the two second legs 84 can be connected to one
another to provide stability and support. In order to
fasten the interior plate 87 after the frame has been
assembled, the spacer devices 74 will typically only be
used on two opposite sides of a sealed unit.
With the spacer device of Figure 6, the second
leg 84 can be bonded to the adjacent edge 80 of the inner
light by structural sealant 90. Further structural sealant
92 is provided between the first section 76 and the inner
surface of the outer light 70. It will thus be appreciated
that the spacer device 74 provides direct structural
support for both the inner and outer lights.
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In the embodimen-ts oE Figures 4 and 6 and
embodirnen-ts clescri~ecl hereinafter, the f.irs-t sectionfi 46
and 76 each have two sldes 94 that ex-tend generally
parallel to the major surfaces of -the glass plates. The
portion of the side 94 closest to the edge of the adjacent
glass plate is flat but the side bends outwardly at 96
towards the adjacent glass plate. ~his bend in each side
forms a cavity between the flat portion of the side 94 and
the adjacen-t glass plate, which cavity is suitable for the
reception of the structural sealant.
In the embodiment of Figure 7, the glass plates
of the uni.t 98 are connected to a mullion frame (not shown)
by means of a spacer device 102. The device 102 includes a
first section 104 forming the dessicant-holding cavity and
located between the two glass plates. The device 102 has a
second section 106 in the form of an integral extension of
the first section and comprising first and second legs 112
and 114. rFhus the second section 106 first projects
outwardly to a position beyond ~he glass edges 108 and 110
and then inwardly past the edge 108. Optionally the second
leg 114 may be extended (as shown by the dashed lines 116)
into a third leg similar to that shown in Figure 6. Again
the second leg 114 is connected to the edge 108 by
strv.ctural sealant 118.
In the embodiment of Figure 7, there is a third
section 120 in the form of an integral extension of the
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firs-t section 104. This third section has a primary leg
122 parallel to -the glass plates and ex-tending to a
position out from the edges 108 and 110 oF the glass plates
and a secon~ary leg 124 extending perpendicularly from the
primary leg and along the adjacent edge 110. The secondary
leg 124 is bonded to -the adjacent edge 110 by structural
sealant 126. A weather seal 128 bridges the gap between
the secondary leg 124 and a similar adjacent leg.
In the embodiment of Figure 8 the connecting
spacer device 130 has a ~irst section 132 with a cavity for
holding dessicant and a second section 134, which is either
an integral extension of the first section or a separate
element, projecting outwardly to a position 136 beyond the
adjacent edges of the glass plates. In this embodiment
there is also a third section 138 integral with the section
132 which projects to and ends at a location directly
between the adjacent edges of the glass plates. The third
section 138 is bonded ~o the adjacent glass plate 140 by
structrual sealant 142. Located between the second section
134 and the inner surface and edge of the glass plate 144
is a glass seat 146. As in the embodiment of Figure 7, the
second section has a first leg extending from the first
section 132 parallel to the glass plates to the
aforemention0d position 136. The second section also has a
second leg 148 extending perpendicularly from the first leg
and past the adjacent edge o~ the glass plate 144 to a
location beyond the plane of the outer surface of the glass
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pla-te 1~4. A ~lange 150 extends Erom one s.ide of the
second leg 148 along the outer sur~ace o~ plate 144. The
flange 150 is an integral par-t of the spacer device 130.
Again a weather seal at 152 is provided to bridge the gap
between adjacent sealed units.
Turning now to Figure 9, in this embodiment the
spacer devices along adjoining edges of adjacent sealed
units differ in a manner which permits them to be
interconnected to each other. As seen in Figure 9, the
right spacer device 154 joins and seals the edge portions
of the glass plates 155 and 156~ The left spacer device
158 joins and seals the edge portions of the glass plates
159 and 160. Each of the spacer devices 154 and 158 has a
first section forming an elongate cavity for holding
dessicant. A second section 162 of the right spacer device
is an integral extension of the first section, projects
parallel to the major surfaces of the glass plates, and is
positioned midway between the planes defined by the outer
surfaces of plates 155 and 156. The second section
projects outwardly to a position between -the adjacent edge
portions 163 and 164 of the plates 159 and 160. The
section 162 also has holes formed therein for the reception
of threaded fasteners 166. These fasteners extend through
holes in a spacer 168 and into threaded holes in the
mullion frame 170. On the other hand the left spacer
device 158 has a second section 172 in the ~orm of an
integral extension of the first section projecting
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05
outwa:rdly -to a position directly between the edges o
pla-tes 159 and 16U. The lef~ spacer device also has a
third section 174 in the form an integral extension Oe the
first section projecting outwardly -to a position directly
between the second and third sections 172 and 174 .is a
channel-shaped recess 176 that is open along the edge of
the sealed unit. It will be appreciated that the second
section 162 of the right spacer device forms connecting
means for fastening the left spacer device 158. The second
10 section 162 provides a flat end portion 178 with a
thickness substantially equal to the width of the recess
176. When the sealed uni-t of plates 159 and 160 is to be
installed in place, the recess 176 is slid over the flat
end portion 178. It will thus be seen that the sealed unit
15 of plates 159 and 160 is adapted to be held in place and
supported on an adjoining support member or frame 170 by
the combination of the spacer device 158 and connecting
means in the form oE an integral extension of the spacer
device of an adjoining sealed unit.
The embodiment o~ Figure 10 is similar in many
respects to the earlier described embodiment o Figure 6.
Accordingly only the differences between the two
embodiments will be described in detail herein. It should
first be noted that with the sealed units shown in Figure
25 10, the outer lights 180 have edge portions 182 that
project beyond the edge portions of -the interior lights 184
in order to minimize the gap between the plates 180 which
requires a weather seal. These sealed units are called
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"stepped" unlts be~au.se of the projecting edge por-tions o:E
one o:E the ].ights. I-t will be appreciated that "stepped"
UllitS can be useA with any of the embocliment~ of the
present invention described herein i:E desired. Each spacer
device :L86 has a first section 187, which section is
positioned generally between -the glass plates and a second
section 1.88 which, as beEore, in an integral extension of
the .irst sec-tion and which projects outwardly to a
position beyond the adjacent edge 190 of the interior light
184. The second section includes a first leg 192 and a
second leg 194 perpendicular to the first leg. The two
adjacent second legs 194 are clamped to the mullion frame
198 by a clamping bar 200. For purposes of the present
invention, the spacer device 186 shall be considered as
projecting from the side o~ the sealed unit even though
only the second leg 194 projects beyond the edge 201 of the
outer light.
The embodiment shown in Figure 11 has a spacer
device with no dessicant-receiving cavity. The spacer
device 202 in cross-sec-tion comprises at least three parts
integrally connected together. There is a first part 204
extending parallel to the glass plates and disposed
entirely between adjacent edge portions 205 of the glass
plates. The second part 206 extends perpendicularly from
the inner end of the first part 204 and the third part 208
is connected to the second part and extends parallel to the
Eirst part to a position beyond the adjacent edges of the
glass plates. Structural sealant 214 bonds the first and
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705
third parts to the inner sur:eaces of the adjacent glass
plates. Immeclia-tely adjacent to -the inside sur:face of the
second part 206 is a compound 216 capable of providing a
dessicant and a vapour seal. This compound extends between
the glass plates and it can be held in place by a flange
218. The compound 216 can be that marketed by Tremco which
comprises dessicant impregnated butyl. The third parts 208
are clamped to the mullion frame 210 by clamping bar 212.
The embodiment shown in Figure 12 is similar to
that o~ Figure 11 except that each sealed unit comprises
three spaced apar-t glass plates, that is the units
connected to the mullion frame by the spacer device 220 are
tripled glaæed units. The device 220 has a first part 222
extending parallel to the glass plates and disposed
entirely and directly between adjacent portions o the
exterior glass plate 224 and the interior glass plate 225
It also has a second part 226 extending perpendicularly
from the inner end of the ~irst part. A third part
consists of a series of five legs 231 to 235, each of which
is perpendicular to the adjacent leg or legs. The leg 231
is connected to the second part 226 and extends parallel to
the first part to a position beyond the edge of plate 230.
Extending around the edge of the glass plate 230 is a glass
seat 236 which is held in place by the legs 231, 232 and
233. Structural sealant 237 firmly fastens the fifth leg
235 to the inner surface of the plate 225. Also it is the
fifth leg 235 that is clamped to the mullion frame by the
clamping bar 238. In order to assemble one of these triple
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glazed units, the glass pla-tes 224, 225, and 230 are
arranged first in their respect:ive relative positions and
the compound 216 is applied. The spacer devices 220 are
then attached while their ends are unconnected to one
another.
The struc~ural spacer 240 shown in Figure 13 is
similar to that shown in Figure 11 and is clamped to a
mullion frame in the same manner. The device in
cross-section has three parts integrally connected together
including a first part 241 ex-tending parallel to the glass
plates and disposed entirely between adjacent edge portions
242 of the plates. A second part 243 extends
perpendicularly from the inner end of the first part and is
spaced inwardly rom t,he edges of the plates. A ~,hird part
244 is connected to the second part and extends parallel to
the first part to a position beyond the adjacent edges of
the ylass plates. Structural sealant 245 bonds the first
and third parts to the glass plates. Unlike the embodiment
of Figure 11, there is a separate spacer member 246
positioned adjacent to the spacer device 240 on the side of
the second part 243 furthest from the adjacent edges 247
and 24~ of the glass plates. The spacer member 246 forms a
substantially enclosed elongate chamber for holding
dessicant and can be held in place by the sealant 245.
In Figure 14 the spacer device 250 comprises two
separate members securely fastened together. This
embodiment allows "standard" manuacturing techniques to be
used in the construction of the unit. It has the further
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'70~
advantage oE permitting the sealed unit to be ~ixed in
place from ~he interior of the building if required. The
first member 252 forms a substantially enclosed, elongate
cavity 253 for holding dessicant. The first member also
has means on the outer wall 254 for holding the second
member 256. While the Eirst member 252 is located entirely
between the glass plates, -the second member ex~ends
outwardly from the first member -to a position beyond the
adjacent edges of the glass plates. The holding means of
the first member 252 deine an elongate slot 258 which is
wider at the bottom than at the mouth thereof. The second
member 256 has an anchor portion 260 adapted to be inserted
in '~snap" fashion in the slot 258 and too wide to be pulled
through the mouth of the slot. The second member may he
constructed in any manner suitable for connectlng the
spacer device to the adjoining frame. The illustrated
second member extends past the edge of the interior light
to a flange 263 and beyond. The flange 263 extends
parallel to the outer surface of the interior light and is
close to this outer surace. A glass seat 264 is inserted
between the Elange 263 and the edge portion of the interior
light. It should also be noted that structural sealant 266
bonds the exterior surfaces of the holding means to the
glass plates on opposite sides of the first member 252.
Figures 15 and 16 lllustrate another orm of
combination that can be used to provide a structural spacer
capable o supporting a sealed glass unit. In this
embodiment each spacer device 269 is constructed in
essentially the same manner as the let spacer device 158
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:. . ..
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-25~
~S'7~)5
in Figure 9. Thus each device forms a ch~nnel-~haped
recess 270 that. is open along the edge of -the unit.
H-shaped connec-tors 271 are provided to fasten adjoining
spacer devices to -the mullion ~rame 272. Typically these
connectors can be spaced apart 6 inches or so with the
spacing based upon wind suction design load. The
construction of each connector 271 can be seen clearly from
Figure 16. The connector includes a stem portion 272
having a square or rectangular cross-section, and two
generally flat arms 273 projecting perpendicularly from one
end of the stem portion 272. Each of these flat arms has a
thickness indicated by the arrow T slightly less or
substantially less than the width of the aforementioned
recess 270. The top surace o~ the arms ~73 is separated
by a groove or slot 274 into which the end of a standard
screwdriver or other suitable tool can be inserted for
rotating the connector about a longitudinal axis extending
through the center of the stem portion 272. Extending
outwardly from the bottom end of stem portion 272 are hook
members 276. Each hook member has an upwardly extending
lip 278 adapted to snap under another lip 280 formed in the
mullion frame as shown in Figure 15.
In order to employ the connectors 271, the
complete sealed units 282 are put in the required position
on the mullion frame and are set on setting blocks in the
conventional manner. At this time there is an open gap 284
b~tween the sealed units and the connectors 271 can be
inserted through this gap when the arms ~73 extend parallel
to the edges o~ the sealed units. .A slot is provided in
~;~. 30 the mullion frame to accommodate the hottom end of -the
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-26
~t~
connector therein. The wldth of -the connector indicated by
the arrow W in Figure 16 is less than the width of this
slot in the mullion Erame. AEter i nsertion of the bottom
end of the connector into -the slot, it is then possible to
turn the connector by inserting a screwdriver in the slot
274 so that it is brought to the position shown in Figure
15. In this position the hook members 276 are locked into
the mullion frame. At the same time the arms 273 extend
into the two opposing recesses 270. Preferably there is a
10 sliding fit between each arm and its respective spacer
device to permit each sealed unit some movement after
installation. However i-t will be understood that the arms
act to clamp the sealed unit -to the mullion frame via the
spacer device. Glass seats 285 are provided between the
15 interior light of each sealed unit and the mullion frame.
After the connectors have been installed, the gap 284 can
be closed by means of a weather seal material 286.
Except for the means to attach the spacer devices
to the mullion frame, the en~bodiment shown in Figure 17 is
20 similar to that shown in Figure 15. The spacer devices 269
of the sealed units are exactly the same as are the glass
seats 285. Extending betw~c~en -~he adjacent spacer devices
at intervals of about 6 inches are flat, elongate metal
plates 287, the construction of which can be seen clearly
25 from Figure 18. Located in the center of each plate is a
hole 288 for receiving a threaded fastener 289. The plate
287 rests on a spacer sleeve or bar 290 through which
extends a hole for passage of the fas tener 289.
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ti5~70~
The a:Eorement.ioned plate 287 is sufficiently
narrow that it can be inserted through the gap 284 between
-the edges oE the sealed units. The plate can then be
turned 90 into the recesses 270 of the spacer devices~
Optionally a nib is provided in the bottom of each plate
287 and this nib locates a groove in the spacer 290 at the
correct rotation. If a nib and groove are used, then the
spacer 290 should be an integral part of the mullion. It
will be appreciated that the end portions 291 of each metal
plate have a thickness slightly less or ~ubstantially less
than the width of the recesses 270. The thickness of the
end portions is such that a sliding fit is preferably
formed between -these end portions and the two spacer
devices connected thereto. I desired each end portion 291
can be bevelled as shown to permit easy insertion into the
recesses 270. The plates 287 a:re adapted to clamp the
sealed units to the frame via the spacer devices 269.
Figures 19 and 20 illustrate structural spacer
: devices constructed in accordance with the present
: 20 invention w~ich permit the glass units to be installed from
the lnterior of the building. This is particularly
advantageous when the sealed units must be in talled on the
upper floors of high buildings where scaf~olding cannot be
empIoyed. The spacer devicas 269 are constructed in the
same manner as earlier described embodiments such as those
illustrated in Figures 15 and 17. Thus each spacer device
provides a channel-shaped recess 270 that is open along the
edge o~ the unit~ The left hand sealed unit 292 shown in
,
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-2~-
ii5~7~35
Figure ]9 is connected directly to the mullion fraTne 293
which i8 Eormed with an integral hook 294, the fla-t end of
which fits snugly in the recess 270. If desired the flat
end of the hook 294 can be bevelled at 295 to permit easy
insertion. A glass seat 296 is provided between the outer
surface of the interior light and the mullion frame. The
left hand edge of each sealed unit is mounted in a
diferent manner than -the right hand edge. The left hand
edge of the unit 297 can be seen in Figure 19. This edge
is connected by means of substantially L-shaped metal
plates 298, each of which has a flat end portion 299
provided by one leg. The plate 298 can be a continuous
plate along each edge of the unit if desirQd or there can
be a number of individual plates 298 along each edge. A
hole for the passage of a threaded~fastener 300 is formed
in the other leg of the connector. A locating tab 301 can
be forrned on the mullion frame to properly orient the plate
298 if desired. After the sealed unit 297 has been mounted
in place with the plates 298, the gap between the mullion
frame and the outside surface of the interior light can be
filled in by meAns of a suitable channel member 302 and a
glass seat 303. The innermost side of the channel 302 is
held by an integral clip 304 formed on the outwardly facing
sur-face of the mullion frame.
In the embodiment illustrated by Figure 20, the
spacer devices 269 are the same as those shown in Figure 19
and previous figures. The sealed units are connected to a
mullion rame 305 by H shaped connectors or clips 306~ The
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~S~705
connec-tors 306 are constructed in the same manner as the
connec-tors 271 shown in Figure 15 except -that they are
provided with means on their inner ends to permi-t ro-tation
about their central axis. Prior to installation of the
sealed units, there is a passageway through the mullion
frame provided by openings 307 and 308 and the cavity 309
in the frame. At this time, the cover plate 310 is
detached from the mullion frame. Thus it is possible to
pass the connector 306 -through the mullion frame from the
inside of the building so that the two arms are brought
into alignment with the recesses in the spacers 269. Then
by means of a special screwdriver inserted into the slot or
recess 311, it is possible to rotate each connector about
the central axis oE its stem so that the arms are brought
into engagement with the recesses. At the same time, the
hook members 312 are snapped over the inwardly directed
lips 313 of the mullion Erame. After installation of all
of the necessary connectors 306, each of the required cover
plates 310 can be attached to the innermost wall of the
20 frame 305. The weather seal 314 can be applied from the
exterior of the building without difficulty in a well known
manner.
Figure 21 illustrates how a structural spacer
constructed in accordance with the present invention can be
used in conjunction with an insulated panel such as a
spandrel glass panel. Each spandrel unit 316 has a glass
light 317 forming the outside surface, an insulating space
318 and an insulating panel 319 having dimensions
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- 30 -
lengthwise and wiclthwise similar to those of -the glass
plate. A structural spacer device 320 constructed in
essentially the same manner as the spacer devices 4~ shown
in Figure 4 joins the light 317 to the panel 319.
Structural sealant is provided at 321 to join the spacer
device to -the light 317 and the panel 319. Generally, with
units of this nature, a reflective material 322 is applied
along the inside surface of -the light 317 so that the panel
319 can no-t be readily seen by an outside observer. Each
of the panels 319 can be constructed with the use of two,
spaced apart metal sheets separated by a layer of
polyurethane or polyethylene 328. Insulating panels of
this nature are well known as building products. The
preferred metal for sheets 329 is either aluminum or
steel.
The preferred embodiment shown in Figure 22 is
similar in some respects to the ambodiment shown in Figures
11 and 17. A spacer device 330 has a channel-shaped recess
332 that is open along the edge of the unit. Structural
sealant 334 is loca-ted on two opposite sides of the device
330 and this sealant bonds each of the sides to an adjacent
inside surface of a respecti~e glass plate. The spacer
device 330, which is generally U-shaped, has small
longitudinal flanges 336 that extend perpendicularily rom
each of the opposite sides and towards the adjacent glass
plate. These flanges help to secure an elongate strip of
compound 338 extending between the glass plates and
immedi.ately adjacent to the surface oE the device 330 which
faces towar the centre of the sealed unit. The compound
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- 3l ~
338 is capable of provicling both a dessicant and a vapour
seal and can be the same compound as the compound 216 used
in -the embodiment of Figure 11. The preEerred material is
dessicant impregnated butyl that adheres to the inside
surfaces of glass plates and is capable of continuing to
adhere to either glass plate in the event the structural
sealant 334 should fail. As can be seen from Figure 22/
the compound 338 preferably extends around and covers the
flanges 336. Thus the edge of each flange does not come
into contact with the adjacent glass plate.
In the illustrated preferred embodiment, the
sealed units of Figure 22 are connected to the mullion
frame 340 by means of clips 342 which can be of the same
construction as that shown in Figure 18. These clips clamp
the sealed units to the mullion frame by means of threaded
fasteners 344. Preferably a glass seat 346 is arranged
between the edge of the sealed unit and the mullion frame
before the sealed unit is clamped into place.
There are several advantages to the construction
shown in Figure 22. It provides a flexible spacer joint
which accomodates lateral and rotational movements and this
increases the service life of each sealed unit. Because of
its simple construction, the cost of tooling for production
of these units is low. Perhaps the greatest advantage
arises from the protection it provides against the
possibility of a failure of the structural sealant 334,
The preferred compound 338, such as a combination of butyl
rubber and polyisobutylene is a fluid material and it can
be sized and shaped so that in the event that the
,. : ,
- 32 -
structural sealan-t should Eail, -the compound 338 will flow
and remain adhered to the glass surfaee. The end result is
tha-t the air space be-tween the glass plates remains sealed.
If a high negative wind load acts on the outer liyht 348,
the light will move relative to the inner light 350 and
thereby increase the volume of the air space between the
two lights until the pressure is equalized on both sides of
the outer light 348. At this point the outer light will be
carrying virtually no load and the inner light 350 which is
mechanically held will carry the majori-ty of the wind load.
Thus the outer light should remain in place if the sealant
334 has failed.
In order to construct the sealed lmit of Figure
22, the spacer devices 330 are preferably made from
extruded aluminum which is notched and cut to length. The
spacer device 330 can be clear anodized for good long term
adhesion and low friction with the clip 342. The next step
in the manufacturing process is to roll the compound 338
onto the spacer device which at this stage has a length
equal to ~he sum of the length of the four sides o~ the
uni~. The aforementioned notching is carried out in order
to permit the device to be bent into a rectangle. After
bending takes place, the butyl aompound 338 is fused at the
previously unconnected fourth corner. Next the bent spacer
device is jigged so that it is square and is placed on one
light o glass. The second light o glass is then put in
place and the entire unit is rolled through a heated roller
press. The silicone structural sealant 334 îs then put in
place by means of a suitable caulking gun and nozzle.
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;.L~tjS~05
A variation on a construction shown in Figure 22
is lllustrated in Figure 23 of the drawings. In this
embodiment even iE there is -total seal failure, that is
failure of the structural sealant as wel] as the seal
provided by the compound 338, the exterior light 348 will
still normally be held in place. As in the embodiment of
Figure 22 the inside light 350 is held in place by
mechanical means w~ich include th~ spacer device 330, clips
342 and -threaded fasteners 344. The exterior light 348 is
normally held in place by the structural sealant 334 as
well as the aforementioned compound 338.
The embodiment of Figure 23 dif-fers from that
shown in Figure 22 in that the weather seal 352 has
pressure equalization holes 354 distributed along its
length and on each side of the sealed unit. The provision
of these holes means that the pressure on the inside of the
outer light 348 and in a bar chamber 356 will be equal with
the pressure on the outside of the building in the event of
total seal failure as indicated at 358. The air seal 346
between the inner light 350 and the glazing bar 360 should
be a good air seal although not necessarily perfect. In
addition partitions 362 should be located at the corner of
each lite. Each of these partitions extends tranversely
across the bar chamber 356 and the effect of the partitions
is to isolate the air into pressure compartments, This can
be accomplished by the injection of an expandible silicone
foam.
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With -the aforemen-tioned embodiment, there can be
a comple-te seal failure between the outer light 348 an~ the
structural spacer 330 on three or four s:ides and yet the
outer light will be held in place. The air entrapped
between the weather seal 352 and the bar chamber 356 will
dampen the wind gust and the pressure equalization holes
354 will equalize the pressure, relieving considerably the
load on the outer light 348 and the weather seals. With
this particular design the inner light 350 is designed to
carry all the wind negative load and is limited in its
deflection so that the outer light 348 will not be forced
to move too much to equalize the pressure in the event of
quick wind gusts. As will be appreciated by those sXilled
in this art, this pressure equaliæation system can be
applied to any double skin wall where the exterior skin or
light is not mechanically held and a back up means is
required so that the outer skin or light will not become
completely detached from the unit.
In the system shown in Figure 24, the sealed
units 362 are mounted on a special frame 364 which is shown
separately in Figure 25. The frame has the same shape and
size as the sealed unit which is mounted on one side of the
frame. Preferably the frame is constructed from aluminum
and has a hook portion 366. It will be appreciated that
the hook portion extends completely around the perimeter of
the frame as indicated in Figure 25. The hook portion has
a L-shape in cross-section and this portion is in the
illustrated embodiment connected to a channel portion 368
to construct the complete assembly, the frame 364 is built
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around the sealed unit 362. A flat end section 370 of the
hook portion projects into -the recess 372 formed by the
spacer device. When the hook portion is engaged on all
sides ! the sections of the frame 364 are assembled by means
of well known port-hole screws 374 or alternatlve methods
typically used with window frames. Preferably an air seal
376 is installed between the interior light and the channeL
portion of the frame. After construction of the unitized
frame consisting of the frame 364 and the sealed unit, the
unitized Erame can be fixed to adjoining supports of the
building from the interior of the building. The weather
seal 378 is then applied to complete the installation.
Another embodiment employing clips 380 is shown
in Figure 26 of the drawings. The clips are used to
connect sealed units 382 to a mullion frame 384. Metal
spacer means 386 are similar in their construction to known
spacer means but, unlike the known spacers, they are inset
from the edges of the unit. Preferably the inset 388 is
approximately 1/2" (13 mm). Except or the inset, the
manufacture of the sealed units 382 is conventional.
In order for the clips 380 to engage the interior
light 390 and clamp it to the mullion rame, each clip is
provided with glass protective seats 392, one at eac~ end.
The preferred material for such seats i5 neoprene. It will
be appreciated that each end portion of the clip 380 with
the glass protec-tive seat in pla~e must have a thickness
less than or equal to the distance between the glass
plates. The sealed unit 3~2 is fastened to the mullion
frame 384 by insertion of the end portions of a number of
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5'~:3~
clips 380 into the edge recess ~ormed by the inset 388 and
by a-ttachmen-t oE the cllps to the adjoining support member
or frame 384. Again a glass seat 394 is preeerably
provided to protect -the inner light.
The advantages of the structural spacer in its
various forms as described will be readily apparent to
those skilled in -the construction of sealed glass units.
The use of such spacers avoids the need Eor exterior stops
or caps and can reduce the load or tension stress on the
seals by 50% or more. Moreover most embodiments of the
sealed units of the invention can be manufactured using
standard manufacturing processes and these structural
spacers can be designed Eor use with all known types of
fastening devices including clips, screws, etc. Further
possible advantages include the ~act that the construction
of the spacers and the use thereof is not dependent on
glass thickness. Sealed units constructed in accordance
with khe present invention can be tested in any of three
possible ways in order to determine whether or not seal
adhesive failure may have taken place. The units can be
visually inspected for condensation, due point tested, or
pressure tested. The second method involves the use o the
well known "due point" apparatus to test the unit. In
pressure testing, gas is blown into the unit via a breather
tube installed during manufacture. A failure of the seal
during this test will not result in glass ~allout but by an
almost instantaneous pressure drop, indicating ~ailure.
,
- 37 -
~Z~';7C~
One method of construc-ting many of the sealed
units, herei.n describecl comprises assemb:Lirlg -the spacer
frame to form a rectangle w.ith either temporary or
permanent corner pieces. Each corner is then dip-soldered
at 53 (see Figure 5) in a well known manner to seal the
corner and permanently fasten the end of one spacer -to the
adjoining spacer. ~e glass pla-tes are then attached -to
the sealed frame.
Various modifications and changes to the
cdescribed embodiments will be apparent to those skilled in
this art after considering the present disclosure and
drawings. All such modifications and changes as fall
within the scope of the appended claims are intended to
form part of the present invention.
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