WO2024118560A1

WO2024118560A1 - Thin triple insulating glass unit assembly methods

Info

Publication number: WO2024118560A1
Application number: PCT/US2023/081274
Authority: WO
Inventors: James Gregory Couillard; Michael Aaron Mcdonald; Eric James SHOMO
Original assignee: Corning Incorporated
Priority date: 2022-11-30
Filing date: 2023-11-28
Publication date: 2024-06-06

Abstract

Methods of making an insulated glass unit (IGU) are provided with a thin center pane in a triple IGU (regardless of CTE or glass type/composition), including various embodiments for incorporating a double inset in the thin triple pane of the IGU.

Description

THIN TRIPLE INSULATING GLASS UNIT ASSEMBLY METHODS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application No. 63/428,795 filed November 30, 2022, the content of which is incorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

[0002] Generally, the present disclosure is directed towards a triple-pane IGU having a thin (e.g. less than about 2.5 mm thick) center pane that is configured with TPS spacer(s) and methods of making the same. More specifically, the present disclosure is directed towards IGUs and methods of making IGUs having a thin center pane, where such IGU is specifically configured to meet thermal requirements (e.g. ENERGY STAR v7) while having improved manufacturability.

BACKGROUND

[0003] At present, building regulations and energy standards are in flux, with increased emphasis on sustainability, energy usage, and thermal efficiency buildings and building products. With recent proposed changes to energy certification programs, and the recent building trend to increase sizes of windows and/or the number of windows in homes and buildings, there is as strong desire among insulated glass unit makers, window-makers, and builders to light-weight IGUs and windows, while at the same time, meet new, more rigorous energy certifications in various jurisdictions.

SUMMARY

[0004] Thin triple-pane IGUS having at thin center pane can provide some challenges in manufacturing, since thin glass can flex, causing instances of potential breakage, inadvertent marks/dirt on the thin substrate; and/or issues managing the adhesive spacer during manufacturing, which can result in bow of the thin center pane, increased breakage, and/or and lower manufacturing yields. In order to enable manual assembly and manufacturing of thin triple IGUs, manufacturing processes that have advantages including, but not limited to: (1 ) reducing bow in the thin center pane of glass; (2) minimizing distortion in the IGU; and/or maintaining tailored (e.g. repeatable, accurate and precise) double insets of the center glass pane from the exterior glass panes, are set forth in one or more of the embodiments disclosed herein.

[0005] In order to manufacture a thin center-pane IGU (e.g. having a thickness of less than about 2 mm; or less than about 1 .6 mm, or less than 1 mm, or less than 0.7 mm thick), it has been found that incorporating a double inset (horizontal and vertical edges of the thin pane of glass) reduces inadvertent handling and/or manufacturing defects. For low volume IGU builds, in particular in prototyping and/or smaller volume builds, manual building of IGUs is relatively common. However, the nuanced considerations of handling and manufacturing with thin glass in large-scale architectural applications can drive up manufacturing losses with manual layups and processes.

[0006] So, in one or more embodiments set forth herein, a support surface configured to pivot from horizontal to generally vertically angled alignment is provided, where such support surface is further configured with elements and features to enable precision alignment and stack-up of the multi-pane IGU components. In some embodiments, some unique features of the methods and systems set forth herein are configured to enable manufacturing of IGUs by utilization of an alignment bracket, more specifically, an inset L-bracket, in combination with a vacuum-enabled support surface to incorporate thin glass retention and placement during manufacturing. The resulting IGUs are configured with tailored, precise and accurate double insetting of thin center panes in a triple pane IGU and increased manufacturing yields as compared to manual builds of IGUs without such embodied features. Thus, the resulting IGUs are believed to have improved features including low to no visual distortion, improved seal integrity, improved/increased manufacturability.

[0007] In one aspect, a method of making an insulated glass unit (IGU), is provided, comprising: positioning a first pane of glass on a support surface, the support surface configured with a support edge and an edge guide, wherein the first pane is aligned on the support surface such that a first side is proximal to the support surface, and a first corner of the first pane, the first corner defined by two adjacent edges of the first pane (a horizontal edge and a vertical edge) are in contact with the support edge and the edge guide (respectively); positioning an inset L-bracket on the second surface of the first pane, proximal to the first corner, such that the inset L-bracket contacts the support edge and the edge guide; positioning a third pane proximal the first pane and in engagement with an inner edge of the inset L-bracket, contacting the first pane and the third pane with a first adhesive to define a first gas cavity between the first pane and the third pane, the first adhesive is configured in a perimetrical bead such that it has a perimeter not greater than the perimeter of the third pane; positioning a second pane of glass, wherein the second pane is aligned on the support edge and edge guide such that a first corner of the second pane has adjacent edges of the second pane is in contact with the support edge and the edge guide; contacting the second pane and the third pane with a second adhesive to define a second gas cavity between the second pane and the third pane, wherein the second adhesive is configured in a perimetrical bead such that it has a perimeter not greater than the perimeter of the third pane; wherein via the inset L-bracket, a triple pane IGU is provided having a third pane configured with a double inset as compared to the first pane and second pane.

[0008] In another aspect, a method of making an insulated glass unit (IGU), is provided comprising: positioning a third pane of glass on a support surface, the support surface configured with, wherein the third pane is aligned on the support surface such that a first side is proximal to the support surface, and a first corner of the third pane defined by two adjacent edges of the third pane (a horizontal edge and a vertical edge) are in contact with an inner edge of an inset L-bracket, the inset L- bracket contacting a support edge and an edge guide of the support surface; positioning a first pane proximal the third pane and in engagement with the support edge and the edge guide of the support surface; contacting the first pane and the third pane with a first adhesive to define a first gas cavity between the first pane and the third pane, the first adhesive is configured in a perimetrical bead such that it has a perimeter not greater than the perimeter of the third pane; configuring the first side of the first pane in contact with the support surface, such that a first corner of the first pane is in contact with the support edge and the edge guide; positioning a second pane of glass, wherein a first corner of the second pane is aligned on the support edge and edge guide such that a first corner of the third pane has adjacent edges of the second pane is in contact with the support edge and the edge guide; contacting the second pane and the third pane with a second adhesive to define a second gas cavity between the second pane and the third pane, wherein the second adhesive is configured in a perimetrical bead such that it has a perimeter not greater than the perimeter of the third pane; wherein via the inset L-bracket, a triple pane IGU is provided having a third pane configured with a double inset as compared to the first pane and second pane.

[0009] In another aspect, an insulating glass unit is provided, comprising: a first pane of glass, having a first side and a second side, a first thickness of at least 2.5 mm, and a CTE 1 ; a second pane of glass, having a first side and a second side, a second thickness of at least 2.5 mm, and a CTE 2; and a third pane of glass, having a first side and a second side, having a third thickness of not greater than 2.5mm, and a CTE3, a first spacer, positioned between the second side of the first pane and the first side of the third pane to define a first gas cavity having a first cavity depth; and a second thermoplastic spacer, positioned between the second side of the third pane and the first side of the second pane to define a second gas cavity having a second cavity depth, wherein the third pane is configured with a vertical inset and a horizontal inset from the first pane and the second pane of at least 1 mm to not greater than 10 mm.

[0010] In some embodiments, the negative pressure is less than 0 to not greater than -1 atm.

[0011] In some embodiments, a first gas cavity is defined between the first pane, the third pane, and the first spacer seal.

[0012] In some embodiments, the method further comprises compressing the IGU by applying compressive force on the first surface of the first pane and the second surface of the second pane. [0013] In some embodiments, compressing further comprises compressing by engaging a plurality of rollers on a first side of the IGU while a second side of the IGU is in contact with a support surface.

[0014] In some embodiments, a second gas cavity is defined between the third pane, the second pane, and the second spacer seal.

[0015] In some embodiments, CTE 3 is less than CTE 1 and wherein CTE 3 is less than CTE 2.

[0016] In some embodiments, the composition of the third pane is different from the first pane and the second pane.

[0017] In some embodiments, the third pane is a boro aluminosilicate glass.

[0018] In some embodiments, the first pane and the second pane are a sodalime glass.

[0019] In some embodiments, CTE 3 is the same as CTE 1 and wherein CTE 3 is the same as CTE 2.

[0020] In some embodiments, the composition of the third pane is the same as the composition of the first pane and the composition of the second pane.

[0021] In some embodiments, the thickness of the third pane is not greater than 1 .6 mm.

[0022] In some embodiments, the second pane has a thickness of at least 3 mm.

[0023] In some embodiments, the first pane has a thickness of at least 3 mm.

[0024] In some embodiments, at least one of the first pane and the second pane are strengthened by: thermal tempering, heat strengthening, or chemically strengthening.

[0025] In some embodiments, both the first pane and second pane are strengthened.

[0026] In some embodiments, the third pane is configured with a vertical inset and a horizontal inset.

[0027] In some embodiments, the third pane is configured with a vertical edge overhang and a horizontal edge overhang. [0028] In some embodiments, the method includes injecting a first gas into a first gas cavity.

[0029] In some embodiments, the method includes comprising injecting a second gas into a second gas cavity.

[0030] In some embodiments, the first gas and the second gas are the same gases or different gases.

[0031] In some embodiments, the third pane has a thickness of at least 0.3 mm to not greater than 2.2 mm. In some embodiments, the third pane has a thickness of at least 0.3 mm to not greater than 1.6 mm. In some embodiments, the third pane has a thickness of at least 0.3 mm to not greater than 1 .3 mm. In some embodiments, the third pane has a thickness of at least 0.45 mm to not greater than 1 mm.

[0032] In some embodiments, CTE 3 is less than either of CTE1 and CTE 2.

[0033] In some embodiments, the third pane is an alumino borosilicate glass. In some embodiments, the third pane is a sodalime glass.

[0034] In some embodiments, at least one of the first pane and the second pane are a sodalime glass.

[0035] In some embodiments, both the first pane and second pane are a sodalime glass.

[0036] In some embodiments, CTE 3 is the same as CTE1 and CTE 2.

[0037] In some embodiments, the third pane, the second pane, and the first pane are each composed of a sodalime glass.

[0038] In some embodiments, the first gas cavity is configured with a gas selected from: air, krypton, argon, and mixtures of at least two of the foregoing.

[0039] In some embodiments, the second gas cavity is configured with a gas selected from: air, krypton, argon, and mixtures of at least two of the foregoing.

[0040] In some embodiments, the third pane has a vertical inset as compared to the first pane and the second pane.

[0041] In some embodiments, the third pane has a horizontal inset as compared to the first pane and the second pane. [0042] Additional features and advantages of the disclosure will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the methods as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

[0043] It is to be understood that both the foregoing general description and the following detailed description present various embodiments of the disclosure and are intended to provide an overview or framework for understanding the nature and character of the claims. The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the disclosure and, together with the description, serve to explain the principles and operations of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The following detailed description can be further understood when read in conjunction with the following drawings in which:

[0045] Figure 1 depicts a schematic, cut-away side view of an embodiment of an insulating glass unity (IGU) having a thin center pane with double insets (vertical and horizontal) in accordance with an aspect of the present disclosure;

[0046] Figure 2 depicts a schematic plan side view of Figure 1 , in accordance with one or more aspects of the present disclosure; and

[0047] Figure 3A depicts, in the upper image, a schematic top plan view of an embodiment of a support system including a support surface having edge support, and edge guide, and an inset L-bracket, configured to illustrate placement of the third pane of glass (the thin center pane) on the support surface with a double inset configuration, in accordance with aspects of the present disclosure.

[0048] Figure 3A depicts, in the lower image, a close-up view of the inset L- bracket, depicting the two offset portions, the vertical offset and the horizontal offset (both labeled “x” for illustrative purposes), in accordance with one or more embodiments of the present disclosure.

[0049] Figure 3B, in the upper image, depicts the side view of the embodied support system including the support surface configured for pivoting/tilting engagement into at least two different positions, the horizontal position and upright position (vertically angled). Both positions are depicted, as well as the arrow which indicates the direction of pivot/tilt from a horizontal position to an upright position, in accordance with one or more aspects of the present disclosure.

[0050] Figure 3B, in the lower image, depicts the side view of the various components in the support system, including the height of the inset L-bracket in comparison with the height of the third pane (thin center pane), and the overall height of the IGU, in accordance with one or more aspects of the present disclosure.

[0051] Figure 4 depicts a schematic representation of a first embodiment of a method of manufacturing a thin triple IGU, in accordance with one or more aspects of the present disclosure.

[0052] Figure 5 depicts a schematic representation of the first embodiment of a method of manufacturing a thin triple IGU, in accordance with one or more aspects of the present disclosure.

[0053] Figure 6 depicts a schematic representation of a second embodiment of a method of manufacturing a thin triple IGU, in accordance with one or more aspects of the present disclosure.

[0054] Figure 7 depicts a schematic representation of the second embodiment of a method of manufacturing a thin triple IGU, in accordance with one or more aspects of the present disclosure.

[0055] Figure 8 depicts a schematic representation of a third embodiment of a method of manufacturing a thin triple IGU, in accordance with one or more aspects of the present disclosure.

[0056] Figure 9 depicts a schematic representation of the third embodiment of a method of manufacturing a thin triple IGU, in accordance with one or more aspects of the present disclosure. [0057] Figure 10 depicts a schematic representation of a fourth embodiment of a method of manufacturing a thin triple IGU, in accordance with one or more aspects of the present disclosure.

[0058] Figure 11 depicts a schematic representation of the fourth embodiment of a method of manufacturing a thin triple IGU, in accordance with one or more aspects of the present disclosure.

[0059] Figure 12 depicts a schematic representation of a fifth embodiment of a method of manufacturing a thin triple IGU, in accordance with one or more aspects of the present disclosure.

[0060] Figure 13 depicts a schematic representation of the fifth embodiment of a method of manufacturing a thin triple IGU, in accordance with one or more aspects of the present disclosure.

[0061] Figure 14 depicts a schematic representation of a sixth embodiment of a method of manufacturing a thin triple IGU, in accordance with one or more aspects of the present disclosure.

[0062] Figure 15 depicts a schematic representation of the sixth embodiment of a method of manufacturing a thin triple IGU, in accordance with one or more aspects of the present disclosure.

DETAILED DESCRIPTION

[0063] Various aspects of the disclosure will now be discussed with reference to the figures, which illustrate aspects of the claimed embodiments, and their components, features, or properties. The following general description is intended to provide an overview of the claimed devices, and various aspects will be more specifically discussed throughout the disclosure with reference to the non-limiting depicted aspects, these aspects generally being interchangeable with one another within the context of the disclosure.

[0064] As shown in Figures 1 and 2, various views of an embodied thin triple pane IGU 10 is depicted. Referring to Figures 1 and 2, the IGU 10 includes three panes, a first pane 20, a second pane 30, and a third pane 40, with the third pane 40 positioned between the first pane 20 and the second pane 30. The panes 20, 40, and 30 are spaced apart to define two predetermined distances: a gap between the first pane 20 and the third pane 40 and a gap between the third pane 40 and the second pane 30.

[0065] The first pane 20 is configured with a cross-sectional thickness, and two major surfaces, a first side of the first pane 22 and a second side of the second pane 24.

[0066] The second pane 30 is configured with a cross-sectional thickness, and two major surfaces, first side of second pane 32 and second side of second pane 34.

[0067] The third pane 40 is configured with a cross-sectional thickness, and two surfaces, a first side of third pane 42 and a second side of third pane 44.

[0068] The predetermined gap between the second side of the first pane 24 and the first side of the third pane 42 and the first spacer 52 defines a first gas cavity 16. More specifically, the first side of the first spacer 54 is in communication with the second side of the first pane 24 and the second side of the first spacer 56 is in communication with the first side of the third pane 42. The predetermined gap between the second side of the third pane 44 and the first side of the second pane 32 and the second spacer 60 defines the second gas cavity 18. More specifically, the first side of the second spacer 62 is in communication with the second side of the third pane 44 and the second side of the second spacer 64 is in communication with the first side of the third pane 32.

[0069] In some embodiments, the third pane 40 is configured with an inset (smaller footprint or cross-sectional area) than the first pane 20 or second pane 30. Figure 1 depicts the first inset 14, where the upper edge and lower edge of the third pane 40 is set inwardly from the respective edges of the upper edges and lower edges of the first pane 20 and second pane 30. Referring to Figure 2, both the first inset 14 (in a vertical manner) and second inset 12 (in a horizontal manner) is depicted.

[0070] In some embodiments, IGU 10 is configured such that the first spacer 52 and second spacer 60 are positioned at a predefined distance from the edge of the third pane 40, to promote seal integrity, ease in formability, and increased yields in manufacturability. In Figure 1 , the overhang of the third pane is represented by first edge overhang 48 (upper edge and lower edge of the third pane 40) in a vertical manner and second edge overhang 46 (side edges of third pane 40, shown in Figure 2).

[0071] In some embodiments, the gas in the gas cavity (first gas cavity or second gas cavity) is: argon, krypton, or air, or mixtures of at least two (e.g. argon and krypton).

[0072] In some embodiments, the first inset is: 0.5 mm to 5 mm. In some embodiments, the first inset is: 1 mm to 5 mm, or 1 mm to 4 mm, or 1 mm to 4 mm, or 1 mm to 3 mm, or 3 mm to 5 mm.

[0073] In some embodiments, the second inset is: 0.5 mm to 5 mm. In some embodiments, the second inset is: 1 mm to 5 mm, or 1 mm to 4 mm, or 1 mm to 4 mm, or 1 mm to 3 mm, or 3 mm to 5 mm.

[0074] In some embodiments, the first inset is: at least 0.5 mm; at least 1 mm; at least 1 .5 mm; at least 2 mm; at least 2.5 mm; at least 3 mm; at least 3.5 mm; at least 4 mm; at least 4.5 mm; at least 5 mm; at least 5.5mm; at least 6 mm; at least

6.5 mm; at least 7 mm; at least 7.5 mm; at least 8 mm; at least 8.5 mm; at least 9 mm; at least 9.5 mm. In some embodiments, the first inset is: not greater than 1 mm; not greater than 1 .5 mm; not greater than 2 mm; not greater than 2.5 mm; not greater than 3 mm; not greater than 3.5 mm; not greater than 4 mm; not greater than 4.5 mm; not greater than 5 mm; not greater than 5.5mm; not greater than 6 mm; not greater than

6.5 mm; not greater than 7 mm; not greater than 7.5 mm; not greater than 8 mm; not greater than 8.5 mm; not greater than 9 mm; not greater than 9.5 mm; or not greater than 10 mm.

[0075] In some embodiments, the second inset is: at least 0.5 mm; at least 1 mm; at least 1 .5 mm; at least 2 mm; at least 2.5 mm; at least 3 mm; at least 3.5 mm; at least 4 mm; at least 4.5 mm; at least 5 mm; at least 5.5mm; at least 6 mm; at least

6.5 mm; at least 7 mm; at least 7.5 mm; at least 8 mm; at least 8.5 mm; at least 9 mm; at least 9.5 mm. In some embodiments, the second inset is: not greater than 1 mm; not greater than 1 .5 mm; not greater than 2 mm; not greater than 2.5 mm; not greater than 3 mm; not greater than 3.5 mm; not greater than 4 mm; not greater than 4.5 mm; not greater than 5 mm; not greater than 5.5mm; not greater than 6 mm; not greater than 6.5 mm; not greater than 7 mm; not greater than 7.5 mm; not greater than 8 mm; not greater than 8.5 mm; not greater than 9 mm; not greater than 9.5 mm; or not greater than 10 mm.

[0076] In some embodiments, the first inset is different than the second inset. In some embodiments, the first inset is the same as the second inset.

[0077] In some embodiments, the first pane is: sodalime silicate glass.

[0078] In some embodiments, the second pane is: sodalime silicate glass.

[0079] In some embodiments, the third pane is: an inorganic glass. In some embodiments, the third pane is EAGLE XG®, commercially available from Corning Incorporated. In some embodiments, the third pane is: sodalime silicate glass.

[0080] In some embodiments, the spacer is: a super spacer (applied at room temperature) or a thermoplastic spacer (TPS) (applied at elevated temperature, e.g. an average range of TPS application temperature is from 110 degrees C to 130 degrees C).

[0081] In some embodiments, the thickness of the first spacer is configured to extend along the first gas cavity, such that the cross-sectional thickness of the first spacer is the same so the first gas cavity. In some embodiments, the thickness of the second spacer is configured to extend along the second gas cavity, such that the cross-sectional thickness of the second spacer is the same so the second gas cavity.

[0082] In some embodiments, the first edge overhang is: at least 0.5 mm to not greater than 2.5 mm. In some embodiments, the first edge overhang is configured in a vertical dimension, such that the third pane slightly extends from the spacers.

[0083] In some embodiments, the second edge overhang is: at least 0.5 mm to not greater than 2.5 mm. In some embodiments, the second edge overhang is configured in a horizontal dimension, such that the third pane slightly extends from the spacers.

[0084] In some embodiments, the first pane cross-sectional thickness is: at least 2.2 to not greater than 10 mm. In some embodiments, the first pane cross- sectional thickness is at least 2.5 mm; at least 3 mm; at least 3.5 mm; at least 4 mm; at least 4.5 mm; at least 5 mm; at least 5.5 mm; at least 6 mm; at least 6.5 mm; at least 7 mm; at least 7.5 mm; at least 8 mm; at least 8.5mm; at least 9 mm; or at least 9.5 mm. In some embodiments, the first pane cross-sectional thickness is: not greater than 3 mm; not greater than 3.5 mm; not greater than 4 mm; not greater than 4.5 mm; not greater than 5 mm; not greater than 5.5 mm; not greater than 6 mm; not greater than 6.5 mm; not greater than 7 mm; not greater than 7.5 mm; not greater than 8 mm; not greater than 8.5mm; not greater than 9 mm; or not greater than 9.5 mm.

[0085] In some embodiments, the second pane cross-sectional thickness is: at least 2.2 to not greater than 10 mm.

[0086] In some embodiments, the first pane cross-sectional thickness is at least 2.5 mm; at least 3 mm; at least 3.5 mm; at least 4 mm; at least 4.5 mm; at least 5 mm; at least 5.5 mm; at least 6 mm; at least 6.5 mm; at least 7 mm; at least 7.5 mm; at least 8 mm; at least 8.5mm; at least 9 mm; or at least 9.5 mm. In some embodiments, the second pane cross-sectional thickness is: not greater than 3 mm; not greater than 3.5 mm; not greater than 4 mm; not greater than 4.5 mm; not greater than 5 mm; not greater than 5.5 mm; not greater than 6 mm; not greater than 6.5 mm; not greater than 7 mm; not greater than 7.5 mm; not greater than 8 mm; not greater than 8.5mm; not greater than 9 mm; or not greater than 9.5 mm.

[0087] In some embodiments, the third pane cross-sectional thickness is: 0.3 to not greater than 3 mm thick.

[0088] In some embodiments, the third pane cross-sectional thickness is not greater than 3 mm; not greater than 2.5 mm; not greater than 2 mm; not greater than

1 .5 mm; not greater than 1 mm; not greater than 0.5mm; not greater than 0.3 mm, or not greater than 0.1 mm. In some embodiments, the third pane cross-sectional thickness is: not greater than 2 mm; not greater than 1 .7 mm; not greater than 1 .5 mm; not greater than 1 .3 mm; not greater than 1 mm; not greater than 0.7mm; not greater than 0.5 mm; not greater than 0.3 mm; or not greater than 0.1 mm.

[0089] In some embodiments, the third pane cross-sectional thickness is at least 2.5 mm; at least 2 mm; at least 1 .5 mm; at least 1 mm; at least 0.5mm; at least 0.3 mm, or at least 0.1 mm. In some embodiments, the third pane cross-sectional thickness is at least 1 .6 mm; at least 1 .3 mm; at least 1 mm; at least 0.8 mm; at least 0.7 mm; at least 0.5 mm, or at least 0.3 mm. [0090] In some embodiments, the third pane cross-sectional thickness is: 0.3 to not greater than 2 mm thick.

[0091] In some embodiments, the first gas cavity cross-sectional thickness is: 4 mm thick to not greater than 20 mm thick. In some embodiments, the first gas cavity cross-sectional thickness is: at least 5 mm; at least 7 mm; at least 10 mm; at least 12 mm; at least 14 mm; at least 16 mm; at least 18 mm; or at least 20 mm. In some embodiments, the first gas cavity cross-sectional thickness is: not greater than 7 mm; not greater than 10 mm; not greater than 12 mm; not greater than 14 mm; not greater than 16 mm; not greater than 18 mm; or not greater than 20 mm.

[0092] In some embodiments, the second gas cavity cross-sectional thickness is: 4 mm thick to not greater than 20 mm thick.

[0093] In some embodiments, the first gas cavity cross-sectional thickness is: at least 5 mm; at least 7 mm; at least 10 mm; at least 12 mm; at least 14 mm; at least 16 mm; at least 18 mm; or at least 20 mm. In some embodiments, the second gas cavity cross-sectional thickness is: not greater than 7 mm; not greater than 10 mm; not greater than 12 mm; not greater than 14 mm; not greater than 16 mm; not greater than 18 mm; or not greater than 20 mm.

[0094] In some embodiments, the spacer is a TPS spacer, such that it is configured as a bead that is an extrudate (extruded in high-temperature, softened form such that it is configurable/positionable from a nozzle onto one of the first, second or third panes. In some embodiments, the spacer is a superspacer, such that it is configured as an adhesive tape that is directed onto a defined path around a glass substrate.

[0095] In some embodiments, one or more of the panes is configured with a coating. In some embodiments, the coating is selected from a low emissivity coating, an anti-reflective coating, or combinations thereof. In some embodiments, a low- emissivity coating may be disposed on surface 22, 24, 32, 34, 42, or 44 or combinations thereof.

[0096] In some embodiments, the IGU is incorporated with a frame having a seal, into a window. The seal is configured to fit perimetrically around the IGU, while fitting into the frame, such that the seal retaining ly engages the IGU into the frame. [0097] The linear coefficient of thermal expansion (CTE) as referenced herein is measured using ASTM standard E831 , “Standard Test Method for Linear Thermal Expansion of Solid Materials by Thermomechanical Analysis,” ASTM E228, “Test Method for Linear Thermal Expansion of Solid Materials With a Push-Rod Dilatometer”, or equivalent. As referenced herein, the coefficient of thermal expansion set forth herein are quantified as a coefficient of thermal expansion (CTE) is measured over a temperature range 0-300°C.

[0098] The CTE of the third pane is less than 70 x 10’⁷/°C and greater than zero as measured over a range of from 0 to about 300 °C. In some embodiments, the CTE of the third pane is less than 50 x 10’⁷/°C and greater than zero as measured over a range of from 0 to about 300 °C. In some embodiments, the CTE of the third pane is less than about 35 x 10’⁷/°C and greater than zero, as measured over a range of from 0 to about 300 °C.

[0099] The first pane and second pane are selected from sodalime glass, a boro-aluminosilicate glass, an alkaline earth boro-aluminosilicate glass, or an alkali- free boro-aluminosilicate glass. The third pane is selected from sodalime glass, a boro-aluminosilicate glass, an alkaline earth boro-aluminosilicate glass, or an alkali- free boro-aluminosilicate glass. Exemplary commercial glass products include, but are not limited to, Corning® EAGLE XG® and Lotus™ NXT glasses. In some embodiments, the first pane or second pane is a float product or fusion draw product. Soda lime glass has a CTE of approximately 90 x 10’⁷/°C. By comparison, Coming EAGLE XG glass has a CTE of approximately 32 x 10’⁷/°C, which is approximately 1/3 (“one-third”) of the CTE of soda lime glass, as measured over a range of from 0 to about 300 °C.

[00100] In some embodiments, the third pane is an architecturally-sized substrate. The IGU incorporating the third pane has a cross-sectional area (areal dimension) of at least 2’x5’; at least 3’x7’; or at least 4’x10’, or larger.

[00101] Figure 3A depicts, in the lower image, a close-up view of the inset L- bracket, depicting the two offset portions, the vertical offset and the horizontal offset (both labeled “x” for illustrative purposes.

[00102] Figure 3B, in the upper image, depicts the side view of the embodied support system including the support surface configured for pivoting/tilting engagement into at least two different positions, the horizontal position and upright position (vertically angled). Both positions are depicted, as well as the arrow which indicates the direction of pivot/ti It from a horizontal position to an upright position.

[00103] Figure 3B, in the lower image, depicts the side view of the various components in the support system, including the height of the inset L-bracket in comparison with the height of the third pane (thin center pane), and the overall height of the IGU.

[00104] In some embodiments, the inset L-bracket is composed of a flexible material that is configured to provide support to maintain spacing of the third pane relative to the support edge, support guide such that it aligns with the first pane and/or second pane in the target inset spacing. As some non-limiting examples, the inset L- bracket can be composed of rubber, plastic, or a polymeric material.

[00105] In some embodiments, the support surface is configured to pivot (e.g. pivoting arm) and lock into position in at least two positions: a horizontal position (generally flat); and an upright position (e.g. vertically angled at a 5-20 degree angle, e.g. 15-20 degree angle).

[00106] In some embodiments, the upright position is angled at 5 degrees to 20 degrees. In some embodiments, the upright position is angled in the range of: at 8 degrees to 20 degrees; or 10 degrees to 15 degrees, or 12 degrees to 17 degrees. In some embodiments, the upright position is angled in the range of: at 5 degrees to 12 degrees; or 5 degrees to 15 degrees, or 5 degrees to 15 degrees.

[00107] In some embodiments, the support surface is a vacuum table. In some embodiments, the vacuum table is configured with a plurality of holes in the support surface. In some embodiments, the support surface is configured to pull a vacuum through the holes and retain at least one glass pane, up to the IGU, in place in upright position in the support surface. In some embodiments, the vacuum is 0 to - 1 atm. In some embodiments, the vacuum table is configured to direct air out of the plurality of holes, such that the vacuum table is configured as an air float above the support surface. The air float is configured to enable the thin, light glass 9or other glass planes) to move onto and off of the support surface in a non-contact position (to avoid scratching and/or getting dust or dirt onto the panes). [00108] In some embodiments, the support surface is configured to pull a negative pressure, to engage with the substrate surface and retain it in place when in an upright position (e.g. vertically oriented).

[00109] In some embodiments, the support surface is configured with at least one support edge. In some embodiments, the support edge is at least as tall as the cross-sectional thickness of the IGU (e.g. distance from the first surface of the first pane to the second surface of the second pane of glass). In some embodiments, the support edge is configured to function as an alignment aid, such that the first pane of glass and second pane of glass are aligned. In some embodiments, the edge support is configured to enable the first pane, second pane, or IGU to be retained in place when the support surface is in the upright position.

[00110] In some embodiments, the support surface is configured with at least one edge guide extending from the support edge, where the edge guide meets the support edge to define a right-angled configuration. In some embodiments, the edge guide is a right-edge guide or a left-edge guide. In some embodiments, the support edge is configured with both a right-edge guide and a left edge guide.

[00111] In some embodiments, the inset L-bracket is configured to be removably positionable relative to the support edge and edge guide to define a third pane (thin glass center pane) double inset (a first inset/horizontal inset and a second inset/vertical inset) relative to the first pane of glass and second pane of glass.

[00112] In some embodiments, the support system is further configured with a vacuum lift assist, where such vacuum lift assist is configured to retain (e.g. through suction engagement with a major surface of one of the panes of glass) the pane and position the pane in an x/y/z direction relative to the support surface and other panes of glass. It will be appreciated that the various disclosed embodiments can involve particular features, elements or steps that are described in connection with that particular embodiment. It will also be appreciated that a particular feature, element or step, although described in relation to one particular embodiment, can be interchanged or combined with alternate embodiments in various non-illustrated combinations or permutations. Prophetic Examples on Thin Triple IGU Build Sequences:

[00113] With continued reference to the previous figures and numbered elements and components, various embodiments are disclosed in further detail the following non-limiting examples of Scenarios.

Scenario 1 :

[00114] Figures 4 and 5 depict a schematic representation of a first embodiment of a method of manufacturing a thin triple IGU.

[00115] With respect to a method of manufacturing a triple pane IGU having a thin center pane, one example provides the following: position the third pane on the support surface, using the inset L-bracket to position the edge of the third pane in spaced relation from the support edge and edge guide; engage the vacuum on the support table while in position 1 (generally flat position) to retain the third pane in place; tilt/position the support table into the upright position (having an angled configuration); position the first pane (the first pane having a spacer thereon) into alignment with the support edge and edge guide, place), once aligned with edges, place the first pane onto the third pane and press into place to form a double IGU (with the first pane and third pane and spacer). Next, position the support table in the horizontal/flat position, remove vacuum, and flip the double IGU such that the third pane is facing upward and the first pane is in contact with the support surface (removing the inset L-bracket or positioning the double IGU relative to the opposite support guide if the inset L-bracket is in fixed position on the support surface). Apply vacuum to retain the IGU to the support surface, and position the support surface in the upright position. Line up the second pane with the support edge and support guide, and press into place with the third pane to form a triple IGU.

[00116] After the triple IGU is formed, the support table can be positioned back into the horizontal position, vacuum removed, and air blown through the plurality of holes to create an air float, such that the IGU can be removed from the support table (e.g. for downstream processes including compression via rollers, injecting gas into the first air cavity and second air cavity, application of the secondary seal (e.g. with a silicone-type secondary seal), etc). In Scenario 1 , the triple IGU is formed with spacers being applied first to the first pane and second pane before they are contacted with the third pane.

Scenario 2:

[00117] Figures 6 and 7 depict a schematic representation of a second embodiment of a method of manufacturing a thin triple IGU.

[00118] Generally, with the second example, the same steps are followed. Here, the spacer is on a different pane as compared to the scenario 1 .

[00119] In Scenario 2, the triple IGU is formed with the first spacer applied to the third pane and the second spacer applied first to the second pane.

Scenario 3:

[00120] Figures 8 and 9 depict a schematic representation of a third embodiment of a method of manufacturing a thin triple IGU.

[00121] Generally, with the third example, the same steps are followed as with Scenario 1 . Here, the spacer is positioned on the second side of the third pane after the double IGU is flipped. Then, the second pane is positioned onto the third pane.

[00122] In Scenario 3, the triple IGU is formed with the first spacer applied to the third pane and the second spacer applied to the third pane before they are configured in alignment and pressed into place to form the IGU.

[00123] It is noted that Scenarios 1 to 3 do not require vacuum engagement of the support table and positioning from a horizontal position to an upright position (with angled configuration). The IGU build can be completed in a horizontal/flat manner.

Scenario 4:

[00124] Figures 10 and 11 depict a schematic representation of a fourth embodiment of a method of manufacturing a thin triple IGU.

[00125] In this fourth example, the first pane is positioned on the support surface in alignment/in contact with the support edge and edge guide. Then, the inset L-bracket is positioned on top of the corner of the first pane, such that the inset L- bracket is in contact with the second side of the first pane and in alignment with the support edge and edge guide. Then, utilizing a lift assist (e.g. spider, or vacuum lift with x,y,z positioning capabilities), the third pane is aligned with the inset L-bracket and pushed into position with the spacer, such that the third pane is aligned relative to the first pane with a double inset (in a horizontal direction and a vertical direction). Then, the inset L-bracket is removed and the second pane (having the second spacer positioned on its first surface) is positioned relative to the third pane, aligned with the support edge and edge guide, and positioned in place with the second surface of the third pane and second spacer to form a triple IGU. By aligning the second pane with the support edge and edge guide, the first pane and second pane are configured in alignment, while the inset L-bracket configures the double inset of the third pane relative to the first pane and the second pane.

[00126] It is noted that many of the steps for Scenarios 1 also apply here; though in this Scenario (and with Scenarios 5 and 6), the double IGU (first pane and third pane and first spacer) do not require any repositioning such that the third pane is upward facing and the first pane is in contact with the support surface. Rather, in these scenarios, the triple IGU is build-up in place (first, third, then second). Vacuum engagement to retain positioning of the first pane and/or double IGU and tilting from a horizontal position into an upright position can be utilized to promote ease of alignment and engagement of the panes and spacers relative to each other.

[00127] In Scenario 4, the triple IGU is formed with the first spacer applied to the first pane and the second spacer applied to the second pane.

Scenario 5:

[00128] Figures 12 and 13 depict a schematic representation of a fifth embodiment of a method of manufacturing a thin triple IGU.

[00129] Generally, with the fifth example, the same steps are followed as with Scenario 4. Here, the spacer is positioned on the second pane. Then, the second pane is positioned onto the third pane.

[00130] In Scenario 5, the triple IGU is formed with the first spacer applied to the third pane and the second spacer applied first to the second pane. Scenario 6:

[00131] Figures 14 and 15 depict a schematic representation of a sixth embodiment of a method of manufacturing a thin triple IGU.

[00132] Generally, with the sixth example, the same steps are followed as with Scenario 4. Here, the spacer is positioned on the second surface of the third pane. Then, the second pane is positioned onto the third pane.

[00133] In Scenario 6, the triple IGU is formed with the first spacer applied to the third pane and the second spacer applied to the third pane before they are configured in alignment and pressed into place to form the IGU.

Reference Numbers

IGU 10 first gas cavity 16 first gas cavity 18 first inset 12 second inset 14 first pane 20 first side of first pane 22 second side of first pane 24 second pane 30 first side of second pane 32 second side of second pane 34 third pane 40 first side of third pane 42 second side of third pane 44 first edge overhang 46 second edge overhand 48 spacer bead 50 first spacer 52 first side of first spacer 54 second side of first spacer 56 second spacer 60 first side of second spacer 62 second side of second spacer 64 support system 100 support surface 110 holes 112 horizontal position 114 upright position 116 support edge 118 edge guide 120 (L and/or R) inset L bracket 122 vertical inset portion 124 horizontal inset portion 126

[00134] It is also to be understood that, as used herein the terms “the,” “a,” or “an,” mean “at least one,” and should not be limited to “only one” unless explicitly indicated to the contrary. Thus, for example, reference to “a component” includes examples having one such “component” or two or more such “components” unless the context clearly indicates otherwise. Similarly, a “plurality” or an “array” is intended to denote two or more, such that an “array of components” or a “plurality of components” denotes two or more such components.

[00135] Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, examples include from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[00136] All numerical values expressed herein are to be interpreted as including “about,” whether or not so stated, unless expressly indicated otherwise. It is further understood, however, that each numerical value recited is precisely contemplated as well, regardless of whether it is expressed as “about” that value. Thus, “a dimension less than 100 nm” and “a dimension less than about 100 nm” both include embodiments of “a dimension less than about 100 nm” as well as “a dimension less than 100 nm.”

[00137] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that any particular order be inferred.

[00138] While various features, elements or steps of particular embodiments can be disclosed using the transitional phrase “comprising,” it is to be understood that alternative embodiments, including those that can be described using the transitional phrases “consisting” or “consisting essentially of,” are implied. Thus, for example, implied alternative embodiments to a device comprising A+B+C include embodiments where a device consists of A+B+C, and embodiments where a device consists essentially of A+B+C.

[00139] It will be apparent to those skilled in the art that various modifications and variations can be made to the present disclosure without departing from the spirit and scope of the disclosure. Since modifications combinations, sub-combinations and variations of the disclosed embodiments incorporating the spirit and substance of the disclosure can occur to persons skilled in the art, the disclosure should be construed to include everything within the scope of the appended claims and their equivalents.

Claims

WHAT IS CLAIMED IS:

1 . A method of making an insulated glass unit (IGU), comprising: a. positioning a first pane of glass on a support surface, the support surface configured with a support edge and an edge guide, wherein the first pane is aligned on the support surface such that a first side is proximal to the support surface, and a first corner of the first pane, the first corner defined by two adjacent edges of the first pane (a horizontal edge and a vertical edge) are in contact with the support edge and the edge guide (respectively); b. positioning an inset L-bracket on the second surface of the first pane, proximal to the first corner, such that the inset L-bracket contacts the support edge and the edge guide; c. positioning a third pane proximal the first pane and in engagement with an inner edge of the inset L-bracket, d. contacting the first pane and the third pane with a first adhesive to define a first gas cavity between the first pane and the third pane, the first adhesive is configured in a perimetrical bead such that it has a perimeter not greater than the perimeter of the third pane; e. positioning a second pane of glass, wherein the second pane is aligned on the support edge and edge guide such that a first corner of the second pane has adjacent edges of the second pane is in contact with the support edge and the edge guide; f. contacting the second pane and the third pane with a second adhesive to define a second gas cavity between the second pane and the third pane, wherein the second adhesive is configured in a perimetrical bead such that it has a perimeter not greater than the perimeter of the third pane; g. wherein via the inset L-bracket, a triple pane IGU is provided having a third pane configured with a double inset as compared to the first pane and second pane. The method of claim 1 , wherein at least one of the second side of the first pane or the first side of the third pane is configured with the first adhesive. The method of claim 1 , wherein the second side of the first pane is configured with the first adhesive. The method of claim 1 , wherein the first side of the third pane is configured with the first adhesive. The method of any of claims 1 to 4, wherein the first adhesive is a TPS spacer or a super spacer. The method of any of claims 1 to 5, wherein at least one of the second side of the third pane or the first side of the second pane is configured with the second adhesive. The method of any of claims 1 to 5, wherein the second side of the third pane is configured with the second adhesive. The method of any of claims 1 to 5, wherein the first side of the second pane is configured with the second adhesive. The method of any of claims 1 to 8, wherein the second adhesive is a TPS spacer or a super spacer. The method of any of claims 1 to 9, wherein the third pane has a thickness of not greater than 2 mm. The method of any of claims 1 to 10, wherein the third pane has a CTE 3 less than the first pane CTE 1 and the second pane CTE 2. The method of any of claim 1 to 11 , wherein the third pane is positioned with a vacuum or suction configured lift assist. The method of any of claims 1 to 12, wherein the second pane is positioned with a vacuum or suction configured lift assist. The method of any of claims 1 to 13, wherein the positioning step further comprises retaining the first pane in place via vacuum engagement via a plurality of holes in the support surface. The method of any of claims 1 to 14, wherein the positioning the first pane step further comprises retaining the first pane in place via vacuum engagement via a plurality of holes in the support surface. A method of making an insulated glass unit (IGU), comprising: a. positioning a third pane of glass on a support surface, the support surface configured with, wherein the third pane is aligned on the support surface such that a first side is proximal to the support surface, and a first corner of the third pane defined by two adjacent edges of the third pane (a horizontal edge and a vertical edge) are in contact with an inner edge of an inset L-bracket, the inset L-bracket contacting a support edge and an edge guide of the support surface; b. positioning a first pane proximal the third pane and in engagement with the support edge and the edge guide of the support surface; c. contacting the first pane and the third pane with a first adhesive to define a first gas cavity between the first pane and the third pane, the first adhesive is configured in a perimetrical bead such that it has a perimeter not greater than the perimeter of the third pane; d. configuring the first side of the first pane in contact with the support surface, such that a first corner of the first pane is in contact with the support edge and the edge guide; e. positioning a second pane of glass, wherein a first corner of the second pane is aligned on the support edge and edge guide such that a first corner of the third pane has adjacent edges of the second pane is in contact with the support edge and the edge guide; f. contacting the second pane and the third pane with a second adhesive to define a second gas cavity between the second pane and the third pane, wherein the second adhesive is configured in a perimetrical bead such that it has a perimeter not greater than the perimeter of the third pane; g. wherein via the inset L-bracket, a triple pane IGU is provided having a third pane configured with a double inset as compared to the first pane and second pane. The method of claim 16, wherein at least one of the second side of the first pane or the first side of the third pane is configured with the first adhesive. The method of claim 16, wherein the second side of the first pane is configured with the first adhesive. The method of claim 16, wherein the first side of the third pane is configured with the first adhesive. The method of any of claims 16 to 19, wherein the first adhesive is a TPS spacer or a super spacer. The method of any of claims 16 to 19, wherein at least one of the second side of the third pane or the first side of the second pane is configured with the second adhesive. The method of any of claims 16 to 19, wherein the second side of the third pane is configured with the second adhesive. The method of any of claims 16 to 19, wherein the first side of the second pane is configured with the second adhesive. The method of any of claims 16 to 23, wherein the second adhesive is a TPS spacer or a super spacer. The method of any of claims 16 to 24, wherein the third pane has a thickness of not greater than 2 mm. The method of any of claims 16 to 25, wherein the third pane has a CTE 3 less than the first pane CTE 1 and the second pane CTE 2. The method of any of claims 16 to 26, wherein the positioning step further comprises retaining the third pane in place via vacuum engagement via a plurality of holes in the support surface. The method of any of claims 16 to 27, wherein the positioning the second pane step further comprises retaining the first pane, third pane, and first adhesive in place via vacuum engagement via a plurality of holes in the support surface. The method of any of claims 16 to 28, wherein the method further comprises compressing the IGU by applying compressive force on the first surface of the first pane and the second surface of the second pane. The method of claim 28, wherein compressing further comprises compressing by engaging a plurality of rollers on a first side of the IGU while a second side of the IGU is in contact with a support surface. An insulating glass unit, comprising: a. a first pane of glass, having a first side and a second side, a first thickness of at least 2.5 mm, and a CTE 1 ; b. a second pane of glass, having a first side and a second side, a second thickness of at least 2.5 mm, and a CTE 2; and c. a third pane of glass, having a first side and a second side, having a third thickness of not greater than 2.5mm, and a CTE3, d. a first spacer, positioned between the second side of the first pane and the first side of the third pane to define a first gas cavity having a first cavity depth; and e. a second thermoplastic spacer, positioned between the second side of the third pane and the first side of the second pane to define a second gas cavity having a second cavity depth, f. wherein the third pane is configured with a vertical inset and a horizontal inset from the first pane and the second pane of at least 1 mm to not greater than 10 mm. The IGU of claim 31 , wherein the third pane has a thickness of at least 0.3 mm to not greater than 2.2 mm. The IGU of any of claims 31 to 32, wherein the third pane has a thickness of at least 0.3 mm to not greater than 1 .6 mm. The IGU of any of claims 31 to 33, wherein the third pane has a thickness of at least 0.3 mm to not greater than 1 .3 mm. The IGU of any of claims 31 to 34, wherein the third pane has a thickness of at least 0.45 mm to not greater than 1 mm. The IGU of any of claims 31 to 35, wherein CTE 3 is less than either of CTE1 and CTE 2. The IGU of any of claims 31 to 36, where the third pane is an alumino borosilicate glass. The IGU of any of claims 31 to 37, where at least one of the first pane and the second pane are a sodalime glass. The IGU of claim 38, where both the first pane and second pane are a sodalime glass. The IGU of any of claims 31 to 35, wherein CTE 3 is the same as than either of CTE1 and CTE 2. The IGU of any 31 to 35, wherein the third pane, the second pane, and the first pane are each composed of a sodalime glass. The IGU of any of claims 31 to 35, wherein the first gas cavity is configured with a gas selected from: air, krypton, argon, and mixtures of at least two of the foregoing. The IGU of any of claims 31 to 35, wherein the second gas cavity is configured with a gas selected from: air, krypton, argon, and mixtures of at least two of the foregoing.