US3928953A

US3928953A - Packaged add-on multiple glazing units and method

Info

Publication number: US3928953A
Application number: US454210A
Authority: US
Inventors: Renato J Mazzoni; George H Bowser; John L Stewart
Original assignee: PPG Industries Inc
Current assignee: PPG Industries Inc
Priority date: 1974-03-25
Filing date: 1974-03-25
Publication date: 1975-12-30
Anticipated expiration: 1992-12-30
Also published as: CA1042722A; GB1510457A; BE826917A

Abstract

Two prefabricated add-on glazing subassemblies are sealed together to form a package for handling, shipping, and storage. When separated, each subassembly is mounted onto an existing single glazed window to convert it to an insulating, sealed, multiple glazed installation.

Description

United States Patent [1 1 Mazzoni et a1.

[ 51 Dec. 30, 1975 PACKAGED ADD-ON MULTIPLE GLAZING UNITS AND METHOD [75]. Inventors: Renato J. Mazzoni, Tarentum;

George H. Bowser, New Kensington; John L. Stewart, Murrysville, all of [73] Assignee: PPG Industries, Inc., Pittsburgh, Pa.

[22] Filed: Mar. 25, 1974 [21] Appl. No.1 454,210

[52] US. Cl. 52/172; 52/203; 52/616; 52/741; 206/454 [51] Int. Cl. B65D 85/48; E06B 3/28 [58] Field of Search 52/172, 173, 202, 203, 52/397, 398, 399, 400, 616, 741; 206/449, 454

[56] References Cited UNITED STATES PATENTS 1,777,435 10/1930 Hogelund 52/203 3,299,591 l/1967 Woelk 52/203 3,460,303 8/1969 Algrain et a1. 52/616 X 3,511,990 5/1970 Hauss 206/454 X 3,618,755 11/1971 Kean et all. 206/454 3,733,237 5/1973 Wolff 52/172 X Primary ExaminerPrice C. Faw, Jr. Attorney, Agent, or Firm-Dennis G. Millman 57 ABSTRACT Two prefabricated add-on glazing subassemblies are sealed together to form a package for handling, shipping, and storage. When separated, each subassembly is mounted onto an existing single glazed window to convert it to an insulating, sealed, multiple glazed installation.

21 Claims, 13 Drawing Figures US. Patent Dec. 30, 1975 Sheet20f5 3,928,953

U.S. Patent Dec. 30, 1975 Sheet4 0f5 3,928,953

US. Patent Dec. 30, 1975 Sheet 5 of5 3,928,953

PACKAGED ADD-ON MULTIPLE GLAZING UNITS AND METHOD BACKGROUND OF THE INVENTION This invention relates to the conversion of installed, single glazed windows into multiple glazed windows, more particularly to an advantageous method and means for handling, storing, and shipping prefabricated subassemblies to be used in such a conversion.

In U.S. Pat. application Ser. No. 454,338 filed on even date herewith by Renato J. Mazzoni, George H. Bowser, and Richard R. Lewchuk, assigned to the assignee of the present invention and which is hereby incorporated by reference, there are disclosed improved methods and means for transforming single glazed windows into hermetically sealed, insulating, multiple glazed units. The embodiments disclosed therein involve the preliminary fastening of a spacer element to the marginal surfaces of the transparent pane which is to be added onto the window. Certain advantages are obtained if the fastening of the spacer is performed at a factory or central distribution facility, such as: the efficiency of mass production techniques, the formation of better bonds and seals due to the availability of specialized equipment, fewer limitations as to the materials that may be used, and a more uniform product because of better quality control and the use of experienced personnel.

Such a prefabrication technique would be even more desirable if a practical means of shipping and handling the prefabricated subassemblies were available. One problem encountered is that it is usually preferred to use spacers containing a desiccating agent, which must be protected from atmospheric moisture during shipping. In many cases, it is desired to provide a reflective coating on the surface of the pane that is to be sealed into the airspace. Many of such coatings are fragile, however, and during shipping of the subassemblies the coatings would be subject to deterioration from exposure to the atmosphere and from abrasion. Furthermore, since the surface of the pane which is to be sealed into the airspace must be meticulously clean at the time of installation, it would be advantageous if stringent factory cleaning operations could be employed and the surface of the pane kept free from contaminants during subsequent shipping and handling.

One approach taken in the prior art is disclosed in US. Pat. No. 1,915,098 to Kile. In that patent, a strippable sheet'of Holland cloth (a heavily sized linen material) is applied across the open face of the subassembly and adhered to the spacer around the perimeter. Such an approach is disadvantageous because of the large amount of material required, because a moisture resistant seal would be difficult to achieve, and because the sheet is susceptible to accidental dislocation and tearing.

Thus, it is an object of the present invention to provide an improved method and means for shipping, storing, and handling add-on glazing subassemblies. The invention is applicable not only to the particular embodiments shown in the above-identified copending application, but to the handling of any glazing unit which has its airspace temporarily open.

SUMMARY OF THE INVENTION In accordance with the present invention, two add-on glazing subassemblies are placed in generally face-toface relation and the airspace therebetween temporarily sealed so as to form an essentially airtight enclosure that protects the interior surfaces and the desiccant. Theairspace is preferably sealed by means of a tape coated with an adhesive or sealant. At the installation site, the subassemblies are separated by peeling or cutting the tape.

DETAILED DESCRIPTION OF THE INVENTION A complete understanding of the invention will be obtained from the following detailed description, taken together with the drawings in which:

FIG. I is a perspective view, partially cut away, of a single glazed window installation upon which the present invention may be practiced;

FIG. 2 is a fragmentary cross-sectional view of one embodiment of an add-on glazing subassembly;

FIG. 3 is a fragmentary cross-sectional view of two subassemblies of the type shown in FIG. 2 joined to form a sealed package in accordance with the present invention;

FIG. 4 is a fragmentary cross-sectional view of a separated subassembly with sealant applied thereto in preparation for mounting;

FIG. 5 is a perspective view, partially broken away, of the window structure shown in FIG. 1 after conversion to double glazing;

FIG. 6 is a fragmentary cross-sectional view, taken along lines 6-6 in FIG. 5 of a completed installation of the subassembly shown in FIG. 4 onto the window installation shown in FIG. 1;

FIG. 7 is a fragmentary cross-sectional view of two add-on glazing subassemblies of a second embodiment joined to form a sealed package in accordance with the present invention;

FIG. 8 is a fragmentary cross-sectional view of a subassembly formed by splitting the package shown in FIG. 7

FIG. 9 is a fragmentary cross-sectional view of a completed installation of the subassembly shown in FIG. 8 onto the window installation of FIG. 15

FIG. 10 is a fragmentary cross-sectional view of two add-on glazing subassemblies of a third embodiment joined to form a sealed package in accordance with the present invention;

FIG. 11 is a fragmentary cross-sectional view of a subassembly formed by cutting apart the package shown in FIG.

FIG. 12 is a fragmentary cross-sectional view of a completed installation of the subassembly shown in FIG. 11 onto the window installation shown in FIG. 15 and FIG. 13 is a fragmentary cross-sectional view of a fourth embodiment of packaged subassemblies.

Depicted in FIG. 1 is an interior view of a single glazed window unit that would typically form part of a building wall structure, the window comprising a pane of glass 15 and a frame 16. The conversion of such a window to double glazing will serve as an illustrative example of this invention.

In FIG. 2, there is shown a preferred embodiment of an add-on glazing subassembly made in accordance with the disclosure of the above-identified copending application. Briefly, the subassembly includes a moisture resistant (i.e., essentially water vapor impervious) ribbon 20, preferably aluminum foil about 8 mils thick, along the length of which is attached an elongated spacer element, preferably flexible, moisture vapor permeable, organic material having a desiccant dispersed therein as disclosed in U.S. Pat. No. 3,758,996. Spacer 21 is adhered to ribbon 20 by means of an adhesive or sealant layer 22. The spacer is affixed to the margin of one major surface of the pane by folding ribbon 20 around the edge of transparent pane 30 (which is the pane to be added) along the entire perimeter of the pane, and sealing the ribbon to the peripheral edge 32 of the pane and to the margin of the other major surface 33 of the pane by means of a layer of sealant 23. Sealant 23 is preferably a tacky, non-curing, butyl-based sealant as disclosed in U.S. Pat. application Ser. No. 454,336 filed under the name of George H. Bowser on even date herewith, assigned to the assignee of the present invention, and hereby incorporated by reference. The other side of ribbbon 20 is folded around a corner of spacer 21 and affixed to a side thereof by means of adhesive or sealant 24. Pane 30 may be glass or plastic, and may be tinted or reflectively coated. If pane 30 includes an easily damaged coating, the coating should be on inner major surface 31, i.e., the surface facing airspace 43 (FIG. 6) of the final assembly.

Turning now to FIG. 3, there can be seen an enclosed package formed by the subassembly shown in FIG. 2 and a second identical subassembly in accordance with the present invention. The elements of the second subassembly, which corresponds to the elements of the FIG. 2 subassembly, are indicated by corresponding primed numerals. The subassemblies are adjoined, with surfaces 31 and 31' disposed in generally face-to-face opposed relation and with the spacers 21 and 21' nonadhesively adjoining each other around the perimeter. The two subassemblies are held together and the interior airspace 39 sealed by applying closure means around the perimeter over the interface between the spacers. The closure means may consist of a tape 37 which is desirably a moisture resistant material, preferably an essentially moisture impervious material such as metallic foil (particularly aluminum foil) or the like, and carries a layer of adhesive 38, which is preferably pressure sensitive. Since the enclosure formed is to be merely temporary and would not normally be exposed to severe temperature conditions, adhesive 38 need not be selected for high moisture resistance properties, but preferably tape 37 and adhesive 38 have sufficient width and moisture resistance to create a relatively long barrier in the path of moisture penetration. For this reason, it is desirable that tape 37 have sufficient width to cover most of the peripheral edge surface of the combined subassemblies. Even greater moisture barrier length can be achieved by using a tape that is wider than the combined subassemblies, and folding the excess width around the outside edges of the subassemblies. A suitable commercially available foilbacked adhesive tape is 3M 425, manufactured by the Minnesota Mining and Manufacturing Co., Minneapolis, Minn.

With a pair of subassemblies thus assembled in packaged form, the units may be handled, shipped, and stored like ordinary factory-made multiple glazed units. Desiccant carried in or on the spacers will be preserved, coatings on the inner surfaces will remain free from marring and deterioration, and cleanliness of the critical inner surfaces will be maintained. At the installation site the tape 37 may be peeled off or split along the interface between the spacers of the two subassemblies with a cutting instrument, taking care not to damage ribbon 20 or the organic spacer. If the tape is to be cut, it should be of relatively thin gauge so as to require relatively little force to cut, thereby reducing the chances of harming the underlying ribbon and spacer. FIG. 2 shows a subassembly that has had the tape 37 peeled off. FIGS. 5 and 6 show the window of FIG. 1 with the subassembly in place so as to create a multiple glazed installation in accordance with the procedures described in the above-identified copending application of R. J. Mazzoni, G. H. Bowser, and R. R. Lewchuk.

Optionally, a band of mastic 34 may be applied along the exposed surface of the folded portion of ribbon 20 which carries the adhesive or mastic 24 as shown in FIG. 4. Mastic 34 desirably should be tacky and noncuring, preferably the butyl-based sealant referred to above in connection with mastic 23. FIG. 6 is a crosssectional view, taken along lines 66 in FIG. 5 showing details of the edge portion of the subassembly after being mounted onto the interior side of the window installation depicted in FIG. 1. A layer of mastic 42 is applied around the periphery of inside surface 41 of installed pane 15 along a path corresponding generally to the outline of spacer 21 on the subassembly. Mastic 42 is preferably the same tacky, non-curing, butylbased sealant as mastic 34.

The subassembly is then moved into position, the spacer aligned with mastic 42, and pressed against pane 15 to effect a seal with mastic 42, thus creating a hermetically sealed airspace 43. As an extra precaution, it may be desirable to extrude a sealant 44 into the gap left around the perimeter of the subassembly. Any resilient sealant or caulking compound may serve this purpose. For decorative purposes, a trim strip 40 may be applied around the periphery of the installation.

FIGS. 7, 8 and 9 relate to a different embodiment of the add-on multiple glazing subassembly and a variation of the packaging technique. This embodiment is particularly directed to a subassembly which includes a hollow metal spacer containing desiccant 51 and including an opening 52. The metal spacer is attached to pane 30 by adhesive or sealant layer 53. One subassembly is aligned with a second subassembly, whose elements are indicated by corresponding primed numerals, with

spacers

51 and 51 non-adhesively adjoined to form a closed space 56 as shown in FIG. 7. The package thus formed is then sealed by applying closure means consisting of moisture resistant tape 54 and adhesive 55 about the perimeter of the combined subassemblies so as to overlie the interface between the spacer elements of the subassemblies. As shown in FIG. 7, the moisture barrier formed by the tape may be extended by using a wide tape that is folded around the outside edges of the subassemblies. The package may be given extra strength by using a heavier tape, such as 8 mil thick aluminum. The greater effort required to cut the heavier tape when separating the units is not a significant drawback when using metal spacers, since the metal spacers are not as susceptible to damage from cutting as are organic spacers. The tape may, of course, be peeled off instead of cut apart. Adhesive 55 is preferably pressure-sensitive, and may advantageously consist of the tacky, non-curing, butyl-based sealant previously referred to.

In FIG. 8, there is shown one subassembly that has been cut from the package of FIG. 7, leaving tape and adhesive portions 54' and 55 attached. The tape and adhesive portions provide extra protection to the seal formed by layer 53 as well as reinforcing the attachment of the spacer to the pane 30. FIG. 9 shows a completed installation of the subassembly of FIG. 8

onto the window structure'shown in FIG. 1. The subassembly is mounted onto the window in the same manner as described in connection with the previous embodiment.

It should be understood that organic spacers could be substituted for the metal spacers'in the arrangement in FIGS. 7-9, provided that the tape 54 is to be removed by peeling or that considerable care is taken when subsequently cutting the units apart.

Another embodiment of the invention is shown in FIG. 10, featuring a spacer element 60, preferably metal, that is filled with a desiccant material 6 and provided with an opening 62. Spacer 60 has indentations 63 along its length adapted to receive a flowable, room temperature setting sealant such as thermoplastics applied in hot melt form or conventional polysulfide-based sealants such as disclosed in U.S. Pat. No. 3,348,351. Such spacers may be employed to make an add-on glazing subassembly by sealing one side of the spacer to the additional pane 30 with a layer of sealant 64, which is preferably a tacky, butyl-based sealant. The subassembly thus formed may be brought together with a second identical subassembly (whose corresponding elements are identified by primed numerals in FIG. 10) with a portion of the surfaces of the spacers in non-adhering contact so as to form a package as shown in FIG. 10. Rather than extending a tape over the interface between the two, spacers to act as the closure means this embodiment contemplates closing the package by extruding a fiowable, room temperature setting sealant 65 such as a polysulfide into the void created by the two adjacent indentations on the opposed spacers. Such a sealant may set to provide structural coherence to the package as well as sealing the enclosed airspace At the installation site, the package of FIG. 10 may be separated by cutting through sealant 65, thereby producing a subassembly as shown in FIG. llll having portion 65' of the sealant retained thereon. Installation onto the existing pane preferably utilizes tacky mastic 42 as referred to above. A flowable sealant 67, such as a polysulfide, is then forced into the space around the subassembly and forced into the void formed by indentation 63 to complete the seal.

In FIG. 13, there is shown yet another type of package arrangement within the contemplation of the pres ent invention. That embodiment is specially adapted so as to provide protection for organic spacers when the package is to be cut apart. This is accomplished in the embodiment illustrated by applying a moisture resistant tape 70, preferably aluminum foil, around the periphery of a pair of subassemblies that are initially aligned with a gap left between the opposing spacers 21 and 21'. The portion of tape 70 which bridges the gap is creased so that an inwardly extending pleat 71 is formed when the subassemblies are urged toward each other. Each half of the package thus formed will essentially comprise the subassembly embodiment of FIG. 2 when the package is cut apart by running a sharp instrument along pleat 71. During the shipping and handling, pleat 71 may be compressed to at least partially adhere adhesive layers 24 and 24' to the spacers. Layers 24 and 24' may alternatively be initially applied to tha spacers rather than to the tape. Another variation may employ a single, continuous layer of tacky, non

curing sealant acrossthe entire width of tape 78. It should be appreciated that, by reason of the presence of pleat 71, the package of FIG. 13 permits rapid cutting without requiring great care to prevent damaging organic spacers.

Each of the sealants, mastics, or adhesives employed in conjunction with this invention is preferably highly moisture resistant, i.e., characterized by low moisture vapor permeability, so as to effect good moisture barriers and hermetic seals. In addition, they are also preferably characterized by excellent. flexibility; cohesive and adhesive bonding; and tear, shear, peel, and tensile strength over a relatively wide range of expected operating temperatures, including temperatures from .60F. to Furthermore, they should be essen tially inert and unaffectedby chemicals, e.g., cleaning solutions, air borne pollutants or the like, with which they may normally be expected to come into contact.

It should be understood, however, that in certain instances related to the location or use of the sealants, mastics, or adhesives in the structures disclosed, one or more of the above characteristics or'properties may be of more dominant importance than another or others and accordingly, the choice of mastic materials used may vary substantially.

For example, moisture resistance may not be a dominant requirement for adhesive 38 in the embodiment of FIG.3 so long as tape 37, in conjunction with the adhesive 38, provides the desired protection against mois ture penetration during shipping or'storage. Another example may be'seen in' the subassembly embodiment utilized in the package assembly of FIG. 3. There, moisture resistance may not be a dominant requirement for layer 22 because adequate protection against moisture penetration can be provided by ribbon 20 in conjunc tion with the other mastics during shipping or storage as well as after final installation to form a multiple glazed window.

It should be apparent from the foregoing description that the present invention is applicable to shipping or storing any add-on glazing unit that includes a spacer element affixed to one pane. Thus, the add-on glazing subassemblies described herein are preferred embodiments and are merely exemplary.

It is also to be understood that other modifications and variations as are known to those of skill in the art may be resorted to without departing from the spirit and scope of the invention as defined by the appended claims.

We claim:

1. A packaged assembly of glazing units comprising:

two discrete glazing subassemblies, each including a transparent pane and a spacer element affixed to marginal portions of one major surface of each said pane; said subassemblies adjoining each other in opposed, substantially non-adhering relation, said spacers lying between said panes in substantial alignment with each other so as to form a substantially enclosed space between said panes; and closure means adhered to edge surface portions of said adjoined subassemblies for retaining said subassemblies in the adjoining relationship.

2. The packaged assembly of claim 1 wherein said closure means also comprises a barrier for resisting penetration of moisture into said enclosed space.

3. The packaged assembly of claim 2 wherein said spacer elements carry desiccant.

4. The packaged assembly of claim 1 wherein said one major surface of at least one of said panes has a coating applied thereto.

5. The packaged assembly of claim 1 wherein said panes are tinted.

6. The packaged assembly of claim 1 wherein said panes are glass.

7. The packaged assembly of claim 1 wherein said closure means comprises a moisture resistant tape.

8. The packaged assembly of claim 7 wherein said tape is metallic and flexible.

9. The packaged assembly of claim 7 wherein said tape includes a pleat disposed between said spacer elements.

10. The packaged assembly of claim 7 wherein said tape is adhered by means of a layer of moisture resistant material between said tape and said edge surface portions.

11. A packaged assembly of glazing units comprising:

two discrete glazing subassemblies, each including a transparent pane and a spacer element affixed to marginal portions of one major surface of each said pane, said subassemblies adjoining each other with said spacer elements having at least a portion of their surfaces in non-adhering contact with each other so as to form a substantially enclosed space between said panes; and

closure means adhered to the exterior of said adjoined subassemblies for maintaining said subassemblies adjoined.

12. The packaged assembly of claim 11 wherein said closure means also comprises a barrier for resisting penetration of moisture into said enclosed space.

13. The packaged assembly of claim 12 wherein said spacer elements carry desiccant.

14. The packaged assembly of claim 11 wherein said one major surface of at least one of said panes has a coating applied therto.

15. The packaged assembly of claim 11 wherein said panes are tinted.

16. The packaged assembly of claim 11 wherein said panes are glass.

17. The packaged assembly of claim 11 wherein said closure means comprises an extrusion of sealant material disposed between said spacer elements.

18. A method of adding an additional transparent pane to an installed pane so as to form a sealed, insulating space therebetween comprising the steps of:

transporting to the installation site a packaged assembly of two glazing subassemblies, each of which includes a transparent pane to be added, and a spacer element affixed to said pane to be added, said subassemblies adjoining each other with said spacer elements disposed therebetween so as to form an enclosed space between said panes to be added, said packaged assembly further including closure means adhered to edge surface portions of said subassemblies for maintaining the adjoining relationship of said subassemblies;

dividing said packaged assembly to separate the two subassemblies; and

mounting one of said subassemblies onto the installed pane with the spacer element disposed between the pane to be added and the installed pane.

19. The method of claim 18 wherein said closure means comprises a moisture resistant tape, and said dividing step comprises peeling off said tape.

20. The method of claim 18 wherein said closure means comprises a moisture resistant tape, and said dividing step comprises cutting said tape.

21. The method of claim 18 wherein said closure means comprises an extrusion of sealant material, and said dividing step comprises cutting said sealant material.

Claims

1. A packaged assembly of glazing units comprising: two discrete glazing subassemblies, each including a transparent pane and a spacer element affixed to marginal portions of one major surface of each said pane; said subassemblies adjoining each other in opposed, substantially non-adhering relation, said spacers lying between said panes in substantial alignment with each other so as to form a substantially enclosed space between said panes; and closure means adhered to peripheral surfaces of said adjoined subassemblies for retaining said subassemblies in the adjoining relationship.

5. The packaged assembly of claim 1 wherein said panes are tinted.

6. The packaged assembly of claim 1 wherein said panes are glass.

8. The packaged assembly of claim 7 wherein said tape is metallic and flexible.

10. The packaged assembly of claim 7 wherein said tape is adhered by means of a layer of moisture resistant material between said tape and said peripheral surfaces.

11. A packaged assembly of glazing units comprising: two discrete glazing subassemblies, each including a transparent pane and a spacer element affixed to marginal portions of one major surface of each said pane, said subassemblies adjoining each other with said spacer elements having at least a portion of their surfaces in non-adhering contact with each other so as to form a substantially enclosed space between said panes; and closure means adhered to the exterior of said adjoined subassemblies for maintaining said subassemblies adjoined.

15. The packaged assembly of claim 11 wherein said panes are tinted.

16. The packaged assembly of claim 11 wherein said panes are glass.

18. A method of adding an additional transparent pane to an installed pane so as to form a sealed, insulating space therebetween comprising the steps of: transporting to the installation site a packaged assembly of two glazing subassemblies, each of which includes a transparent pane to be added, and a spacer element affixed to said pane to be added, said subassemblies adjoining each other with said spacer elements disposed therebetween so as to form an enclosed space betweeN said panes to be added, said packaged assembly further including closure means adhered to peripheral surfaces of said subassemblies for maintaining the adjoining relationship of said subassemblies; dividing said packaged assembly to separate the two subassemblies; and mounting one of said subassemblies onto the installed pane with the spacer element disposed between the pane to be added and the installed pane. pg,16