U.S. patent application number 11/367604 was filed with the patent office on 2006-07-06 for insulated panel and glazing system comprising the same.
This patent application is currently assigned to Cabot Corporation. Invention is credited to James N. Litrun, Stephane F. Rouanet.
Application Number | 20060144013 11/367604 |
Document ID | / |
Family ID | 34394101 |
Filed Date | 2006-07-06 |
United States Patent
Application |
20060144013 |
Kind Code |
A1 |
Rouanet; Stephane F. ; et
al. |
July 6, 2006 |
Insulated panel and glazing system comprising the same
Abstract
The invention provides a translucent glazing panel comprising:
(a) a thermoplastic panel comprising (i) an outer wall having an
inner surface defining an internal channel, the internal channel
having an internal volume, and (ii) at least one inner wall
protruding from the inner surface into the internal channel, and
(b) hydrophobic aerogel particles, the hydrophobic aerogel
particles being disposed within the channel. The invention also
provides an insulated glazing system comprising: (a) a first
U-shaped element, (b) a second U-shaped element, the first and
second elements being disposed to define a cavity therebetween, and
(c) an insulating panel disposed within the cavity. The insulated
glazing system can further comprise hydrophobic aerogel particles
disposed within the internal channel of the insulating panel. The
insulating panel of the glazing system also can be the same as the
translucent glazing panel described herein.
Inventors: |
Rouanet; Stephane F.;
(Westford, MA) ; Litrun; James N.; (Pepperell,
MA) |
Correspondence
Address: |
Michelle B. Lando;Cabot Corporation
Billerica Technical Center
157 Concord Road
Billerica
MA
01821-7001
US
|
Assignee: |
Cabot Corporation
Boston
MA
|
Family ID: |
34394101 |
Appl. No.: |
11/367604 |
Filed: |
March 3, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10679121 |
Oct 3, 2003 |
|
|
|
11367604 |
Mar 3, 2006 |
|
|
|
Current U.S.
Class: |
52/782.1 |
Current CPC
Class: |
E04C 2/54 20130101; Y10T
428/239 20150115; Y10T 428/24661 20150115; Y10T 428/234
20150115 |
Class at
Publication: |
052/782.1 |
International
Class: |
E04C 2/00 20060101
E04C002/00 |
Claims
1-76. (canceled)
77. A glazing panel made of a thermoplastic material and comprising
outer walls connected by one or more inner walls to form internal
channels and having at least one of the channels and at least one
wall treated to enhance at least one of thermal, insulating, and
moisture-control properties.
78. The glazing panel of claim 77, wherein at least one of the
internal channels is filled with aerogel particles.
79. The glazing panel of claim 77, wherein all of the internal
channels are filled with aerogel particles.
80. The glazing panel of claim 77, wherein a sealant is applied to
at least one outer wall.
81. The glazing panel of claim 77, wherein at least one of the
internal channels is filled with insulation material.
82. The glazing panel of claim 81, wherein the insulation material
is applied to a single layer of internal channels.
83. The glazing panel of claim 81, wherein the insulation material
is translucent.
84. The glazing panel of claim 81, wherein the insulation material
is inorganic aerogel particles.
85. The glazing panel of claim 84, wherein the inorganic aerogel
particles are silica aerogel particles.
86. The glazing panel of claim 77, wherein the panel further
comprises at least one material for enhancing thermal
properties.
87. The glazing panel of claim 86, wherein the material for
enhancing thermal properties is silicone.
88. The glazing panel of claim 86, wherein the material for
enhancing thermal properties is a polymeric sealant.
89. The glazing panel of claim 77, wherein the thermoplastic
material is polycarbonate.
90. A glazing panel made of a thermoplastic material and comprising
outer walls connected by an inner surface that defines at least one
internal channel, the structure having its open ends covered by
either the outer walls, wherein at least one of the internal
channels and at least one wall are treated to enhance at least one
of thermal, insulating, and moisture-control properties.
91. The glazing panel of claim 90, wherein the internal channels
have a square or rectangular shape.
92. The glazing panel of claim 90, wherein the inner surface
enhances at least one of thermal, insulating, and moisture-control
properties.
93. The glazing panel of claim 90, wherein at least one of the
internal channels is filled with aerogel particles.
94. The glazing panel of claim 90, wherein all of the internal
channels are filled with aerogel particles.
95. The glazing panel of claim 90, wherein a sealant is applied to
at least one outer wall.
96. The glazing panel of claim 90, wherein the glazing panel has at
least one internal channel filled with insulation material.
97. The glazing panel of claim 96, wherein the insulation material
is applied to a single layer of internal channels.
98. The glazing panel of claim 96, wherein the insulation material
is translucent.
99. The glazing panel of claim 96, wherein the insulation material
is inorganic aerogel particles.
100. The glazing panel of claim 99, wherein the inorganic aerogel
particles are silica aerogel particles.
101. The glazing panel of claim 90, wherein the panel further
comprises at least one material for enhancing thermal
properties.
102. The glazing panel of claim 101, wherein the material for
enhancing thermal properties is silicone.
103. The glazing panel of claim 101, wherein the material for
enhancing thermal properties is a polymeric sealant.
104. The glazing panel of claim 90, wherein the thermoplastic
material is polycarbonate.
Description
FIELD OF THE INVENTION
[0001] This invention pertains to insulated panels and glazing
systems comprising the same.
BACKGROUND OF THE INVENTION
[0002] In an effort to improve indoor lighting conditions and the
aesthetic appeal of enclosed spaces, architects and builders have
begun to construct buildings using an increasing large amount of
glazing materials and systems, such as windows, skylights, and
transparent or translucent walls and roofs. While the use of such
glazing materials can dramatically improve the quality of indoor
lighting, buildings incorporating relatively large amounts of such
glazing materials often are poorly insulated. More specifically,
the thermal transmission of conventional glazing materials
typically is significantly higher than the thermal transmission of
conventional building materials or structures, such as framed roofs
and walls. Therefore, the overall thermal transmission of a
building incorporating relatively large amounts of such glazing
materials typically is significantly higher than a similar
structure using less of the same, and such buildings often
experience relatively large amounts of heat flux across the glazing
materials, which can dramatically increase the cost of maintaining
the climate within the building at a level considered comfortable
by the occupants. Accordingly, several attempts have been made to
address the relatively poor (i.e., high) thermal transmission of
conventional glazing materials and systems.
[0003] For example, glazing materials and systems, such as windows,
have been developed which incorporate an air space between two
vitreous (e.g., glass) or thermoplastic surfaces. One such popular
glazing material is commonly referred to as a "multiwall panel."
These multiwall panels typically comprise two thermoplastic sheets
and a plurality of supporting members disposed between the
thermoplastic sheets. The thermoplastic sheets and the supporting
members together define a plurality of chambers disposed between
the thermoplastic sheets and the supporting members. Insofar as
gases have lower thermal conductivities than solid materials, such
as glass and thermoplastics, the gases within the chamber provide
an insulating layer that serves to decrease and/or retard thermal
transmission across the panel. While such multiwall panels do
exhibit improved (i.e., lower) thermal transmission than
conventional, single-pane glazing materials, condensation often
forms within the chambers as the panels are exposed to differences
in temperature and/or humidity across the major surfaces of the
panel. The humid environment provided by such condensation can
promote the growth of mold and mildew within the chambers of the
panel. Furthermore, the structure of the multiwall panels often
causes the panel to unevenly refract visible light, which can
negatively impact the indoor lighting quality of a structure
incorporating the panels as a glazing material.
[0004] Another glazing system that has been developed to provide an
improved (i.e., lower) thermal transmission relative to
conventional glazing materials and systems is commonly referred to
as double-glazed U-profile or U-channel glass. These glazing
systems typically comprise a pair of U-shaped glass elements
disposed in such a way as to form a chamber between the two
elements. While the gases contained within this channel can retard
thermal transmission across the glazing system (i.e., between the
two glass elements), the glazing system typically further comprises
an insulating material disposed within the chamber formed between
the two elements. The most commonly used insulating material is a
rigid panel which consists of a plurality of acrylic (e.g.,
poly(methyl methacrylate)) capillaries covered by two glass fiber
mats. The individual acrylic capillaries are arranged in a
substantially parallel direction so that the panel resembles a
honeycomb structure, the ends of which are covered by the glass
fiber mats. These rigid insulation panels can often dramatically
improve (i.e., lower) the thermal transmission of a glazing system
incorporating the same.
[0005] However, the costs saved due to the improved thermal
transmission of the glazing system can often be partially offset by
the relatively high labor costs associated with the installation of
such insulating panels. For instance, the insulating panels are
extremely fragile and frequently break during the installation due
to their relatively large dimensions (e.g., up to about 6 meters or
more in length). The debris generated by such breakage (e.g.,.
glass fibers) can create an environmental hazard for the workers
installing the insulating panels and must be painstakingly removed.
Furthermore, the insulating panels typically are adhered to one of
the glass elements (e.g., the glass element facing the outside of
the building) before the other glass element is installed. In such
a configuration, the insulating panel impedes the drainage of
condensation that forms on the glass element to which the panel is
adhered. As noted above, the humid environment provided by such
condensation can then promote the growth of mold and mildew within
the chamber formed by the glass elements.
[0006] A need therefore exits for an insulated panel that is
suitable for use as a glazing material and a glazing system
comprising such an insulated panel, both of which address the
foregoing and other problems associated with existing insulated
glazing materials and systems. The invention provides such an
insulated panel and glazing system. These and other advantages of
the invention, as well as additional inventive features, will be
apparent from the description of the invention provided herein.
BRIEF SUMMARY OF THE INVENTION
[0007] The invention provides a glazing panel, preferably
translucent, comprising: (a) a thermoplastic panel comprising (i)
an outer wall having an inner surface defining an internal channel,
the internal channel having an internal volume, and (ii) at least
one inner wall protruding from the inner surface into the internal
channel, and (b) hydrophobic aerogel particles, the hydrophobic
aerogel particles being disposed within the channel.
[0008] The invention further provides a glazing panel, preferably
translucent, comprising: (a) a thermoplastic panel comprising (i) a
first thermoplastic sheet, (ii) a second thermoplastic sheet, and
(iii) two or more supporting members, the supporting members being
disposed between the first and second thermoplastic sheets, and the
supporting members defining at least one channel disposed between
the first and second thermoplastic sheets, the channel having an
internal volume, and (b) hydrophobic aerogel particles, the
hydrophobic aerogel particles being disposed within the
channel.
[0009] The invention also provides an insulated glazing system
comprising: (a) a first element, preferably a U-shaped glass
element comprising a base from which at least two legs extend, (b)
a second element, preferably a U-shaped glass element comprising a
base from which at least two legs extend, the first and second
elements being disposed to define a cavity therebetween, (c) an
insulating panel disposed within the cavity, the insulating panel
comprising an outer wall defining an internal channel, the internal
channel having an internal volume, and (d) hydrophobic aerogel
particles, the hydrophobic aerogel particles being disposed within
the internal channel.
[0010] The invention additionally provides an insulated glazing
system comprising: (a) a first element, preferably a U-shaped glass
element comprising a base from which at least two legs extend, (b)
a second element, preferably a U-shaped glass element comprising a
base from which at least two legs extend, the first and second
elements being disposed to define a cavity therebetween, and (c) an
insulating panel disposed within the cavity, the insulating panel
comprising (i) an outer wall having an inner surface defining an
internal channel, the internal channel having an internal volume,
and (ii) at least one inner wall protruding from the inner surface
into the internal channel, the outer wall and inner wall being
unitarily formed of a thermoplastic resin.
[0011] The invention provides an insulated glazing system
comprising: (a) a first element, preferably a U-shaped glass
element comprising a base from which at least two legs extend, (b)
a second element, preferably a U-shaped glass element comprising a
base from which at least two legs extend, the first and second
elements being disposed to define a cavity therebetween, and (c) an
insulating panel disposed within the cavity, the insulating panel
comprising (i) a first thermoplastic sheet, (ii) a second
thermoplastic sheet, the first and second thermoplastic sheets
being substantially parallel to each other, and (iii) at least two
supporting members, the supporting members being disposed between
the first and second thermoplastic sheets, and the supporting
members defining at least one channel disposed between the first
and second thermoplastic sheets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a perspective sectional view of an insulating
panel according to teachings of the invention comprising an outer
wall defining an internal channel and at least one inner wall
protruding into the inner channel.
[0013] FIG. 2 is a perspective sectional view of another insulating
panel according to teachings of the invention comprising an outer
wall defining an internal channel and a plurality of inner walls
protruding into the inner channel from opposing portions of the
inner surface of the outer wall.
[0014] FIG. 3 is a perspective sectional view of an insulating
panel according to teachings of the invention comprising an outer
wall defining an internal channel and at least one inner wall
protruding into the internal channel and contacting the inner
surface of the outer wall at at least two distinct points.
[0015] FIG. 4 is a perspective sectional view of an insulating
panel according to teachings of the invention comprising a first
thermoplastic sheet, a second thermoplastic sheet, and two or more
supporting members disposed between the first and second
thermoplastic sheets to define at least one channel disposed
between the first and second thermoplastic sheets.
[0016] FIG. 5 is a perspective sectional view of an insulating
panel similar to the panel depicted in FIG. 4 in which a third
thermoplastic sheet is disposed between the first and second
thermoplastic sheets.
[0017] FIG. 6 is a perspective sectional view of an insulating
panel similar to the panel depicted in FIG. 5 in which
substantially all of the internal volume of the channels is filled
with hydrophobic aerogel particles.
[0018] FIG. 7 is a perspective sectional view of an insulated
glazing system according to teachings of the invention comprising a
first U-shaped element, a second U-shaped element, and an
insulating panel disposed within the cavity formed by the
elements.
[0019] FIG. 8 is a perspective sectional view of an insulated
glazing system similar to the system depicted in FIG. 7 in which
the insulating panel further comprises at least one inner wall
protruding into the internal channel of the insulating panel.
[0020] FIG. 9 is a perspective sectional view of an insulated
glazing system similar to the system depicted in FIG. 8 in which at
least one of the inner walls intersect the inner surface of the
outer wall at at least two distinct points.
[0021] FIG. 10 is a perspective sectional view of an insulated
glazing system according to teachings of the invention comprising a
first element, a second element, and an insulating panel disposed
within the cavity formed by the elements, the insulating panel
comprising a first thermoplastic sheet, a second thermoplastic
sheet, and at least two supporting members disposed between the
first and second thermoplastic sheets to define at least one
channel disposed between the first and second thermoplastic
sheets.
[0022] FIG. 11 is a perspective sectional view of an insulated
glazing system similar to the system depicted in FIG. 10 in which
the insulating panel further comprises a third thermoplastic sheet
disposed between the first and second thermoplastic sheets.
[0023] FIG. 12 is a perspective sectional view of an insulated
glazing system similar to the system depicted in FIG. 10 in which
the glazing system further comprises a sealant disposed between the
elements.
[0024] FIG. 13 is a perspective sectional view of an insulated
glazing system similar to the system depicted in FIG. 10 in which a
sealant is attached to the perimeter of the insulating panel.
[0025] FIG. 14 is a perspective sectional view of an insulated
glazing system similar to the system depicted in FIG. 10 in which
the sealant is attached to the perimeter of the insulating panel,
and the sealant also is disposed between the elements.
[0026] FIG. 15 is a sectional view of a modular insulated glazing
system comprising an insulated glazing system similar to that
depicted in FIG. 14.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Turning now to the drawings, there is shown in FIG. 1, a
glazing panel 100 constructed in accordance with teachings of the
invention. The glazing panel 100 has a length and comprises an
outer wall 102 having an inner surface 104. The outer wall 102
defines an internal channel 106.
[0028] In accordance with the invention, and in order to maximize
the insulating, light-transmitting, and moisture-resistant
properties of the glazing panel, the panel 100 is preferably
transparent or translucent and comprises hydrophobic aerogel
particles 110 disposed within the internal channel. For the
purposes of this disclosure, the term translucent will be used to
describe both transparent and translucent materials and structures.
While not wishing to be bound to any particular theory, it is
believed that the relatively large internal volume of the
hydrophobic aerogel particles provides an insulating layer in the
glazing panel, thereby decreasing the thermal transmission (i.e.,
U-value) of a glazing panel according to the invention.
Furthermore, it is believed that the aggregate light scattering
properties of a collection of the hydrophobic aerogel particles
(e.g., the particle contained within the channel or any part
thereof) contributes to the diffusion of visible light transmitted
through the panel, thereby improving the quality of transmitted
light that passes through the panel and improving the internal
lighting of any structure utilizing the same as a glazing material
(e.g., a window, skylight, or structural glazing element). Lastly,
it is believed that the hydrophobic nature of the hydrophobic
areogel particles prevents, at least in part, the formation of
condensation on the internal surfaces of a translucent glazing
panel according to the invention as the glazing panel is exposed to
differences in temperature and/or humidity across the major
surfaces of the glazing panel (e.g., across the interior surface
and exterior surface of a window incorporating a translucent
glazing panel according to the invention).
[0029] The hydrophobic aerogel particles contained in a glazing
panel according to the invention can be any suitable hydrophobic
aerogel particles. The hydrophobic aerogel particles can comprise
organic aerogel particles, inorganic aerogel particles (e.g., metal
oxide aerogel particles), or a mixture thereof. When the
hydrophobic aerogel particles comprise organic aerogel particles,
the organic aerogel particles preferably are selected from the
group consisting of resorcinol-formaldehyde aerogel particles,
melamine-formaldehyde aerogel particles, and combinations thereof.
When the hydrophobic aerogel particles comprise inorganic aerogel
particles, the inorganic aerogel particles preferably are metal
oxide aerogel particles selected from the group consisting of
silica aerogel particles, titania aerogel particles, alumina
aerogel particles, and combinations thereof. Most preferably, the
hydrophobic aerogel particles are silica aerogel particles.
[0030] In order to further control placement and distribution of
the aerogel particles within the internal channel 106, the panel
100 preferably further includes one or more inner walls 108, as
shown in FIG. 1. The inner wall 108 protrudes into the internal
channel 106 from the inner surface 104 of the outer wall 102 to at
least partially divide the internal channel 106. In this way, the
aerogel particles 110 are disposed within and fill at least a
portion of the internal channel 106 formed by the outer wall 102.
In the currently preferred embodiment, substantially all of the
internal volume of the internal channel 106 is filled with
hydrophobic aerogel particles 110.
[0031] Preferably, the panel 100 comprises a plurality of inner
walls 108 (e.g., two or more internal walls) protruding from the
inner surface 104 of the outer wall 102. When the translucent
glazing panel 100 comprises a plurality of inner walls 108, the
inner walls 108 can be provided in any suitable configuration. For
example, in FIG. 1, the inner walls 108 are disposed adjacent one
another, protruding from a single section of the inner wall 108.
Conversely, in FIG. 2, a plurality of inner walls 208 protrude from
opposing portions of the inner surface 204 of the outer wall 202.
(As a general matter, similar reference numerals will be utilized
in the various illustrated embodiments of the invention.)
[0032] In order to further control the distribution of the aerogel
particles 110 within the internal channel 106, 206, the volume of
the internal channel 106, 206 may be further divided into a
plurality of channels. As shown in FIG. 3, the inner wall 308a of
the panel 300 can intersect the inner surface 304 of the outer wall
302 at at least two distinct points. The panel 300 can include one
such wall 308a, as shown in FIG. 3, so that the outer wall 302 and
inner wall 308a define two internal channels 306, 310 having
internal volumes. It will be appreciated by those of skill in the
art that the inner wall 308a may extend substantially the entire
length of the panel 300 or extend only a portion of the length.
Thus, where the inner wall 308a extends along at least a portion of
the length, the outer wall 302 and inner wall 308a define first and
second internal channels 306, 310. Further, the inner wall 308a may
have any cross-sectional configuration. For example, it may be
curved, or it may include an angular portion, or it may be formed
from, in essence, the engagement of two inner walls (such as 308)
that intersect the inner surface 304 at only one point. The inner
walls may also intersect the inner surface 304 at three or more
points.
[0033] The panel 300 may likewise include one or more inner walls
308 that protrude from the inner surface 304 of the outer wall 302,
but do not intersect the inner surface 304 of the outer wall 302 at
at least two distinct points, such as walls 108 and 208 in FIGS. 1
and 2. Hydrophobic aerogel particles 312 are disposed within at
least one of the internal channels 306, 310, preferably, filling at
least a portion of the internal volume of both of the internal
channels 306, 310. In a currently preferred embodiment,
substantially all of the internal volume of the internal channels
306, 310 is filled with hydrophobic aerogel particles 312. While
the inner wall 308a prevents or inhibits movement of the particles
312 between the channels 306, 310, the inner walls 308 further
control the location of the aerogel particles 312, but do not
necessarily prevent particle 312 movement within a given channel
306, 310 in and of themselves.
[0034] It will thus be appreciated by those of skill in the art,
that the internal configuration of the panel 300 may include a
plurality of such inner walls 308a that intersect the inner surface
304 to create a plurality of such channels 306, 310, with or
without such inner walls 308 that intersect the inner surface 304
at only one position. For example, the panel 400, 500 may include a
plurality of inner walls 406, 506, 512 that intersect the internal
surface of the outer wall at two or more points, as shown in FIGS.
4 and 5, respectively.
[0035] More specifically, as depicted in FIG. 4, for example, the
translucent glazing panel comprises a first thermoplastic sheet
402, a second thermoplastic sheet 404, and two or more supporting
members 406 disposed between the first and second thermoplastic
sheets 402, 404. The first thermoplastic sheet 402 preferably is
substantially parallel to the second thermoplastic sheet 404. The
supporting members 406 define at least one channel 408 disposed
between the first and second thermoplastic sheets 402, 404. As with
the other embodiments, the glazing panel further comprises
hydrophobic aerogel particles 410 disposed within at least one, and
preferably at least a portion of or all, of the channels 408
defined by the supporting members 406.
[0036] As depicted in FIG. 5, the thermoplastic panel 500 can
further comprise a third thermoplastic sheet 512 disposed between
the first thermoplastic sheet 502 and the second thermoplastic
sheet 504, the third thermoplastic sheet 512 and the supporting
members 506 defining at least two rows of channels 508 disposed
between the first and second thermoplastic sheets 502, 504. As
shown in FIG. 5, preferably, the third thermoplastic sheet 512 is
substantially parallel to the first and second thermoplastic sheets
502, 504. The hydrophobic aerogel particles 510 are disposed within
at least one, and preferably a portion of or all, of the channels
508 formed by the third thermoplastic sheet 512 and the supporting
members 506. Most preferably, as depicted in FIG. 6, substantially
all of the internal volume of each of the channels 508 defined by
the first, second, and third thermoplastic sheets 502, 504, 512 and
the supporting members 506 are filled with hydrophobic aerogel
particles 510.
[0037] The outer wall and inner wall(s) of the glazing panel can be
formed using any suitable method, with any suitable material.
Referring to FIG. 1, for example, the outer wall 102 and inner
walls 108 can be unitarily formed of a thermoplastic resin using
thermoplastic molding methods known in the art (e.g., injection
molding, extrusion molding, etc.). Alternatively, the glazing panel
can include separately formed components that are later assembled.
For example, the outer wall 102 can comprise, for example, a first
thermoplastic sheet 112, a second thermoplastic sheet 114, and at
least two supporting members 116 disposed between the first and
second thermoplastic sheets 112, 114 to form the outer wall 102. In
such an embodiment, the first thermoplastic sheet 112, second
thermoplastic sheet 114, supporting members 116, and internal walls
108 may be joined using an adhesive, sonic welding, or any other
method suitable for joining two or more articles comprising the
material of the walls.
[0038] Similar fabrication methods may be utilized with the other
embodiments. For example, in the embodiment of FIG. 4, the entire
panel 400 may be injection molded or extruded. Alternately, the
first thermoplastic sheet 402, second thermoplastic sheet 404, and
supporting members 406 of the glazing panel 400 can be formed using
any suitable method, and then joined using an adhesive, sonic
welding, or any other method suitable for joining two or more
articles comprising the material of the walls.
[0039] A thermoplastic panel preferably comprises any suitable
thermoplastic resin. Suitable thermoplastic resins preferably
exhibit a relatively high mechanical strength and can withstand
large temperature gradients. The thermoplastic of the panel
preferably comprises a thermoplastic resin selected from the group
consisting of polycarbonate, polyethylene, poly(methyl
methacrylate), poly(vinyl chloride), and mixtures thereof. Most
preferably, the thermoplastic of the panel comprises
polycarbonate.
[0040] The glazing panel of the invention can be provided in any
suitable size and/or shape. Typically, the glazing panel can be
used to replace the vitreous glazing material (e.g., glass) used in
conventional glazing systems (e.g., windows, skylights, etc.).
Accordingly, a glazing panel according to the invention generally
has a thickness of less than about 100 mm. When the glazing panel
comprises an outer wall and at least one inner wall protruding from
the surface thereof, as depicted in FIG. 1, the opposing surfaces
of the outer wall 102 forming the thickness of the glazing panel
100 typically are separated by less than about 100 mm, preferably
less than about 50 mm, and more preferably less than about 30 mm.
Alternatively, when the glazing panel comprises a first
thermoplastic sheet and a second thermoplastic sheet, as depicted
in FIG. 4, for example, the first thermoplastic sheet 402 and the
second thermoplastic sheet 404 typically are separated by less than
about 1 cm, preferably less than about 50 mm, and more preferably
less than about 30 mm.
[0041] The quality of visible light transmitted through a glazing
panel according to the invention preferably is more diffuse than
the visible light transmitted through similar glazing panels that
are not filled with hydrophobic aerogel particles. In particular, a
glazing panel according to the invention preferably exhibits an
improved haze value (e.g., a higher haze value) than a similar
glazing panel that is not filled with hydrophobic aerogel
particles. The haze value is a measurement of light-transmitting
and wide-angle-light-scattering properties of planar sections of
materials, such as glazing materials (e.g., transparent or
translucent plastics). The haze value is defined in ASTM Standard
D1003, entitled "Standard Test Method for Haze and Luminous
Transmittance of Transparent Plastics," and can be measured in
accordance with the procedures set forth therein. As utilized
herein, the term "haze value" refers to the haze value of a glazing
panel as defined and measured in accordance with ASTM Standard
D1003. Preferably, a thermoplastic glazing panel according to the
invention has a haze value of about 50% or more, more preferably
about 75% or more.
[0042] In accordance with another aspect of the invention, the
inventive glazing panels, as shown for example in FIGS. 1-6, may be
incorporated into a so-called U-channel glass glazing system or
other appropriate glazing system. Turning now to FIG. 7, the
insulated glazing system 700 comprises elements 702, 708 that
define a cavity 714 there between. In the illustrated embodiment, a
pair of elongated, U-shaped glass elements 702, 708 are provided;
The first U-shaped glass element 702 comprises a base 704 from
which at least two legs 706 extend, and the second U-shaped element
708 comprises a base 710 from which at least two legs 712 extend.
It will be appreciated that the elements 702, 708 could have an
alternately structure. For example, they could each have an
"L-shaped" structure, or one could have a "U-shaped" structure and
the other an elongated flat structure which covers the internal
channel of the U-shaped structure to form an elongated cavity
therebetween. Thus, the invention is not limited to the inclusion
of such U-shaped glass elements and the following explanation of
structures utilizing such U-shaped glass elements is equally
applicable to elongated elements of an alternate shape or
cross-section.
[0043] In assembly, the first and second glass elements 702, 708
are disposed to define a cavity 714 therebetween. While the legs
706, 712 of the U-shaped glass elements 702, 708 are disposed in a
staggered arrangement in the embodiment of FIG. 7, it will be
appreciated that the first and second glass elements 702, 704 can
be arranged in any suitable manner to define the cavity. For
example, the legs of the first glass element can be disposed
adjacent to the base of the second glass element, thereby defining
a cavity bounded by the base and legs of the first glass element
and the base of the second glass element. Alternatively, the ends
of the legs of the first and second glass elements can be disposed
adjacent to each other, thereby defining a cavity bounded by the
base and legs of the first and second glass elements. The alternate
possible cross-sectional shaped glass element structures may be
similarly disposed in various manners to define the cavity.
[0044] The glazing system 700 according to teachings of the
invention further comprises an insulating panel 716 disposed within
the cavity 714 formed by the first and second glass elements 702,
708. The insulating panel of a glazing system according to the
invention can have any suitable dimension. As disclosed above, the
insulating panel 716 comprises an outer wall 718 defining an
internal channel 720 that preferably comprises hydrophobic aerogel
particles 722. Typically, at least a portion, and preferably
substantially all, of the internal volume of the internal channel
720 is filled with hydrophobic aerogel particles 722. The structure
of the insulating panel itself may be of any appropriate design. By
way of example only, the structure of the insulating panel 100 of
FIG. 1 may be included in the glazing system 800, as shown in FIG.
8; the insulating panel 400 of FIG. 4 may be included in the
glazing system 1000 of FIG. 10; or the insulating panel 500 of FIG.
5 may be included in the glazing system 1100 of FIG. 11. It will be
appreciated, however, that the insulating panel 916 may have an
alternate design, such as is disclosed, for example in FIG. 9.
[0045] Turning now to FIG. 12, in assembly, the first and second
glass elements 1202, 1208 are disposed to form the cavity 1214
therebetween. The first and second glass elements 1202, 1208 of
this embodiment are U-shaped and include legs 1206, 1212 extending
from bases 1204, 1210, respectively. In order to reduce thermal
transmission between the first and second glass elements 1202,
1208, an insulated glazing system according to the invention
preferably comprises at least one sealant 1228 disposed between at
least a portion of adjacent sections of the first and second glass
elements 1202, 1208. As depicted in FIG. 12, the sealant 1228
typically is disposed to surround the distal tips 1206a, 1212a of
the internally disposed legs 1206, 1212 of first and second
U-shaped glass elements 1202, 1208. In this way, the sealant 1228
provides a seal not only between adjacently disposed legs, 1206,
1212, but also between the distal tips 1206a, 1212a of the
internally disposed legs 1206, 1212 and the bases 1206, 1212. It
will be appreciated, however, that the sealant 1228 can be
alternately disposed.
[0046] Furthermore, in order to minimize or prevent thermal
conduction between the insulating panel and the first and second
glass elements, a sealant can be attached to at least a portion of
the perimeter of the insulating panel. As depicted in FIG. 13, the
sealant 1328 can be attached to the perimeter of the insulating
panel 400, thereby separating and isolating the insulating panel
400 from the adjacent legs 1306, 1312 of the first and second glass
elements. 1302, 1308.
[0047] Alternatively, the sealant can be attached to the perimeter
of the insulating panel in such a way as to separate and isolate
the insulating panel from the bases of the first and second glass
elements. Preferably, at least a portion of the sealant is disposed
between the insulating panel and at least one of the first and
second glass elements. A currently preferred example of such an
embodiment of the glazing system of the invention is depicted in
FIG. 14. In particular, the sealant 1428 is disposed between the
insulating panel 400 and the adjacent legs 1406, 1412 of the first
and second glass elements 1402, 1408. As illustrated, the sealant
1428 is further disposed between the adjacent legs 1406, 1412 of
the first and second glass elements 1402, 1408, as well as between
the adjacent portions of one of the legs 1406, 1412 of the glass
elements and the base 1404, 1410 of the other glass element. It
will be appreciated by those of skill in the art that the
insulating panel is preferably spaced away from the inside surfaces
of the glass elements as shown in FIGS. 7-14. In this way, should
any condensation from on an inside surface of either or both of the
glass elements or on the outside surface of the insulating panel,
the condensation can run down the surface, rather than collecting
between the same.
[0048] The sealant can comprise any suitable material. Suitable
sealants include, but are not limited to, silicone (e.g., silicone
caulk, silicone adhesive, silicone gaskets), polymeric sealants
(e.g., polyethylene gaskets), etc. Preferably, the sealant
comprises silicone, more preferably a silicone gasket.
[0049] The insulated glazing system can be assembled in any
appropriate order. For example, a first of the glass elements may
be placed, the insulating panel disposed therebetween, and then the
second of the glass elements placed. Alternately, the glass
elements may be assembled together and the insulating panel then
inserted in the cavity between the glass elements.
[0050] An insulated glazing system according to teaching of the
invention to be utilized in the construction of modular glazing
systems is shown, for example, in FIG. 15. In such a modular
arrangement, individual, partially assembled modules of glass
elements with an enclosed insulating panel may be provided, the
partially assembled modules of glass elements with insulating
panels may then be assembled on site to form an extended glazed
structure. In particular, the modular glazing system 1500 comprises
a first U-shaped glass element 1502 comprising a base 1504 from
which at least two legs 1506 extend and a second U-shaped glass
element 1508 comprising a base 1510 from which at least two legs
1512 extend. The first and second glass elements 1502, 1508 are
disposed to define a cavity 1514 therebetween. The glazing system
1500 further comprises an insulating panel 1516 disposed within the
cavity 1514 formed by the first and second glass elements 1502,
1508. The insulating panel 1516 can comprise any of the insulating
panels described above for the insulated glazing system of the
invention. As depicted, the insulating panel 1516 comprises a first
thermoplastic sheet 1518, a second thermoplastic sheet 1520, and at
least two supporting members 1522. The supporting members 1522 are
disposed between the first and second thermoplastic sheets 1518,
1520 in such a way to define at least one channel 1524 disposed
between the first and second thermoplastic sheets 1518, 1520. In
order to improve (i.e., lower) the thermal transmission of the
glazing system 1500, the glazing system can further comprise
hydrophobic aerogel particles 1526 disposed within at least one of
the channels 1524 formed by the supporting members 1522.
Preferably, at least a portion of the internal volume of one of the
channels 1524 is filled with hydrophobic aerogel particles 1526.
More preferably, substantially all of the internal volume of at
least one of the channels 1524 is filled with hydrophobic aerogel
particles 1526. Most preferably, at least a portion (or
substantially all) of the internal volume of each of the channels
1524 is filled with hydrophobic aerogel particles 1526. The glazing
system 1500 can further comprise at least one sealant 1528 disposed
between the insulating panel 1516 and adjacent portions of the
first and second glass elements 1502, 1508. In order to prevent
contact between the glass elements, the sealant 1528 preferably is
further disposed between adjacent portions of the first and second
glass elements (e.g., between the legs 1506, 1512 of the first or
second glass element 1502, 1508 and the base 1504 of the other
glass element).
[0051] In summary, in order to minimize the thermal transmission of
the glazing system, the insulating panel preferably is
substantially coextensive with the length and the width of the
cavity defined by the first and second glass elements (e.g., the
length and width of the insulating panel are substantially the same
as the length and width of the cavity). More preferably, the
insulating panel is coextensive with the width of the cavity (e.g.,
the difference between the width of the cavity and the width of the
panel is limited to the amount necessary to allow the panel to be
inserted into the cavity and to accommodate any sealant disposed
between the insulating panel and the adjacent surfaces of the glass
elements forming the cavity). However, as noted above, the
insulating panel preferably does not directly contact the first or
second glass elements. Contact between the insulating panel and the
glass elements can be prevented in any suitable manner, but a
sealant preferably is disposed between the insulating panel and the
first or second glass elements.
[0052] The hydrophobic aerogel particles that can be contained
within the insulating panel of the glazing system can be any
suitable hydrophobic aerogel particles. The hydrophobic aerogel
particles can comprise organic aerogel particles, inorganic aerogel
particles (e.g., metal oxide aerogel particles), or a mixture
thereof. When the hydrophobic aerogel particles comprise organic
aerogel particles, the organic aerogel particles preferably are
selected from the group consisting of resorcinol-formaldehyde
aerogel particles, melamine-formaldehyde aerogel particles, and
combinations thereof. When the hydrophobic aerogel particles
comprise inorganic aerogel particles, the inorganic aerogel
particles preferably are metal oxide aerogel particles selected
from the group consisting of silica aerogel particles, titania
aerogel particles, alumina aerogel particles, and combinations
thereof. Most preferably, the hydrophobic aerogel particles are
silica aerogel particles.
[0053] The following examples further illustrate the invention but,
of course, should not be construed as in any way limiting its
scope.
EXAMPLE 1
[0054] This example demonstrates the improved U value (i.e., lower
thermal transmission) exhibited by a glazing panel according to the
invention relative to other glazing panels that do not comprise
hydrophobic aerogel particles. The corrected U values for eleven
similar translucent glazing panels were measured. Each of the
glazing panels comprised a first polycarbonate sheet, a second
polycarbonate sheet, and a plurality of supporting members disposed
between the first and second polycarbonate sheets to define a
plurality of channels between the first and second polycarbonate
sheets.
[0055] Glazing Panels 1A (comparative) and 1B (invention) measured
approximately 10 mm in thickness, and Glazing Panel 1B (invention)
comprised hydrophobic aerogel particles disposed within the
channels of the panel.
[0056] Glazing Panels 1C-1E measured approximately 16 mm in
thickness and further comprised a third polycarbonate sheet
disposed between and parallel to the first and second polycarbonate
sheets, thereby forming two rows of channels disposed between the
first and second polycarbonate sheets. Glazing Panel 1C
(comparative) did not contain hydrophobic aerogel particles.
Glazing Panel 1D (invention) contained hydrophobic aerogel
particles disposed within both rows of channels disposed between
the first and second polycarbonate sheets, and Glazing Panel 1E
(invention) contained hydrophobic aerogel particles disposed within
only one row of channels disposed between the first and second
polycarbonate sheets.
[0057] Glazing Panels 1F-1H measured approximately 20 mm in
thickness and further comprised a third polycarbonate sheet
disposed between and parallel to the first and second polycarbonate
sheets, thereby forming two rows of channels disposed between the
first and second polycarbonate sheets. Glazing Panel 1F
(comparative) did not contain hydrophobic aerogel particles.
Glazing Panel 1G (invention) contained hydrophobic aerogel
particles disposed within both rows of channels disposed between
the first and second polycarbonate sheets, and Glazing Panel 1H
(invention) contained hydrophobic aerogel particles disposed within
only one row of channels disposed between the first and second
polycarbonate sheets.
[0058] Glazing Panels 1I-1K measured approximately 25 mm in
thickness and further comprised a third polycarbonate sheet
disposed between and parallel to the first and second polycarbonate
sheets, thereby forming two rows of channels disposed between the
first and second polycarbonate sheets. Glazing Panel 1I
(comparative) did not contain hydrophobic aerogel particles.
Glazing Panel 1J (invention) contained hydrophobic aerogel
particles disposed within both rows of channels disposed between
the first and second polycarbonate sheets, and Glazing Panel 1K
(invention) contained hydrophobic aerogel particles disposed within
only one row of channels disposed between the first and second
polycarbonate sheets.
[0059] The U value of each glazing system was measured in
accordance with ASTM Standard C518-98, entitled "Standard Test
Method for Steady-State Thermal Transmission Properties by Means of
the Heat Flow Meter Apparatus." The U values obtained from these
measurements were then corrected to account for the air film
thermal resistance in accordance with the guidelines set forth in
Chapter 30 of the 2001 ASHRAE Fundamentals Handbook. The corrected
U values for Glazing Panels 1A-1K obtained by these measurements
and corrections are set forth in Table 1 below. TABLE-US-00001
TABLE 1 Thickness, Fill Particulars, Rows of Channels Filled, and
Corrected U Values for Glazing Panels 1A-1K. Rows of Glazing
Thickness Channels Corrected U Panel (mm) Fill Filled Value
(W/m.sup.2K) 1A 10 -- -- 3.12 1B 10 Hydrophobic One 1.93 Aerogel
Particles 1C 16 -- -- 2.40 1D 16 Hydrophobic Two 1.31 Aerogel
Particles 1E 16 Hydrophobic One 1.70 Aerogel Particles 1F 20 -- --
1.89 1G 20 Hydrophobic Two 1.06 Aerogel Particles 1H 20 Hydrophobic
One 1.55 Aerogel Particles 1I 25 -- -- 1.66 1J 25 Hydrophobic Two
0.89 Aerogel Particles 1K 25 Hydrophobic One 1.39 Aerogel
Particles
[0060] The data set forth in Table 1 demonstrates that a glazing
panel according to the invention exhibits a lower U value (i.e.,
lower thermal transmission) than a similar glazing panel that does
not comprise hydrophobic aerogel particles. In particular, a
glazing panel that does not comprise hydrophobic aerogel particles
disposed within the channel(s) exhibits a corrected U value that is
at least about 20% higher than a similar glazing panel that
comprises hydrophobic aerogel particles disposed within the
channel(s) or at least one row of the channels. Indeed, Glazing
Panel 1I (comparative) exhibited a corrected U value that was
approximately 85% greater than the corrected U value of Glazing
Panel 1J (invention).
EXAMPLE 2
[0061] This example demonstrates the improved light diffusing
properties (i.e., higher haze value) exhibited by a glazing panel
according to the invention relative to other glazing panels that do
not comprise hydrophobic aerogel particles. Six similar translucent
glazing panels (Glazing Panels 2A-2F) were measured to determine
the haze value of each panel. Each of the glazing panels comprised
a first polycarbonate sheet, a second polycarbonate sheet, and a
plurality of supporting members disposed between the first and
second polycarbonate sheets to define a plurality of channels
between the first and second polycarbonate sheets. Glazing Panels
2A (comparative) and 2D (invention) measured approximately 6 mm in
thickness, Glazing Panels 2B (comparative) and 2E (invention)
measured approximately 10 mm in thickness, and Glazing Panels 2C
(comparative) and 2F (invention) measured approximately 20 mm in
thickness. The channels of Glazing Panels 2D-2F (invention) were
filled with hydrophobic aerogel particles. The channels of Glazing
Panels 2A-2C (comparative) were not filled with hydrophobic aerogel
particles (i.e., the channels merely contained air).
[0062] The haze value of each glazing panel was measured using an
ULTRASCAN.RTM. XE spectrophotometer (available from HunterLab
Associates, Reston, Va.). The results from these measurements are
set forth in Table 2 below. TABLE-US-00002 TABLE 2 Thickness, Fill
Particulars, and Haze Values for Glazing Panels 2A-2F. Haze Glazing
Panel Thickness (mm) Fill Value (%) 2A (comparative) 6 -- 48 2B
(comparative) 10 -- 39 2C (comparative) 20 -- 31 2D (invention) 6
Hydrophobic 89 Aerogel Particles 2E (invention) 10 Hydrophobic 94
Aerogel Particles 2F (invention) 20 Hydrophobic 97 Aerogel
Particles
[0063] The data set forth in Table 2 demonstrates that a glazing
panel according to the invention exhibits a higher haze value than
a similar glazing panel that does not contain hydrophobic aerogel
particles. In particular, the haze value (measured in %) for a
glazing panel according to the invention (i.e., Glazing Panels
2D-2F) is approximately two or more times greater than the haze
value for a similar glazing panel that does not contain hydrophobic
aerogel particles (i.e., Glazing Panels 2A-2C).
EXAMPLE 3
[0064] This example demonstrates the improved U value (i.e., lower
thermal transmission) of a glazing system according to the
invention relative to other glazing systems. The U values for four
similar glazing systems were measured. Each of the four glazing
systems (Glazing Systems 3A-3D) was constructed using two similar
U-shaped glass elements. The glass elements comprised a base, which
measured approximately 262 mm in length, and two legs
perpendicularly extending from the base, which legs measured
approximately 60 mm in length. The glass from which each element
was constructed was approximately 7 mm thick. In order to prevent
contact between the legs of one element and the inside surface of
the base of the other element, a polymeric gasket was placed on the
distal end of each leg. The two U-shaped glass elements were
arranged so that the legs of each glass element projected from the
base of the glass element toward the base of the other glass
element, thereby defining a cavity between the two glass
elements.
[0065] Glazing System 3A (comparative) did not comprise an
insulation material disposed within the cavity formed by the glass
elements.
[0066] Glazing System 3B (comparative) comprised a rigid insulation
material measuring approximately 20 mm in thickness (Okapane.RTM.
available from OkaLux GmbH, Marktheidenfeld-Altfeld, Germany)
disposed within the cavity formed by the glass elements. The
Okapane.RTM. rigid insulation material comprised a plurality of
hollow poly(methyl methacrylate) tubes measuring approximately 20
mm in length and arranged in a substantially parallel relationship.
Two glass fiber mats were adhered to the ends of the tubes, thereby
forming a rigid insulation material in which the tubes were
substantially perpendicular to the glass fiber mats.
[0067] Glazing System 3C (comparative) comprised another rigid
insulation material measuring approximately 50 mm in thickness
(Moniflex.RTM. available from Isoflex AB, Gustafs, Sweden) disposed
within the cavity formed by the glass elements. The Moniflex.RTM.
rigid insulation material comprised approximately 10 layers of
corrugated cellulose acetate films, in which the pleats of each
film were disposed in a substantially perpendicular direction to
the pleats in the adjacent films. The individual layers of
cellulose acetate film were glued together to form the rigid
insulation material.
[0068] Glazing System 3D (invention) comprised a hydrophobic
aerogel-filled insulated panel measuring approximately 20 mm in
thickness. The insulated panel comprised a first polycarbonate
sheet, a second polycarbonate sheet, and a plurality of supporting
members disposed between the first and second polycarbonate sheets
to define a plurality of channels between the first and second
polycarbonate sheets. The hydrophobic aerogel particles were
disposed within the channels formed by the supporting members.
[0069] The U value of each glazing system was measured in
accordance with ASTM Standard C518-98. The U values obtained from
such measurements were not corrected to account for air film
thermal resistance. The results of these measurement are set forth
in Table 3 below. TABLE-US-00003 TABLE 3 Insulation Type and
Thickness and U Values for Glazing Systems 3A-3D. Glazing System
Insulation U Value (W/m.sup.2K) 3A (comparative) -- 3.2 3B
(comparative) 20 mm Okapane .RTM. 1.6 3C (comparative) 50 mm
Moniflex .RTM. 1.4 3D (invention) 20 mm Aerogel-filled Panel
1.0
[0070] As evidenced by the data set forth in Table 3, a glazing
system according to the invention exhibits a U value that is
significantly lower than similar glazing systems that do not
comprise an insulating panel according to the invention. In
particular, a comparison of the U values for Glazing Systems 3A and
3D reveals that the U value for a glazing system that did not
contain any insulation material disposed within the cavity formed
by the glass elements (i.e., Glazing System 3A) exhibited a U value
that was approximately 220% greater than the U value of a glazing
system according to the invention (i.e., Glazing System 3D). A
comparison of the U values for Glazing Systems 3B-3D further
reveals that the U value for glazing systems comprising
commercially available insulation materials disposed within the
cavity formed by the glass elements exhibited U values that were
approximately 60% (Glazing System 3B) and 40% (Glazing System 3C)
greater that the U value of a glazing system according to the
invention (i.e., Glazing System 3D).
[0071] All references, including publications, patent applications,
and patents, cited herein are hereby incorporated by reference to
the same extent as if each reference were individually and
specifically indicated to be incorporated by reference and were set
forth in its entirety herein.
[0072] The use of the terms "a" and "an" and "the" and similar
referents in the context of describing the invention (especially in
the context of the following claims) are to be construed to cover
both the singular and the plural, unless otherwise indicated herein
or clearly contradicted by context. The terms "comprising,"
"having," "including," and "containing" are to be construed as
open-ended terms (i.e., meaning "including, but not limited to,")
unless otherwise noted. Recitation of ranges of values herein are
merely intended to serve as a shorthand method of referring
individually to each separate value falling within the range,
unless otherwise indicated herein, and each separate value is
incorporated into the specification as if it were individually
recited herein. All methods described herein can be performed in
any suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as") provided herein, is
intended merely to better illuminate the invention and does not
pose a limitation on the scope of the invention unless otherwise
claimed. No language in the specification should be construed as
indicating any non-claimed element as essential to the practice of
the invention.
[0073] Preferred embodiments of this invention are described
herein, including the best mode known to the inventors for carrying
out the invention. Variations of those preferred embodiments may
become apparent to those of ordinary skill in the art upon reading
the foregoing description. The inventors expect skilled artisans to
employ such variations as appropriate, and the inventors intend for
the invention to be practiced otherwise than as specifically
described herein. Accordingly, this invention includes all
modifications and equivalents of the subject matter recited in the
claims appended hereto as permitted by applicable law. Moreover,
any combination of the above-described elements in all possible
variations thereof is encompassed by the invention unless otherwise
indicated herein or otherwise clearly contradicted by context.
* * * * *