Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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CA UZSOZ069 LUUD-U3-Zd
SPACER P'ROFILBS FOR DOUBLE GLAMGS
TECFII=AL FIFI.D
[0001] Tye praseat inveation relates to spacer pm$les that can be formed
(e.g., beat)
iom tpaeer frames ibr momtiag withim ea imaating wisidow uait (double glrzing)
The
spaex profiles ate deaigned to support and separata two window panes.
DESCRBTION OF'1HE RF.Y.A71D ART
[0002] Kwwn qa= pmfda we tu*t by cosmmnly-owaed U S. Patent Nos.
6,035,596, 6,389,779 and 6,339,909. Additional spacer profiles ara taught by
U.S. Patent
Ncs. 5,460,862, 3,962,090, 6,061,994, 6,192,652 and 6,537,629. PCT Publicanon
Nos.
WO 03114830 and WO 03l74831, Ompm I'atmtt Publication No. 0 003 715 and Getman
Patent PublitWon No. 33 02 659.
100031 Kaown insnladmg vvindow uaits ntilize two or mm glass psm. The sptcer
pcofite is placed bete-m two glass paaes in order to suppott and sepaiate the
tovo glass
pa=s. The space batween tha gisse pam is tlua typically filed with an inert,
insu[rtiu,g
gas, such as argoa, sad the space is scsted. The window panes also may be
coated or
finished in order to iazpart speCid fvnations to tht bmbting window ueic, mh
as
iaccqsed heat inaulatiag and/or sowd insulating upabilities.
[00041 Insulating window uaita that are intended to provide high insalation
values sre
typically desiped to rninimize 9ie heat transmission charactesis6cs of tha
pecipberal
connecti*s), including tlte spaoer frame. In addition, the spmenr profile is
p:rSersbly
cksigned to munimize or eliminate tha formetion of water condwsttion on the
ianer
susfaces of the window penes, even when subjected to cold outside
tempecatmres.
Moreovec, the spacer proftle pemabty shoeld be t eadily beadable evea at
relatively low
temperataees (e.g., raom tanperature) without aubsisntiolly dQforming thz
stivcQM
defining the spacer profile.
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SUMMARY OF THE IN'V'ENTTON
100051 It is one object of the present teachings to provide improved spacer
profiles.
[0006} In one aspect of the present teachings, spaccr profiles are taught that
can be
inexpensively manufactured in, large volumes, while providing good heat
insulating
properties, minimizing water condensation inside the assembled insulating
window unit
(double glazing) and being readily bendable without undesired defonnation.
Such spacer
profiles offer advantageous applications in the field of "warm-edge"
insulating window
units that seek to minirnixc or prcv,eat watcr condensation on an inner
surtace of an inner
window pane by maintainizxg the temperature at an edge connection area as high
as
possible, even when the outer window pane is subjected to relatively cold
outside
temperatures.
-. ~ 100071 in another aspect of the present teacbangs, spacer profiles are
taught that enable
. -,
the production of one-piece' spacer frames by bending a linear spacer profile.
T'he
resulting bent spacer frame does not have undesirable deformations, even when
the spacer
profile is bent while cold or only slightly warmed using conventional bending
machinery.
Further, insulating window units may be prcpated by.placing the bent spacer
frame
between two window panes in a manner and position that permits a limited range
of
relative movement by the window panes when the assembled insulating window
unit is
subjected to pressure changes and/or shearing stt=ai.n.
[0008] In another aspect of the present teachings, spacer profilcs preferably
include a
profile body contprising an elastically-plastically deformable material (e.g.,
a plastic or
resin material) having relatively low heat conductivity. A deform.able
reinforcenunt
material or layer (e.g,, a metal) preferably is coupled to the elastically
plastically
deformable anaterial. Optioaally, terminal cnd portions of the reintforcemant
layer may be
or partially or completely embedded within the profile body. In another
optional
embodinaent, the eatire reinforcement layer may be partially or completely
embedded
(disposed) within the profile body. The combined structure (i.e., the profile
body and the
reinforcement layer, which will be refetred to as a "spacer profile" herein)
is preferably
bendable without undesirable deformation of the inherent sttuttures, even when
bent at
relatively low temperatures.
[ooo9) Prefenrd elasticapy-plastically deformable materials include synthetic
or natural
mateials that undergo plastic, irreversible deformation after the elastic
restoring forces of
the bent material have been overcome. In such preferred matcrials,
substantially no clastic
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restoring forces are active af-or deformation (bending) of the spacer profile
beyond its
apparent yielding point. Representative plastic materials also preferably
exhibit a
relatively low heat conductivity (i.e., preferred materials are heat-
insulating materials),
such as heat conductivities of less than about 5 W/(m=K), more preferably less
than about
I'W'l(m=K), and even more preferably less thaa about 0.3 W/(m=K). Particularly
preferred
material,s for the profile body are thermoplastic synthetic materials
including, but not
limited to, polypropylene, polyethylene terephthalate, polyamide and/or
polycarbonate.
Thc plastic matcrial(s) may also contain commonly used fillers (e.g., fibrous
materials),
additives, dyes, U'V' protection agents, etc.
[oolol Preferred plastically deformable reinforcement materials include metals
that
provide substantially no elastic restoring force after being bent beyond the
apparent
yielding point of the metal. Prefen-ed materials for the profile body
optionally exbibit a
heat conduction value that is at least about 10 times less than the heat
conduction value of
the reinforrement m,ateriat, more preferably about 50 times less tbm the heat
canduction
value of the reinforcement material and most preferably about 100 times less
thaa the beat
conduction value of the reinforcement material.
[00111 In another aspect of the present teachings, spacer profiles preferably
include a
relatively large hollow inner space or chamber, which rtiay be partially or
completely
coated andlor filled with a hygroscopic material (also known as a'desiccant or
dzying
agent). Preferably, the hygroscopic material is disposed in a manner that
permits the
hygroscopic material to communicate with the space (i.e., gas) defined between
the
window panes of the assembled insulating window unit (double glazing). In this
case, the
hygroscopic matezial can remove (absorb) moisture from the gas disposed
between the
window panes. By removing moisture, it is possible to minirnixe or prevent the
formation
of water condensatioh (fogging) on the inner sutface(s) of the window pane(s).
Two or
more hygroscopic materials may be utilized in combination and the present
teachings are
not particularly limited concerning the types of hygroscopic materials that
may be
disposed within the hollow chamber of the spacer profile.
100121 In one representative embodiment, the plastic portion (profilc body) of
the spacer
profile may be permanently coupled (or materially connected) to the
reinforcement layer,
e.g., by co-extruding cho profila body with thc rainforcement laycr. In the
altcrnarive, thc
reinforcement layer may be permanently coupled (materially connected) by
larninating the
reinforcement layer on the plastic portion and/or by disposing an adhesive
between the
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plastic portion and the reinforcement layer. In this case, the reinforcement
layer is
preferably bonded to the profile body with a peeling value (forceJadhesion
width) of equal
to or greater than 4 NAnm using a 180 peeling test on the finished product. A
variety of
manufacturing techniques may be utilized to make the spacer profiles of the
present
teachings, which manufacturing techniques are not particularly limited.
[00131 In another aspect of the present teachings, the cross-section of the
hollow inner
space or chamber of the spacer profile is preferably substantially T-shaped,
bell-shaped or
stepped pyramid-shapad. In othcr words, thc width of the hollow inner space or
chamber
preferably decreases in the height dircction of the spacer profile. The width
of the hollow
inner space or chamber may decrease continuously or in a step-wise manner, or
partially
continuously and partially step-wise. Various chamber designs are possible
within this
aspect of the present teachings, as will be discussed furth.er below.
lo0141 In one prefexred ex.ample; the widest width space of the chamber
prefembly is
adjacent to a base wall of the spacer profile. The base wall is designed to
face the inner
space defined between the two window panes when the insulating window unit is
assembled. Further, a plurality of apertures is preferably defined in the base
wall, thereby
enabling.the hygroscopie material disposed within the chamber to readily
communicate
with the inner space of the insulating window unit. Thus, by designing the
chamber in this
manner, a relatively large surface area of hygroscopic material faces the base
wall and the
inner space of the ixisulating window unit.
[0015] In another preferred example, the hollow chamber may be defined as
containing a
first space and a second space, The cross-section of one or both of the first
space and
second space may be substantially rectangular or oval shape. For example, the
width of
the first space is preferably gre= tltan the width of the second space and the
f rst space is
closest to the base wall. The width direction of the first spaoe and the
second space is
defined as being parallel to the base wall. The second space optionally may
have a
substantially square or circular shape in cross-section.
[0016] The reinforcement layer is preferably disposed on the side of the
spacer profile
(e.g., the upper wall of the spacer profile) that will face towards the
outside of the
iansuIating window unit after the spacer profile has been bent into the spacer
frame. At
least a portion of the reinforcement layer, such as peripheral terminal edge
portions
thereof; optionally may be partially or cotnpletely embedded within the spacer
profile. As
a result of the geometric confignrations of the rcinforcement layers taught
herein, att arc-
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preserving bending resistance moment is imparted to the spacer, profile. Such
are-
preserving being resistance contributes to the cold pliability of the spacer
profile, which
permits bending of the spacer profile without undesirable deformations. In
addition or in
the atternative, the reinforcement layer and the side walls of the profile
body may define a
flush surface, if the reinforcement layer does not completely cover the side
walls.
100171 The reinforcement layer preferably extends continuously from a first
side wall
across an upper wall to a second side wall of the spacer profile. Further, the
reinforcement
layor prcferably covcl,s Cirsi and second connecting segments provided between
the upper
wall azid the respective first and second side walls. By introducing
additional bends,
curves andlor angles along the lateral width of the reinforcement layer (i.e.,
from the first
side wall to the second side wall), a relatively high arc-preserving bending
resistance
moment can be imparted to the spacer profile. In this case, although stronger
be~nding
forces may be resluired to bend the spacer profile ta form the spacer frame
(i.e., than the
bending forces required to bend spacer profiles without such additional bends,
curves or
angles), the resulting spacer frame will have a particularly low resilience
and a high degree
of comer stiffness,
[0018] According to one advantageous embodiment of the preseat teachings, the
connecting segments are preferably defined at corner portions of the hollow
chamber. If
the reinforcement material covers the connecting segments, the bending
behavior and the
heat insulating properties of the spacer profile are improved. In otuer words,
the path of
the reinforcemcnt layer is prcferably modified, such that the length of the
reinforcement
layer is greater than the distance between the two window panes in the
insulating window
unit. Such designs serve to improve the overall beat insulating propeRies of
the spacar
profile. In other words, if the reinforc,ement material is made of a metal
that conducts heat
relatively welt, the overall heat conduction properties of the reinforcement
material can be
reduced by extending the Iength of the reinforcement material. For example, by
introducing additional bends, curves or angles along the path of the
reinforcement
material, a longer heat conduction path is provided between the first window
and the
second window of the assembled insulated window unit, thereby reducing the
ove,rall heat
conduction of the reinforcement layer.
100191 In addition to advantageous mechanical properties, the reinforccmertt
layer
optionally also may possess gas and vapor barrier propcrties. The
reinforcement layer is
preferably resistant or substantiafly impermeable to gases diffusing
theretbrough in order
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to maintain the integrity of the insulating gas (e.g., argon) disposed between
the window
panes in the assembted window unit A gas and vapor barrier can be achieved by
utilizing
a reinforcement layer, e.g., that comprises stainless steel foil having a
thickness of less
than about 0.2 mm, more preferably less than about 0.15 mm and most preferably
less than
or about 0.1 mm. The minimum thiclrness of the reinforcement layer is
preferably selected
so that the required stiffness of the spacer p'rofile is achieved and the
diffusion resistance is
also maintained after beuding, particularly in the bent areas or portions.
GeneraIly
speaking, for thc abuvc-identfSed metallic materials, a minimum layer
thickness of about
0.02 mm is appropriatey although thiclmesses between about 0.5 and 2.0 mm are
preferab[e.
[002o1 Depending on the manner in whicla the spacer profile is finally
integrated within
the insulating window unit, it can be advantageous to also provide a
protective layer on the
exposed side of the reinforcement layer, which exposed side may be sensitive
to
mechanical and/or chemical influences. Representative protective layers
include, e.g.,
lacquer andlor plastic materlals. In addition or in the alternative, a thin
layer of the beat
insulating material may be provided on the reinforcement layer, such as a
material
exhibiting relatively low heat conductivity. Such a thin layer optionally may
be embeddcd
in one or more portions of the spacer profile.
[00211 (Ienerally speaking, the walls of the spacer proffiYe that define the
chamber may
have substantially the same walt thiclsness, It is preferable to maximize the
volume of the
chamber, whiclt will maximixe the amount of hygroscopic matexi.al that may be
disposed
within the chamber. For example, the wall thicimess of one or more of the
walls is
preferably minimized in order to maximiza the chamber volume.
[0022] The present spacer profiles enable the manufacture of insulating window
units
from a single linear piece that is only required to be bent and then closed by
one
connector. For example, commorcially available bending tools may be easily
utilized to
bend the spacer profile so as to provide corners, Preferably, even after being
bent, the
surfaces of side walls of the spacer profile preferably remain planar
(substantially flat),
and substaatiaIIy perpcndicular to the base wall, so that the side surfaces
will be parallel,
or substantially parallel, to the respective window panes in the assembled
insulating
window unit. I,f thc clastically-plastically defozmable, heat-insulating
material is
permanently coupled (bonded) to the plasticalty deformable reinforcement
layer, a good
balance of forces is imparked to the spacer profile, even during cold bending.
However, the
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expected bending points of the spacer profile may be slightly warmed before
bending in
order to accelerate relaxation of the spacer profile and reinforcement layer
at the portions
that will be bent. Moreover, various connectors may be suitably utilized to
connect the
terminal ends of the bent spacer frame, including corner connectors and
straight
connectors.
100231 According to another advantageous embodiment, a mechanically
stabilizing
sealing material may completely fill up the free space defined along the outer
peripheral
margin of the asscmbkd 'uisulating window unit, or may substantially fil1 up
that free
space. Commercially available insulating glass adhesives oontaining
polysulfides,
polyurethartes or silicons are suitable sealing materials. Further, butyl
sealing matcrials,
e.g., containing polyisobutylenes, are suitable diffason-resistant adhesive
materials for
bonding the side waIIs of the spacer frame to the respective window panes.
[00241 Further objects, aspects and advantages of the present teachings will
be readily
understood after reading the following description with reference to the
drawings and the
appended claims.
BRZEF DESCRIPTION OF THE DRAWINGS
[0025) FIG. l shows a representative spacer profile according to the present
teachings,
loo261 FIG. 2 shows the representative spacer profile of FIG. 1, which has
been bent
into a spacer fratne and disposed between two window panes to form an
asseznbled double
glazing (insulating window unit).
DETAILED DESCItIl'TION OF THE INVENTION
100271 In one embodiment of the present teachings, spacer profiles may include
a profile
body having a base wall, first and second side walls extending from the base
wall, and an
upper wall extending substantially in parallel with the base wall. A first
connecting
segment preferably connects the first side wall to the upper waD and a second
connecting
segment prefeTably connects the second side wall to the upper wall. The first
and second
connecting segments respectively may define an inwardly curved or angled
(e.g.,
substantially V-shaped or U-shaped) groove (or recess) between the upper wall
and the
respective first and second side walls. In addition, the profile body
prOforably is formed as
a single, integral, continuous piece without borders (interfaces) between the
various
components thereof (i.e., no interfaces between the upper wall, side walls,
base wall, and
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connecting segments). In addition, the profile body preferably comprises an
elasticaily-
plastically deformable material having a heat conductivity of less than about
0.3 W/(m-K).
Such profile bodies can be readiry manufacWred using known extrusion
techniques.
(00281 A hollow chamber is defined within the profile body. Preferably, the
hollow
chamber includes a first space in communication with a second space. The first
space is
defined adjacent to the base wall and the seoond space is defined adjacent to
the upper
wall. Preferably, the first space has a greater width than the second space
along a lateral
or transverse clirection of the elongated spacer profile.
[00291 A reinforcement layer may be permanently coupled or bonded to at least
the
upper wall, the 5rst and second connecting segments, and the first and second
side walls.
The rcinforcement layer preferably has a heat conductivity of less than about
50 WI(m-K)
and optionally is resistant to diffusion of gas and vapor therethrough..
100301 The hollow chamber may baave a cross-section selected from the group
consisting
of substantially T-shaped, substantially bell-shaped, substantially pyramid
shaped and
substantially stepped-shaped. In addition or in the alternative, the first and
second spaces
are each substantially rectangular shaped and the first space optionally may
have a larger
cross-sectional area than the second space. In another alternative definition
of the
chamber dimensions, the cbamber may comprise a central space communicating
with two
IatetaAy periplteral spaces, which laterally peripheral spaces are bounded by
the base wall,
but are not bounded by the upper wall. As noted abovc, a hygroscopic material
optionally
may be disposed witban the hollow chamber and a plurality of apertures may be
defined in
the base wall,
100311 The reinforcement layer of the spacer profile prefc~ably has a breaking
dongation of at least 20% and more preferably about 25-30%. The reinforccment
layer
preferably may comprise a staioless steel layer having a thickness of less
than about 0.2
xnm, or morm preferably equal to or less than about 0.1 mm. Morc preferably,
the heat
conductivity of the reinforcement layer is equal to or less than about 15 W/(m-
IG). Further,
the spacer profile optionally may have an overall tensile strength of about
350-370
Nlmma.
[0032] The reinforcement layer preferably extends continuously from the first
side wall
to the second side wall. The profile body may be formed as one continuous,
integral piece
(i.e., without interfaces between the various components of the profile body)
and may
comprise one or more of polypropylene, polyethylene terephthalate, polyarnide
and/or
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polyearbonate. The profile body may be reinforced or not reinforced. If
reinforced, the
profile body may comprise one or more fibrous materials, such as a glass
fiber, a carbon
fiber and/or a natural fiber, dispersed within the profile body. Optionally,
the profile body
may contain glass particles, such as fiberglass, and/or a filler, such as
talc, dispersed
therein.
[0033] Optionally, the grooves (or recesses) respectively defined within the
connecting
segments may have a substantially U-shaped cross-section (e.g., the grooves
are inwardly
curved, but have substantially perallcl opposing walls) or may have a
substantially V-
shaped cross-section (e.g., the opposing walls are not parallel to each
other). If the cross-
section of the groove is substantially V-shaped, the opposing walls of the
groove
preferably may define an acute angle or a right angle. In one etnbodiinent of
a connector
segment having a substantially V-shaped groove defined therein, the opposing
walls of the
groove may define an angle of about 60-90 . A hypothetical vertex formed by
the
intersection of the opposing walls of the connecting segments is preferably
disposed
inwardly of a hypothetical line connecting a terminal end of the respective
side wall to the
terminal end of the upper wall. However, even if the groove is substantially V-
shaped, it
is not necessary for the opposing walls to intersect at a point. Instead, the
opposing walls
=may be cottnected by a rounded or carved portion. The cross-section of the
rounded or
curved portion optionally may be substanrially circular or substantially oval.
100341 In addition or in the alternative, each of the first and second
connecting segments
may include a first portion (first opposing wall) extending substantially
perpendicularly
fxom the upper wall and a second portion tsecond opposing wall) connecting the
first
porcion to the respective side wall. Optionally, the respective second
portions of the first
and second connecting segments may each extend substantia[ly perpendicularly
from the
respective side wall. In addition or in the alternative, the first and second
grooves may
eacb, extend (inwardly) toward the base wall below a hypothetical line
cotmecting a
terrninal end of the first side wall and a terminal end of the second side
wall, which
terminal ends arc opposite of the base wall.
100351 Further, the first and second grooves optionally may each have a depth
that is
between about 0.1 and 1 times the length of the first poraons, In addition or
in the
altem.ative, the depth of the first and second grooves may be between about
0.5 to 5 times
the thickness of the side walls. In addition or in the alternative, the depth
of the first and
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second grooves is preferably less than twice the width of the frst and second
grooves.
More preferably, the depth of the grooves is equal to or less than the width
of the grooves,
[0036] An assembled insulating window uWt preferably may include a first
window
pane disposed substantially in parallel with a second window pane. A spacer
framc is
preferably formed by bending and connecting the terminal ends of any one of
the spacer
profiles described above or below. The bent spacer frame is disposed between
and
supports the first and second window panes. The respective side walls of the
spacer Erame
may be adhered to the first and second window panes using an adhesive.
Further, the base
wall of the spacer frame is preferably oriented toward a space defined between
the first
and second window panes. In this case, the upper wall of the spacer frame is
thus oriented
toward an outer peripheral edge of the first and second window panes. In
addition, a
mechanically stabilizing sealing matcrial is preferably disposed on the upper
wall between
the first and second window panes.
[0037] Each of the additional features and teachings disclosed below may be
utilized
sepaira-tely or in conjunction with other features and teachings to provide
improved spacer
profiles and methods for designing and using the same. Representative examples
of the
present invention, which examples utilize many of these additional features
and teachings
both sepatately and in combination, will now be descn'bed in further detail
with reference
to the attached drawings. Tltis detailed description is merely intended to
teach a person of
skill in the art finther details for practicing preferred aspects of the
present teachings and is
not intended to linlit the scope of the invention. Therefore, combinations of
features and
steps disclosed in the following detail description may not be necessary to
practice the
invention in the broadest sense, and are instead taugb.t merely to
particularly describe
representative examples of the present teachings.
[0038] Moreover, the various features of the representative examples and the
dependent
claims may be combined in ways that are not specifically and explicitly
enumerated in
order to provide additional useful embodimenfs of the present teachings. In
addition, it is
expressly noted that all features disclosed in the description and/or the
claims are intended
to be disclosed separately and independently from each other for the purpose
of original
disclosure, as well as for the purpose of restricting the claimed subject
matter independent
of the compositions of the features in the embodiments and/or the claims. It
is also
expressly noted that all value ranges or indications of groups of entities
disclose every
CA 02502069 2008-07-11
possible intermediate value or intermediate entity for tha purpose of original
disclosure, as
well as for the purposc of restricting the claimed subject matter.
[00391 FIG. I shows a cross-section of a representative spacer profile 1
according to the
present teachings. A chamber (or hollow space) 7 is preferably defined by a
base wa112, a
pair of side walls 3 and an upper wa114. Connecting segmertts 5 connect the
respective
side walls 3 to the upper wal14. The base wall 2 is preferably longer than the
upper wall
4. The side walls 3 preferably have the same leagth. For purposes of
reference, FIG. 1
sb.ows a cross-section of the representative spacer profile 2 along a Z
ditcction thcrcof ancl
defines an X direction and a Y direction of the spacer profile 1. In other
words, the Z
direction is perpendicular to the X and Y directions and extends
perpendicttlarly to the
drawing sheet. Thus, the base wall 2 and the upper wall 4 exterad
substantially in the X
direction and the side walls 3 extend substantially in the Y direction. The
entire spacer
profile 1 is elongated in the Z direction. Hereitt, the X direction will also
be referred to as
the width direction of the spacer profile 1 and the Y direction will also be
refetred to as the
height direction of the spacer profile 1.
[0040] In this embodiment, the chamber 7 has a substantially T-shaped or bell-
shaped
cross-section. For example, the chamber 7 may include a base (first) space 11
closest to
the base wall 2 that has a longer width or lateral dimension (i.e., along the
X direction)
than an upper (second) space 10 closest to the upper wal14. As was discussed
above, in
other embodiments, the chamber 7 may have a cross-section that is
substantially stepped-
shaped or pyramid-shaaped. In other words, the chamber 7 preferably includes
laterally
peripheral spaces (i.e., along the X direction) adjacent to the base wal12,
which laterally
peripheral spaces are tapered or step-wise terminated along the height
direction (i.e., the Y
direction) towards the upper wall 4. In addition, the coraers of the chamber 7
may be
substantially rounded or cuived, as shown in FIG. 1, or the corners may be
nngular, such
as right angles, acute angles or obtuse angles.
[0041) The inner surface of the chamber-7 is preferably coated with a
hygroscopic
material, such as a silica gel or molecular sieves, and/or the chamber 7 may
be filled, or
substantially filled, with the hygrostopic material or a material that
comprises, at least in
part, a hygroscopic material. A plurality of apertures 8 is preferably
defined, e.g., in the
base wall 2, to peimit communication with the chamber 7. Prefened bygroscopic
materials are capable of absorbing moisture from the gas (e.g., argon)
disposed berween
the window panes of the assembled insulting window unit. Thus, by providing
the
11
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apertures 8, the chamber 7 can communicate with the gas disposed between the
window
panes in order to remove moisture fram the gas, As a result, the as&embled
window unit
(double glazing) can be prevented from fogging (i.e., condensed water) on the
inside of the
window panes during cold weather conditions, because the hygroscopic material
maintains
the insulating gas in a relatively dry (low humidity) state.
[00421 The side walls 3 preferably each have a length (height) that is less
than the
distance between the outer peripheral surfaces of the base wall 2 and the
upper wall 4. As
shown in FIG. 1, a groove (or reccss) 9 ia defanod by tbe sidC wal13, the
upper waU 4 and
the connecting segtnent 5. However, the groove 9 may be defined by only the
connecting
segment 5 or by the connecting segment 5 and one of the side wall 3 and the
upper wa114.
Further, the shape of the groove 9 is not particularly limited according to
the present
teaehi.ngs, as the groove 9 may be, e.g., inwardly curved or angled.
100431 preferably, the groove 9 extends at least partially inward (i.e.,
towards the center
or the base wal12 of the spacer profile 1) of a hypothetical line B connecting
the terminal
end of the side waI13 (which tenninal end is closest to the upper wall 4) and
the tenriinal
end of the upper wal14 (which tenninal end is closest to the side wal13). In
addition or in
the aIternative, the groove 9 extends at least partially inward of a
hypothetical line A
connecting the terminal ends of the first and second side walJs 3. The size of
the side walls
3, upper wall 4 and connecting segments 5 may be suitably modified in order to
provide
various shapes for the groove 9. For example, the side walls 3, connecting
segments 5
and upper wal14 may be preferably designed such that the depth T) of the
groove 9 is less
than twice the width H of the groove 9 and more preferably, the depth D is
less than or
equal to the width H.
100441 In the embodiment shown in FIG. 1, the groove 9 is substantially U-
shaped.
However, in another preferred embodiment, the groove 9 may be rather shallow
and
defiwed substantially as a right angle. In another embodiment, the connecting
segments 5
may define substantially an acute angle therebetween. For example, the
opposing walls of
the groove 9 may define an angle of between about 64-90 .
100451 In addition or in the alteznative, the connecting segments 5 may extend
from
substantially the terminal ends of the respective side walls 3. Tn this case,
the connecting
segments 5 may extend, e.g., substantially perpetxdicularly from the terminal
ends of the
side walls 3. As a result, the connecting segments 5 may contiect to the upper
wall 4 at
substantially a right angle or a relatively large Acute angle. In such an
embodiment, the
12
CA 02502069 2008-07-11
upper space 10 and the base space 11 may each have a substantially rectangular
cross-
section. Tho width of the upper space 10 (i.e., along the X direction) is
preferably less
than the width of the base space 11. Optionally, the upper space 10 also may
comprise a
larger cross-sectional area than the cross-sectioinal area of the base space
11.
[0046] The side walls 3 preferably extend substantially in parallel along the
height or Y
direction of the spacer profile 1, as shown in FIG. 1. Each of the walls 2, 3,
4, and the
connecting segments 5 may have substantially the same thiclmess. Further, the
material
for thc walls 2, 3 and 4 and the eonnecting segments 5 is preferably diffusion-
proof
(impermeable) or diffusion-resistant (substantiaIly impermeable), so as to
prevent or at
least mininlize the diffusion (htansmission) of gases or liquids through the
spacer profile 1.
In addition or in the alteraative, a layer of difFusion-proof material may be
disposed on an
outer surface of the spacer profile I in order to prevent diffusion of
substances, such as
water and atmospheric gases (e.g., nitrogen and oxygen), through the spacer
profile 1 so as
to maintain the integrity of the insulating gas (e.g., argon) disposed between
the window
panes of the assembled double glazing.
100471 Preferably, a reinforcement material (layer) 6 is disposed along at
least the upper
wall 4 of the spacer profile 1. More preferably, the reinforcem.eztt 'material
6 also extends
along the connecting segments 5 and the side walls 3. By covering the side
walls 3 with
the reinforcexnent material 6, improved adhesion properties may be attained
when the
spacer profile I is adbered or bonded to the window panes to form the
assembled double
glazing. Moreover, the spacer profile 1 will have improved bending properties,
due to the
permanently bonded sandwich structure (i.e., the connecting segments 5 and the
side walls
3 are surrounded by the reinforcenient layer 6). The reinforcement material 6
may be
disposed on the outer surface of the spacer profile 1, or may be partially or
completely
embedded within the spacer profile 1. In the latter case, a protrusion 12 of
the side waIl 3
may overlap the terminal end of the reinforcement material6.
100481 If the reinforeetnent material 6 comprises a metal, a heat-conductive
path will be
defined through the reinforcetnent material 6 from one side wa113, which will
be closest to
a first window pane, to the other side wall 3, which will be closest to a
second window
pane. However, as discussed herein, additional measures can be taken to reduce
the heat-
conductivity of this path in order to improve the overall insulating propenies
of the spacer
profile 1.
13
CA 02502069 2008-07-11
[00491 ln one modification of the spacer profile I shown in FIG, 1, the base
wall 2 may
be replaced with a porous material that permits moisture to diffuse into the
chamber 7. In
this case, the apertures 8 optionally may be eliminated.
[0050] In addition oT in the alternative, either another reinforcement
material or the same
reinforcement material 6 may partially or completely cover the outer surface
of the base
wall 2. In addition or in the alternative, a decorative layer and/or a heat
radiation
reflecting layer optionally may be disposed on the outer surface of the basa
wall 2.
[00511 Optionally, the side walls 3 may extend from the base wall 2 at other
than a right
angle. For example, the side walls 3 may extend outwardly from the edge of the
base wall
2 so as to form an obtuse or acute angle with the base wa112.
[00521 In another optional modification of the representative embodime,nt
shown -in FIG.
1, the base wai12 may be omitted. In that case, the chamber 7 may be designed
as a
trough or channel. The hygroscopic material may be embedded in a polymer
matrix that is
disposed in the troughlchannel, thereby filling or substantially filling the
trouglt/channel.
Optionally, an adhesive may be coated on the inner surface of the
troughlchannel before
filling the troughlchannel with the polymer matrix. Moreover, in this optional
embodiment, the reinforcement material 6 may be fust disposed along the inner
surface of
the trougb/channel before filling the troughlchannel with the polymer matrix.
hi this case,
the reinforcement material 6 optionally need not be disposed along the outer
surface of the
upper and side walls 4 and 6 and the connecting segments S.
[00531 The spacer profile I is preferably bendable so as to forrn a support
frame. More
preferably, the spacer profile I is bezrdable without undesirable deformation
along the side
walls 3 of the corner portion, even when the spacer profile I is bent at a
relatively low
temperature (e.g., room fomperature). The bent support frame is then disposed
between a
pair of window panes 23 to form an assembled double glazing structure
(insulating
window unit) 20. One representative embodiment of a double glazing structure
20
according to the present teachings is shown in FIG. 2 and is discussed further
below.
[00541 Referring to FIG. 2, the respective side walls 3 of the spacer profile
I preferably
support the respective inner surfaces of the window panes 23. Preferably, even
after being
bent, the side walls 3 remain substantially perpendicular to the base wai12 so
that the side
walls 3 are parallcl, or substantially parallel, to the window panes 23 in the
assembled
double glazing 20. Further, in order to protect the reinforcement material 6,
a protective
14
CA 02502069 2008-07-11
layer optionally may be disposed along the outer surface of the reinforcement
material 6
before inserting the spacer profile 1 between the window panes 23.
[00551 Sealing material 22 preferably serves to support the spacer profile 1
between the
window panes 23 and imparts an airtight, or substantially air-tigbt, sea], In
addition, an
adhesive material 21 is preferably disposed between the side walls 3 and the
window
pa,nes 23, For example, the spacer profile I may be first affixed to the
respective inner
surfaces of the window panes 23 using the adhesive 21, Then, the remaining
space may
be filled with a mechanically stabilizing sealing matprial 22, which also
prCfCrrably
provides an airtight/watertight seal or a substantially airtight/watertight
seal. In other
words, the sealing materia122 is preferably selected so as to prevent or
minimize moisture,
and other undesirable gases, from entering Into the enclosed space between the
window
panes 23 in the assembled double glazing stcucture 20.
10056I In an optional modification of the double glazing struct= shown in FIG.
2, two
or more different scaling materials 22 may be u.tilized to fill the outer or
peripheral space
bounded in part by the spacer profile I and the window panes 23. For example,
a first
sealing matcrial 22 may be filled into the space and allowed to set.
Thereafter, a second
sealing material 22 may be disposed, at least partially, over the first
sealixtig material 22.
100571 In particularly prefezxed embodiments of the present teachings, the
base, side and
upper walls 2, 3, 4 and the connecting segments 5 may comprise polypropylene
Novolen
1040K and may have a wall thickness of about ] mm. In the alternative, the
base, side and
upper walls 2, 3, 4 and the connecting segments 5 may comprise polypropylene
MC208U,
which comprises 20% talc, or polypropylene BA110CF, which is a beterophasic
copolymer, both of which are available from Borealis A/S of Kongens Lyngby,
Den,mark.
.J In the alternative, the base, side and upper walls 2, 3, 4 and the
connecting segments 5
may comprise AdstxfQD HA840YC., which is a polypropylene homopolymor available
from
Basell Polyolefins Company NV.
100581 The reinforcement material 6 may be a metal foil or thin metaI plate
materia.I,
e.g., Andralyt E2, 8/2, 8T57, and may have a thickness of about 0.1 mm. The
metal
material 6 may be co-extruded with or laminated onto the upper and side walls
3, 4 and the
comecting segments 5. For example, the reinforcement material 6 may be adhered
to the
plastic portion of the spacer profile I using a 50 micron layer of a bonding
agent
(adhesive), such as a polyurethane and/or a polysulfide. Further, the outer
side of the
CA 02502069 2008-07-11
metal foil or thin metal plate (film) preferably has been treated to prevent
corrosion (e.g.,
rust).
[0059] In an optional embodiment, the reinforcement material 6 may be a tin-
plated iron
foil. The base portion of the tin-plated iron foil may have a chemical
compositioa of:
carbon 0.070%, mangancse 0.400"/0, silicon 0.018 h, aluminum 0.045%,
phosphorus
0,020%, nitrogen 0.007%, the balance being iron. A tin layer having a
weightlsurface
ratio of 2.8 glm2 may be applied to the base portion at a thickness of about
0.38 microns.
[0060] In thc alterr,ative, tla; cninrorc:ement material 6 may preferably
comprise a
staiuless steel foil, e.g., Krupp Yerdol Aluchaorn I SE, having a thickness of
about 0,05-
0.2 mm, more preferably about 0.05 mm to 0.2 mm and most preferably about 0.1
mm.
The chemical composition of this stainless steel may be approximately:
chromium 19-
21%, carbon maximum 0.03%, manganese maxirnum 0,50 l0, silicon maximum 0.60%,
=1 =
aluminum 4.7-5.5%, the balance beiAg iron.
[0061) In the alternative, the reinforcement material 6 may comprise aluminum
metal
having a thickness of about 0.2-0.4 mm.
[o062] In the alternative, a galvanized iron/steel sheet having a thickness of
about 0.1-
0.1 S mm may be utilized as thc reinforcement material 6.
[0063) Although various dimensions are possible in accord.ance with the
present
tsachings, the assembled spacer profile 1 preferably may have a width (X
directaon) of
about 16 mm and a height (Y direction) of about 6.5 mm. The chamber 7 may have
a
height of about 5 mm. The base space I1 of the chamber 7 may have a width of
about
13.5 mm and the upper spaca 10 of the chamber 7 may have a width of about 10
mm.
[oo64) The charttber 7 may be filled with a lcnown drying agent (hygroscopic
m.ateiial),
such as the molecular sieve Phonosorb 555, which is manufactured by W.R. Grace
&
Company. As discussed above, two rows of apettt=s 8 may be provided in the
base wall
2, so,that the drying agent can communicate with the space between the window
panes 23.
[0065] The elongated spacer profile 1 optionally may be cut into lengths
(i.e., along the
Z direction) of 6 meters (20 feet) and then fiuther processed using known
bending devices
in order to form the support frame. For example, the automatic bending machine
made by
F.X. BAYBIt can be utilized to form type VE spacer frames cut to customized
dimensions.
The spacer profile 1 may be bent to form four corners therein and the terminal
Gnds of the
bent spacer profile 1 may be connected using a straight connector to form tha
spacer
frame.
16
CA 02502069 2008-07-11
[OO66I Known tec'ques may be utilized to connect the support frame to two
large
float-glass panes 23 to form the assembled insulating window unit (double
glazing
structure) 20. One of the window panes 23 optionally may be provided with a
heat-
protective layer having an emittance of about O.J. The enclosed space defined
between the
window panes 23 and bounded by the spacer frame may be filled with argon or
another
inert andlor insulating gaseous substance. In a particularly preferred
embodiment, the
encloswi space has an argon content of at Ieast about 90% of the total gas
volume within
the enclosed space.
1o0671 The adhesive 21 preferably may be a butyl sealing material, such as
polyisobutylene. The adhesive 21 may have a width of about 0.25 mm and a
height of
about 4 mm. The sealing mmteria122 may be a polysulfide adhesive having a
thic[rness of
about 3 mm.
[00681 In prefezxed embodiments, the reinforcement layer 6 and the plastic
portion
(profile body) of the spacer profile I may exhibit the following preferred
properties. The
reinforcement layer 6 and the profile body of the spacer profile I
respectively may have an
elastic modulus of about 180-220 kNlmrnz and about 1.5-2.5 kNlmm2. In addition
or in
the alternative, the reinforcement layer 6 and the profile body of the spacer
profile I
respectively may have a te,nsile strength of about 350-650 N/mmz and 35-40
N/mmz. The
spacer profile 1(i.e., the combined plastic portions (spacer body) and the
reinforcement
material 6) preferably has a total or overall terisilo strength of about 350-
370Nlmsa~.
[0069] In aMkon or in the aitemtive, the reinforcement layer 6 and the plastic
portion
of the spaccr profile 1 respectively may have an elasticity limit or yield
point of about
280-580 N/mmZ and 35-40 N/rnm'. In addition or in the alternative, the
reinforcement
layer 6 aad the profile body of the spacer profile I respectively tnay have a
breaking
elongation of about 20-30% and about 500%. More preferably, the reinforcement
material
6 has a breaking elongation of about 25-30%.
100701 In addition or in the alteraative, the reinforcement layer 6 and the
profile body of
the spacer profile I respectively may have a thernnal conductivity of 15-35 W/
m-K and
equal to or less than 0.3 W/ m-K, more preferably equal to or less than 0.15
W/ m-K. In
addition or in the alternative, the reinforcement layer 6 and the profile body
of the spacer
profle 1 respcctively have an elastic extensibility of about 0.2% and about 7
!o.
[oon1 St- order to demonstrate the advantages of the present designs when used
with the
preferred materials, 90 bends were introduced into four different spacer
profiles using the
17
CA 02502069 2008-07-11
automatic bending machine made by F.X. BAYER. The spacer profiles were at room
temperature when bent and each spacer profile had a width (X direction) of 16
rnm. The
differences between the four spacer profiles are further described in the
following.
100721 The first spacer profile I was constrneted according to the present
teachings with
side walls 3 having a height (Y direction) of 5.2 mm and a total height (Y
direction from
ttxe outer surface of tbo base r+va112 to the outer surface of the upper wall
4) of 7.0 rnm.
The upper wall 4 had a width of 11.1 mm. The distance from the outer surface
of the
upper wall 4 to the base of groove 9 was 2.4 rnnm. A first portion uf the
bollow chamber 7
closest to the base wall 2 had an inner width (X direction) of 13.3 mm and a
height of 3.1
mm. A sedond (adjoining) portion of the bollow chamber 7 closest to the upper
wall 4 had
a width of 9.43 mm and a height of 2,4 mm. The spacer body was" formed of
polypropylene. The reinforcement layer 6 was disposed on the outer surface of
the side
walls 3, upper wall 4 and the connecting portions S. In addition, the
reinforcement layer 6
had a thickness of 0.13 rnm and was formed of stainless steel!
100731 After bending the first spacer profile 1, the side walls had a height
of 4.9 to 5.0
mm at the corner portions and the side walls 3 remained substantially flat and
perpmdicular to the base wall 2. No noticeable indetttations were formed in
the corner
portions. In other words, the spacer profile 1 of the present teachings could
be "cold" bent
without significant distottion or deformation at the comer portions. Thus, the
side walls 3
at the comer portions of the bent spacer profile 1 present a substantially
flat surface for
adhering to the window panes 23 of the assembled double glazing structare 20.
J00741 The second profile spacer was constructed entirely from stainless steel
with the
trapezoidal shape described by U.S. Patent No. 6,601,994. Before bending, the
side walls
of the second profile spacer had a height of 4.4 rttm. After bending, the side
waiIs had a
height of 3.4 mm at the corner portions and several relatively large
indentations were
presept in the side walls at the corner portion. Thus, after bending, the
stainless steel
spacer profile having a trapezoidal shape showed significatit distortions and
deformation
in the side walls at the cortier portions thereof.
100751 The third profile spacer was constructed entirely from aluminum with
the
trapezoidal shape described by U.S. Patent No. 6,601,994. Before bending, the
side walls
of the third profile spacer had a height of 5.0 mm. After bending, the side
walls had a
height of 4.15 mm at the corner portions and several small indentations were
present in the
side walls at the corner portions. Thus, after bending, the aluminum spacer
profile having
18
CA 02502069 2008-07-11
a trapezoidaI shape also showed significant distortions and deformation in the
side walls at
the corner portions thereof. -
[0076I The fourth profile spacer was a composite material having the
trapezoidal shape
described by U.S. Patent No. 6,601,994. The profile body was made of
polypropylene. A
reinforcement layer of stainless steel is embedded within the profile body and
the
reinforcement layer extended from one side wall to the other side wall, along
the upper
wall of the spacer profile. In other words, the reinforcement layer did not
extend along the
base wall of the 9paccr profilc. Before bcnding, the side walls of the third
profile spacer
had a height of 4.7 mm. After bending, the side walls had a height of 4.3 mm
at the corner
portions and one relatively large indentation was present in the side walls at
the corner
portions of the spacer profile.' Thus, after bending, the fourth (composite)
spacer profile
having a trapezoidal shape also showed significant distortions and
deformatiott in the side
walls at the corner portions thereof.
100771 Thus, these experimental results demonstrate the clear advantages of
the present
spacer profiles 1, as compared to known designs that have a trapezoidal shape.
I00781 Furthermore, in another advantage of the present teachings, it is noted
that the
hollow chamber 11 of the first spacer profile describcd in paragraph [0074]
has an inner
cross-sectional area of 63.9 square millimetcrs. On the other hand, the
improved spacer
profile described in U.S. Patent No. 6,339,909 having the same widtb (16 mm)
and a
height of 6.5 inm has an inner cross-sectional area of 46.1 square
millimeters. Thus, the
present designs provide an increased volume for accommodating the hygroscopic
material
without increasing the outer dimensional sizes of the spacer profile.
Consequently, the
presemt designs provide the additional advantage of being capable of
maintaining the inner
(gas) space of the assembled double glazing in a dry state for a longer period
of time as
compared to spacer profiles having similar outer dimensions (i.e., similar
widths and
beights).
[0079) Additional teachings relevant to, and advantageously combinable with
the
present teachings, are found in, e.g., commonly-owned US Patent Nos.
6,035,596,
6,389,779, 6,339,909 and 6,582,643.
19
