MXPA00004833A - Spacer for insulated glass assembly - Google Patents

Abstract

A spacer (10) for insulated glass assembly and the like. A spacer is formed from a spacer core, having side faces (12,14) which face the substrates, with at least one elongate recess extending longitudinally within at least one of the side faces. A sealant material (26) covers the side faces (12,14) to engage the substrates, with the sealant material (26) filling the recess. A tongue and groove arrangement is formed between the core and sealant to prevent separation of the sealant from the core. A front face of the core may include a vapor barrier (32). Additional sealing capabilities may be provided by a second sealant material (30) joined to the first sealant (26), with the vapor barrier (32) at least partially embedded within the second sealant (30).

Description

SEPARATOR FOR ISOLATED GLASS ASSEMBLY Field of the Invention This invention relates to a separator that is used in assemblies of insulated substrates, such as insulated glass assemblies ("IG"), to separate the substrates at their peripheries, while providing an insulating function.

Background of the Invention Isolated assemblies currently known within the art incorporate the use of various polymeric substances, in combination with other materials. Such a assembly includes a butylated polymer in which a separating strip of corrugated metal is interlocked. Despite being useful, this type of insulating strip is limited in that over time, the metal stripper is exposed to the substrates, which results in a drastic depreciation of strip efficiency. This particular difficulty rises with the transmission of moisture vapor, when the metal strip is exposed and makes contact with the substrates. REF .: 119397 Additionally, several butylated polymers currently used in insulated glass assemblies are integrated together with a desiccant. This results in an even greater problem, that is, a butylated insulator with decreased adhesiveness. Gl over et al within U.S. Patent No. 4,950,344, provides a separator assembly that includes a foam body separated by a vapor barrier and additionally including insulating means around the periphery of the assembly. Although this configuration is particularly efficient from the point of view of energy, one of the key limitations is that the assembly must be manufactured through a large number of steps. Generally speaking, the insulator must be applied with a gun around the periphery, in a step subsequent to the initial placement of the separator. This has certain ramifications during the manufacturing phase and is directly related to the increase in production costs and consequently, the increase in costs in the assembly itself. One of the main weaknesses of existing separator bodies and separator assemblies is related to the transmission of energy through the separator. Typically, in the existing configurations, the path of the heat energy flow passing through the separator is simplified contrary to the complicated previous configurations and in the case of the previous one, the result is the easy transmission of energy from substrates to the another way of the separator. In the prior art, this difficulty is compounded by the fact that they are material employees that have a strong tendency to conduct thermal energy. It has been found particularly advantageous to incorporate materials with a high thermal performance. In one embodiment, a main component of the separator may comprise a flexible insulated and sealed body of material having a low thermal conductivity. These materials can be cellular and examples of materials that have been found to be useful, include natural and synthetic elastomers (rubber), cork, EPDM, silicones, polyurethanes and polysilicones in foam, urethanes and other appropriate materials in the form of foam. Significant benefits are presented from the choice of these materials, as not only are excellent insulators from an energy point of view, but additionally, depending on the materials that are used, the separator as a whole can maintain a certain degree sealing. This is important where, for example, windows that are fixed with such a strip, experience fluctuating pressure forces, as well as thermal shrinkage and expansion. By making use of a sealed body, these efforts are relieved and accordingly, the effort is not transferred to the substrates, as might be the case, for example, of the assemblies that incorporate relatively rigid spacers. When the insulating body is composed of foam material, the foam body can be manufactured from thermoplastic or thermosetting plastics. Suitable examples of thermosetting materials include silicone and polyurethane. In terms of thermoplastic materials, examples include silicone foam or elastomers, an example of the latter being the SANTOPRENE ™. The advantages that can be attributed to the aforementioned compounds include, in addition to what has been included above, high durability, minimum gas evolution, low compression, high elasticity and temperature stability, among other things. Of particular use are silicone and polyurethane foams. These types of materials offer high strength and provide significant structural integrity for assembly. The foam material is particularly suitable for use in insulating glass or glazed assemblies, since a high volume of air can be incorporated into the material without sacrificing any structural integrity in the body. This is convenient, since air is known to be a good insulator and when the use of a foam is combined with a material that has a low thermal conductivity, together with the additional features of the separator that will be established later, they result in a highly efficient composition separator. In addition, the foam is not susceptible to contracting or expanding in situations where temperature fluctuations occur. This is clearly beneficial to maintain a long-term, uncomplicated seal, within the assembly of insulated substrates. The insulating body can be selected from a set of appropriate materials, as has been stated herein and in addition, it being understood that appropriate materials having natural interstices, synthetically created materials having interstices, can be useful.

It has been found to be particularly advantageous to provide a composite structure comprising a separator core having a high thermal performance, elastic characteristics, surrounded in part by a shell having characteristics that fix to a superior substrate and also preferably incorporating a layer impervious to steam. The carapace must adhere firmly to the core, in order to avoid any separation between the two components. Additionally, the shell may comprise a composite structure to maximize its desired characteristics. It may be desirable to have a composite separator that overcomes the limitations of the materials used previously and the prior art, and the energy limitations associated therewith. The present invention is directed to satisfy these limitations.

Brief Compendium of the Invention An object of the present invention is to provide an improved composite separator for use in glass assemblies or insulated substrates. A further objective of the present invention is to provide a composite separator for separating substrates in an isolated assembly, the assembly characterized by an interior space defined by an atmosphere, comprising: a separator core comprising a flexible and elongate insulating body which includes a front face that faces the interior space, a rear face opposite the front face and side faces that join the front and rear faces; at least one elongated slot extending longitudinally within at least one of the side faces; a first sealing material which covers the side faces to provide first and second surfaces which fix the substrate, with the insulating material filling at least one groove, consequently blocking the insulating material and the core from each other, to form a separating assembly integral . This configuration achieves a separator that has superior insulating qualities through the selection of an appropriate core material, while maintaining the appropriate insulating characteristics through a selection of an appropriate insulator on the core side faces, while minimizing the risk of separation of the two components, by virtue of the effective tongue and groove configuration, described above. Preferably, the front face of the core will include a vapor barrier means, whereby the separator assembly will be substantially impervious to steam. The separator may additionally include a dried matrix, for example, on the front face. In a further version, a double seal is formed from a second insulating material, different from the first insulating material, attached to the first insulating material in a coplanar configuration to form a co-planar substrate that conforms to the surface formed from the insulating materials. two insulating materials attached. The means of barrier to. steam can be locked at least partially within the second insulator. Conveniently, one of the insulators can comprise a heat-melted material and the other a polyisobutylene. The core may comprise an EPDM, or a foam of other cellular material.

The third insulator can be provided, different from the first and / or second insulator, and also in contact with the vapor barrier means. The resulting triple seal configuration provides superior insulating characteristics, minimizing the risk of separation of a separator with its substrates, as it expands and contracts, and which could otherwise be dislodged over time. One or more of the insulating materials is conveniently cured by the application of UV rays or other energy source, to melt the insulator with the substrates and / or the vapor barrier means. As will be appreciated by those skilled in the art, assembly may employ polyisobutylene (PIB), butyl, heat-melted mixture, or any other insulator or appropriate butylated material. A seal or other adhesion for the insulated body can be achieved by providing special adhesives, for example, acrylic adhesives, pressure sensitive adhesives, hot melt blend, among others. By providing at least two different insulating materials, it results in the insulating surfaces, discontinuous and separate, being attributed to the separator. This is useful in the event that only one insulator is understood. The insulating materials may be embedded one inside the other. With respect to the vapor barrier, this may be a metallized film, already well known to those skilled in the art. Other appropriate examples will be immediately apparent. The dried matrix can be configured to conform to any shape that is required by the separator body. There are many advantages to adding a dried matrix, these being: i) the addition of structural integrity to the separator; ii) the density difference of the dried matrix, relative to the cell body, which further reduces the transmission of energy through the separator from one side to the other; and iii) the hygroscopic properties of the desiccant material help to maintain an arid atmosphere between the substrates.

Suitable desiccant materials are well known in the art and may include, as an example, beads of zeolite, silica gel, calcium chloride, potassium chloride, among others, all of which may be matrixed into a flexible semipermeable material, such as a polysilicone or any other suitable semipermeable substance. Having this generally described to the invention, reference is now made to the accompanying drawings which illustrate the preferred embodiments.

Brief Description of the Drawings Fig. 1 is a perspective view of a core of a separator according to the present invention; Fig. 2 is an exploded end view of a separator according to the invention; Fig. 3 is an exploded side view illustrating an alternative embodiment; Figs. 4 (a) and 4 (b) are end views of alternative embodiments of the spacer of Fig. 2, with several components omitted for purposes of clarity; Fig. 5 is an exploded end view illustrating an alternative embodiment; and Fig. 6 is a perspective view of the separator in place between the substrates.

Similar numerals in the drawings denote similar elements.

Detailed Description of the Preferred Modalities Referring to the figures, a composite separator is designated globally as 10, and comprises in general terms a spacer core 11, surrounded on its three sides by a shell 26. Referring now to Fig. 1, the spacer core is shown of an embodiment of the present invention in which, the numeral 11 denotes overall the core of the separator. In the embodiment shown, the spacer core 11 includes a pair of side faces 12 and 14 in a spaced relation and a front face, denoted globally by 16, and a back face denoted globally by the numeral 18. The face front 16 is facing the inside of an insulated glass assembly, as shown in Fig. 6. With respect to the core of the separator 11, it can be composed of a cellular material, which can be synthetic or of natural occurrence . In the case where the cellular material is composed of a material that occurs naturally, the cork and the sponge may be appropriate examples and in a synthetic version suitable polymers may be suitable examples, including but not limited to polyvinyl chlorides, Polysilicone, polyurethane, polystyrene, among others. A cellular material is desirable, since said materials, while providing structural integrity, additionally provide a high degree of interstices or cracks between the material. In this way a high volume of air is included inside the structure and when this is combined with a complete insulating material, the air fissures complement the effectiveness of the insulation. When the choice of material is not cellular, any number of highly insulating materials known to be useful for the subject matter discussed here may be selected. A slot-shaped recess 15 that is disposed within each of the side faces 12 and 14, whose function will be discussed later. The recess extends longitudinally along the entire extension of the sides and in depth that extends in part towards the interior of the core 11. In a cross-sectional configuration, as seen in the figures, the recess 15 has side walls generally straight 15 (a) and a bifurcated floor 15 (b). Referring now to Fig. 2, shown as a mode of the separator 10, which can typically be employed in an insulated glass assembly as seen in Fig. 6, where the separator 10 is disposed between two substrates 42 and 44, such as glass slabs. In greater detail concerning Fig. 2, the core 11 is surrounded on three sides, called the sides 12 and 14, and the front face 16 with a first insulating material 26 which may comprise, as an example, a hot melt mixture. . The insulator 26 generally subscribes to a form of C. Adjacent to the first insulator 26, a second insulator is included which differs from the molten mixture - to the heat. The second insulator, generally denoted by the numeral 30, generally comprises polyisobutylene (PIB). Other suitable materials or insulators and / or adhesion properties include acrylic adhesives, pressure sensitive adhesives, hot melt blend, polyisobutylene, other suitable butyl materials known to have utility in bonding said surfaces. The double insulated composite structure provides superior insulation capabilities when compared to a single insulating structure composed of a single insulator. The insulating material 26 fills the recesses 15 within the core 11 with a flange-shaped member 17 that extends in an inward direction of the shell or insulator. This structure improves the connection between the core 11 and the insulator 26, by means of providing a serpentine contact face of "locking tongue and groove" type between the respective members. As will be shown below, the tongue and locking slot structure can be provided in numerous versions, several of which will be illustrated below. As an additional feature within the embodiment shown in Fig. 2, it includes a vapor barrier 32 which can comprise any material suitable for this purpose, including examples of this to polyester films, polyvinyl fluoride films, etc. In addition, the vapor barrier 32 can be metallized. A useful example of this is a metalized Mylar ™ film. In order to further improve the effectiveness of the configuration, the vapor barrier 32 may be interlocked within the polyisobutylene represented by the numerals 28 and 30. This provision locates the barrier 32 and increases the structural integrity of the separator 10. An important feature related to the location of the vapor barrier 32, the insulator 26 and the body of the waterproof separator 11, is the degree of deformation achieved by the assembly as a whole and the vapor barrier 32. Since the barrier 32 is adjacent to the body Isolated and deformed 11, does not suffer any undue mechanical stress that could result in the delamination of any of the elements of the complete assembly. The advantage of this configuration is that deformation is possible, without compromising the substrate insulation. A complementary advantage to the deformable body 11 occurs in that the insulator 26 is in direct adhesive contact with the body 11. This has the particular value of facilitating the elasticity and deformation of the insulator 26, thus preventing the disruption or breaking, found in systems devoid of this characteristic. Coupled to the vapor barrier 32 by means of fusion, adhesion or any other means of contact, a dried matrix 38 is additionally included. The dried matrix 38 is placed in a juxtaposed manner to the vapor barrier 32. The matrices.

Dried are already well known in the art and suitable desiccant materials include beads of zeolite, calcium chloride, potassium chloride, silica gel, among others, matrices within a semipermeable material such as polysilicones, etc. The die 38 is maintained in position by means of the insulators 34 and 36 associated with the vapor barrier 32. The dried die 38 is directed towards the interior atmosphere of the assembly and at this end, the rear face 18 of the core 11 can include an additional peripheral insulating material. The selection of the peripheral insulation will depend, of course, on the intended use and the environment in which the assembly is used. A strong mechanical bond can be achieved by using the integration of suitable materials, examples of which may include silicones, polysulfonated materials, mixtures of butylated compounds thereof, etc. Fig. 3 illustrates an alternative embodiment of the assembly shown in Fig. 2. In the illustrated embodiment, the dried die 38 has corners cut in from inside 46 and 48 adjacent to the contact with the surfaces of the substrate (not shown). In this way, the recesses formed by the corners already removed, provide two areas within which polyisobutylene can be placed as shown. The removed areas have the utility of containing the polyisobutylene from any "slip" into the interior atmosphere of the assembly, when the separator is placed as shown in Fig. 6. Additionally, the recesses cooperate with those on the body 11 for firmly placing the vapor barrier 32. There are any number of shape possibilities for the portions removed from the matrix 38. As an example, the portions may be more arched. Referring now to Figs. 4 (a) to 4 (d), additional embodiments of the separator are shown, as illustrated in Fig. 1. In particular, Fig. 4 (a) provides a configuration of. sawtooth on each of the surfaces 12 and 14. Fig. 4 (c) provides a version wherein the surfaces 12 and 14 include spherical recesses, are scattered, while Fig. 4 (d) generally provides a profile H. In the case where the material of which the body of the separator is composed, is formed of material with elongation capabilities, then the difficulty can be obviated by screwing around the corners of insulated mounting by means of, simply elongate or "lengthening" the body 11, before turning the corner of an isolated assembly, as illustrated in Fig. 6. In this instance, the thickness of the separator body will be reduced due to the elongation and consequently, when it is rotated around a corner, the problem of threading will not result. This procedure of previous effort is applicable where the material has elongation capabilities and can, of course, exclude cork and other cellular materials that are not prone to exerting previously. It will be understood that the selection of cellular material may vary and that the first and / or second insulating materials may comprise blends of cellular materials to further improve the insulating ability of the assembly. Fig. 5 illustrates another embodiment of the present invention, in which at least three different insulating materials are incorporated into the separator 10. Fig. 5 illustrates a further feature wherein the core of the separator 11 characterizes a portion of the removed material. of each corner, formed between the side and front faces, thereby forming a tapered portion of the core to reduce threading when the spacer is flexed around a corner. With respect to the insulators, in combination with the polyisobutylene 28 and 30, the partially blocked vapor barrier 32 and the insulator 24, a third insulator / adhesive material 50 and 52 adjacent to the impermeable barrier 32 can be provided and filling the areas of body corner 11, as illustrated. In this embodiment, the material will probably be selected from any uncured insulator / adhesive material known to those skilled in the art. Useful examples include, but are not limited to, various silicones and urethanes. Said curable materials that can be cured by means of ultraviolet or infrared rays, or other forms of electromagnetic energy provide utility in insulated assemblies since these, when cured, are capable of melting with glass substrates (not shown in Fig. 5). , see Fig. 6) and the impermeable barrier 32. When exposed to curing conditions, the previously established configuration results in the fusion of the different sites, call the interface of the insulator 50, 52 with each substrate (not shown) and with the vapor impermeable barrier 32. This feature is very beneficial for the total mechanical integrity and the consolidation of the separator within the assembly. An advantage that draws attention additionally to this configuration, refers to the multiple different insulating surfaces that provide concomitant insulation against the ingress of moisture or energy transfer. Optionally, the surfaces coupling to the dried matrix substrates 54 and 56 may include curable adhesive materials, rather than regular adhesives / insulators. Additionally, it is contemplated that several different materials may be incorporated within the cellular material of the separator body, as set forth herein. In addition, it should be understood that when the body is composed of several different materials, the materials do not need to be formed homogeneously within a cell body, for example, by means of foam etc., it can be composed of a core body. with multiple sections, composed of several different materials stacked together. Although the embodiments of the invention have been described above, they are not limited thereto and it will be apparent to those skilled in the art that numerous modifications form part of the present invention, to the extent that they do not detach from the essence, nature and field of the invention described and claimed. It is noted that, with regard to this date, the best method known by the requested, to carry out the present invention, is that which is clear from the present, discovering the invention. Having described the invention as above, the content of the following is claimed as property.

Claims (13)

1. CLAIMS An elastic composite separator for separating substrates, to define a space containing an atmosphere, characterized in that it comprises: a separator core comprising a flexible elastic body that includes a front face facing into the interior space and a rear face in a separate relationship and side walls that attach to the front and rear faces, at least one of the side faces having a recess within these, at least one elongated longitudinal recess extending generally through the length of the spacer core; a first insulating material that covers the side faces to provide first and second substrate coupling surfaces, the insulating material filling at least one recess, thereby forming an adjustment configuration of which tongue and recess between the insulator and the core .
2. The composite separator according to claim 1, characterized in that it comprises a second insulating material different from the first insulating material associated with each of the side faces and in contact with the first insulating material to provide a second insulating surface.
3. The elastic composite separator according to claim 1, characterized in that the front face includes a vapor barrier means.
4. The elastic composite separator according to claim 3, characterized in that the composite separator further includes a dried matrix.
5. The composite separator according to claim 1, characterized in that the vapor barrier means are at least partially locked to the second insulator.
6. The composite separator according to claim 1, characterized in that the first insulator comprises a hot melt mixture.
7. The composite separator according to claim 6, characterized in that the second insulator comprises a polyisobutylene.
8. 8. The composite separator according to claim 1, characterized in that the elastic body comprises an EPDM (Ethylene-Propylene-Diene-Monomer).
9. 9. The composite separator according to claim 1, characterized in that the elastic body comprises a foam material.
10. 10. The composite separator according to claim 8, characterized in that the foam material includes at least two chemical materials.
11. 11. The composite separator according to claim 5, characterized in that the dried matrix has at least a portion of material removed from each substrate contacting the surface.
12. 12. The composite separator according to claim 1, characterized in that the elastic body comprises a cellular body.
13. 13. The composite separator according to claim 3, characterized in that it additionally comprises: a third insulator different from the first insulator and the second insulator, in contact with the vapor barrier means; and a dried matrix in adhesive contact with the third insulator and with the vapor barrier means. The composite separator according to claim 12, characterized in that in combination with glass substrates coupled with a respective substrate, it is coupled to the surface to form an insulated glass unit. The separator according to claim 13, characterized in that the curable insulation is melted to the substrates and to the vapor barrier means. The separator according to claim 12, characterized in that the insulating body comprises a cellular body. > • SEPARATOR FOR ISOLATED GLASS ASSEMBLY Summary of the Invention A separator for an insulated glass assembly and the like is disclosed. A spacer is formed from a spacer core, having side faces facing the substrates, with at least one elongated recess extending longitudinally into at least one of the side faces. An insulating material covers the side faces for 10 attach to the substrates, with the insulating material filling the recess. A tongue and recess configuration is formed between the core and the insulator to prevent separation of the insulator from the core. A front wall of the core may include a barrier to 15 steam. Additional insulation capabilities can be provided by means of a second insulating material bonded to the first insulator, with the vapor barrier at least partially nestled within the second insulator.