A PANE MODULE ADAPTED TO BE INSTALLED ON A WINDOW FRAME AND A METHOD FOR MAKING A PANE MODULE

Abstract

The invention relates to a pane module adapted to be installed on a window frame and comprising a two-sheet pane element and a border element, which surrounds the pane element, extending along at least some of its outer sides. The border element is made by moulding and attached to the pane element during the moulding process, and the pane module further comprises a thermal insulating element, which is encased in the border element and extends along at least some of the outer sides of the pane element. The insulating element is arranged on the interior and/or exterior side of the pane element and covers the spacer member when seen perpendicular to the interior and/or exterior side of the pane element. The invention also relates to a method for making such a pane module.

Claims

1. A pane module configured to be installed on a window frame and comprising a pane element and a border element, where the pane element includes at least two sheet elements, such as sheets of glass, separated by one or more spacer members, where the pane element is a vacuum insulated glass unit with an evacuated cavity and comprising an array of pillars between the sheet elements, where the pane element has an exterior side intended to face the exterior of a building in a mounted state, an interior side intended to face the interior of a building in a mounted state, and outer sides extending between the exterior side and the interior side and delimiting a pane area, where the border element surrounds the pane element, extending along at least some of its outer sides, and where the border element is made by moulding and is attached to the pane element during the moulding process, characterized in that a thermal insulating element is encased in the border element and extends along at least some of the outer sides of the pane element, and that the insulating element is arranged to cover a part of the interior and/or exterior side of the pane element and extends to a distance d from the outer side, said distance d being so that the insulating element at least covers the spacer member when seen perpendicular to the interior and/or exterior side of the pane element.

2. A pane module according to claim 1, where the thermal insulating element is in direct contact with the pane element.

3. A pane module according to claim 2, where the thermal insulating element extends along all outer sides of the pane element.

4. A pane module according to claim 3, where the thermal insulating element includes separate thermal insulating members, arranged with one thermal insulating member at each side of the pane element.

5. A pane module according to claim 4, where the thermal insulating members are arranged at a distance from each other when seen in parallel to the exterior side of the pane, said distance being at least 2 mm, and/or that the thermal insulating element is provided with one or more passages allowing material used for moulding the border element to pass through them.

6. A pane module according to claim 1, where the thermal insulating element is arranged at the exterior side of the pane element so that it covers a part of the pane area.

7. A pane module according to claim 1, where the border element contacts at least two of the following: (i) interior side of the pane element, cii) the exterior side of the pane element, and (iii) an outer side of the pane element.

8. A pane module according to claim 1, where an inner side of the border element extends at a non-perpendicular angle to the exterior side of the pane element.

9. A pane module according to claim 1, further comprising one or more stiffening and/or connector elements, which is/are embedded in the moulded border element.

10. A pane module according to claim 1, wherein a side seal of the vacuum insulated glass unit comprises rigid solder.

11. A window frame with a pane module according to claim 1 and with hinges for suspending the pane element in an openable manner either by the border element being connected to the hinges or by the pane element being connected to the hinges through an intermediate sash.

12. A method for making a pane module adapted to be installed on a window frame and comprising a pane element and a border element, where the pane element includes at least two sheet elements, such as sheets of glass, separated by one or more spacer members, where the pane element is a vacuum insulated glass unit with an evacuated cavity and comprising an array of pillars between the sheet elements, and where the pane element has an exterior intended to face the exterior of a building in a mounted state, an interior side intended to face the interior of a building in a mounted state, and outer sides extending between the exterior side and the interior side and delimiting a pane area, said method including the following steps: A) arranging a thermal insulating element so that it extends along outer sides of the pane element and covers a part of the interior and/or exterior side of the pane element and extends to a distance d from the outer side, said distance d being so that the insulating element at least covers the spacer member when seen perpendicular to the interior and/or exterior side of the pane element, B) moulding the border element onto the pane element so that it surrounds the pane element, extending along at least some of its outer sides, and so that it encases the thermal insulating element.

13. A pane module according to claim 1, where the thermal insulating element extends along all outer sides of the pane element.

14. A pane module according to claim 1, where the thermal insulating element includes separate thermal insulating members, arranged with one thermal insulating member at each side of the pane element.

15. A pane module according to claim 3, where the thermal insulating element includes separate thermal insulating members.

16. A pane module according to claim 4, where the thermal insulating members are arranged at a distance from each other when seen in parallel to the exterior side of the pane.

17. A pane module according to claim 4, where the border element contacts at least two of the following: (i) interior side of the pane element, (ii) the exterior side of the pane element, and (iii) an outer side of the pane element.

18. A pane module according to claim 5, where the border element contacts at least two of the following: (i) interior side of the pane element, (ii) the exterior side of the pane element, and (iii) an outer side of the pane element.

19. A method according to claim 12, where the thermal insulating element includes separate thermal insulating members.

20. A method according to claim 12, where the thermal insulating element includes separate thermal insulating members, arranged with one thermal insulating member at each side of the pane element.

Description

[0030] In the following the invention will be described in more detail with reference to the drawing showing different embodiments of the invention, where

[0031] FIG. 1 is a schematic sketch of a pane module,

[0032] FIG. 2 shows a schematic sketch of a first embodiment in a cross-section along the line II-II in FIG. 1,

[0033] FIG. 3 shows a second embodiment in a cross-section along the line II-II in FIG. 1, but without a projecting connector element,

[0034] FIG. 4 shows a schematic sketch of a third embodiment in a cross-section along the line II-II in FIG. 1,

[0035] FIG. 5 shows a schematic sketch of a fourth embodiment in a cross-section along the line II-II in FIG. 1,

[0036] FIG. 6 shows a schematic sketch of a fifth embodiment in a cross-section along the line II-II in FIG. 1, but without an embedded connector element, and

[0037] FIG. 7 shows a schematic sketch in a cross-section along the plane VII in FIG. 1 showing only the lower right-hand corner of the pane module.

[0038] A pane module according to the invention is shown in FIG. 1. It comprises a pane element 1, a border element 2 and a stiffening and connector element 3, which is embedded in the moulded border element and adapted for use in connecting the pane module to another element (not shown), such as for example a window sash. Here the border element 2 surrounds the pane element 1 along all four sides of the pane element, defining a top, a bottom and two sides of the pane module, but it is within the scope of the invention to have the border element extending only along some sides, for example the top and side edges of the pane element.

[0039] The pane element 1 includes an interior sheet element 11 and an exterior sheet element 12, which are separated by one or more spacer members 13 as shown in FIG. 2. The interior sheet element defines an interior side 14 intended to face the interior of a building in a mounted state and the exterior sheet element defines an exterior side 15 intended to face the exterior of a building in a mounted state. Outer sides 16 extend between the exterior side and the interior side and delimit a pane area. The outer sides also define two side edges, a top edge, and a bottom edge of the pane element when the pane element is rectangular as in FIG. 1.

[0040] Here the pane element 1 is depicted as a traditional thermos pane, but it might as well have been a vacuum pane. This also applies to the following embodiments.

[0041] In the embodiment in FIG. 2, the border element 2 engages both the interior side 14, the exterior side 15 and the outer side 16 of the pane element 1, thus surrounding the edge of the pane element, but as will be explained later, this need not be case in all embodiments. When moulding the border element, the soft moulding material adheres to the pane element so that the border element becomes attached to the pane element, and the adhesion to one surface of the pane element may be sufficient to achieve a reliable fixation of the pane element to the border element.

[0042] The pane module further comprises a thermal insulating element 5, which is encased in the border element 2 and extends along the outer side 16 of the pane element.

[0043] The stiffening and connector element 3 is here a rail member with an angular cross-sectional shape, where a first leg 31 extends along the interior side 14 of the pane element and a second leg 32 extends in a direction substantially perpendicular to the interior sheet element 11. The first leg 31 supports the pane element and provides strength and stiffness to the border element. The second leg 32 connects the pane module to a frame member 4, which in this embodiment forms part of a window sash, but it is also possible to connect the pane module to a stationary frame or like fixed construction. The stiffening and connector element 3 may have multiple substantially parallel first legs 31 and may also sandwich the pane element 1 and the insulating element 5 between the substantially parallel legs (not shown).

[0044] In the embodiment in FIG. 2 the insulating element 5 is arranged on the exterior side 15 of the pane element 1 so that it covers a part of the pane area, and has a trapezoidal shape so that its height decreases as the distance to the outer side 16 of the pane element increases. The distance d between the outer side 16 of the pane element 1 and the inner-most point 51 on the insulating element is chosen in a balanced consideration of the desired insulating properties and the need for maintaining a certain light admitting area. The distance d should, however, be equal to or larger than the width of the spacer member 13 so that the insulating element 5 covers the spacer member 13 and a reduction of the stress at the edge of the pane element is achieved. Also, a mask may be provided on at least one side of the pane element. In one example the exterior side 15 has a mask substantially covering the distance d.

[0045] The insulating element 5 may be provided with an adhesive (not shown) on its interior side 52 in order to keep it in place during the moulding of the border element 2, or otherwise attached to the pane element 1 prior to the moulding of the border element. Alternatively, the border element 2 may be made prior to the application of the insulating member 5. The border element is then formed with a hollow having the desired shape of the insulating element, and the hollow is subsequently filled with an insulating material, which may be in a liquid, powdered or particulate form. It is also possible to make the border element 2 and the insulating member 5 simultaneously, for example by extrusion or printing.

[0046] In this embodiment the border element 2 follows the shape of the insulating element 5 so that its inner side 21 extends at a non-perpendicular angle to the exterior side 15 of the pane element. This angle may both serve to provide the pane module with a desired aesthetic appearance and prevent water and dirt from collecting at the joint between the border element 2 and the pane element 1.

[0047] On the exterior side 22, the border element 2 is provided with two feathers 23, which are intended to keep water and wind from penetrating into the construction in which the pane module is mounted. The two feathers may serve as a drainage gutter extending along the sides of a roof window.

[0048] FIG. 3 shows a different embodiment of a pane module in a cross-section corresponding to that in FIG. 2, but showing also the top member 24 of the border element 2 and displaying the pane element 1 in a simplified form as a single unit.

[0049] In FIG. 3 as well as in the following figures the same reference numbers as in FIG. 2 have been used and unless otherwise stated features having the same reference numbers have substantially the same properties and functions.

[0050] As will be seen the feathers 23 on the exterior side of the border element 2 are positioned differently than in FIG. 2 but serve the same purpose, and the thickness of the border element varies more than in FIG. 2 in order to provide the border element material where it is most needed. The outer dimensions of the border element 2 are defined by the inner shape of the mould used when forming the border element and are thus in principle independent of the shape of the pane element 1, insulating element 5 and other items embedded therein.

[0051] The embodiment in FIG. 3 further differs from that in FIG. 2 in that the stiffening and connector element 3 does not project through the interior side of the border element 2 and here primarily serves as a stiffening element. Instead the inner side of the border element 2 is provided with two beads 25, which are intended to mate with depressions (not shown) in a frame or the like to which the pane module is to be connected. The second leg 32 of the stiffening and connector element 3 is here short and extends into one of the beads 25, thereby reinforcing it.

[0052] The pane module in FIG. 3 is further provided with a sealing gasket 6 provided at the joint between the border element 2 and the pane element 1. If providing the insulating element 5 before moulding the border element, the sealing gasket 6 may be provided on the insulating element 5 in a position so that it is compressed between the pane element 1 and the border element 2 under the influence of the moulding pressure, or it may be provided on the pane element before moulding the border element. It is also possible to provide a similar sealing in the form of a soft joint sealant. It will be understood that the use of a sealing gasket is in principle independent of the shape of the border element, the presence of a stiffening and connector element, etc.

[0053] A still further embodiment of the pane module is shown in FIG. 4. Here the insulating element 5 is provided on the interior side of the pane element 1, and the stiffening and connector element 3 is of a simple, plate shaped design.

[0054] The pane element in FIG. 4 differs from that shown in the other figures in that the exterior sheet element 12 is larger than the interior sheet element 11 and projecting outwards from the spacer member 13. The larger exterior sheet element 12 projects over the border element 2, which thus only extends along the interior and outer sides 14, 16 of the pane element 1, thereby protecting the joint between the border element and the pane element. Though here shown at the side edge of the pane module, it will be understood that this embodiment is particularly well suited for use at the bottom of a roof or faade window, and it is to be understood that the exterior sheet element does not have to project at all edges.

[0055] In an alternative embodiment (not shown), the interior sheet 11 element is larger than the exterior sheet 12 element. The stiffening and connector element 3 may then grasp the larger interior sheet 11 edge which extends and forms a ledge. Again this may be on all four sides of the pane element or only on some of them.

[0056] Turning now to FIG. 5 a further embodiment of the pane module is shown. Here the insulating element 5 not only covers part of the exterior side 15 of the pane element 1 as in FIGS. 2 and 3, but also extends down along the outer side 16 of the pane element for further improved insulation. Moreover, the first leg 31 of the stiffening and connector element 3 is here extending on the exterior side of the insulating element 5 and the pane element 1 in order to provide further reinforcement of the border element 2. If choosing this design of the stiffening and connector element 3 care should be taken that it does not unintentionally form a thermal bridge, which has negative influences on the insulating properties.

[0057] Generally, the stiffening and connector element 3 may have a perforated portion. Hereby the thermal bridge effect is reduced and the moulding process can efficiently encase at least a part of the stiffening and connector element 3 in the material of the border element.

[0058] The stiffening and connector element 3 may for example be a metal profile or a plastic profile or fibre reinforced plastic profile, have a hollow cross section profile, and/or extend along all four sides of the pane element.

[0059] Generally, the stiffening and connector element 3 may be designed to hold or position the insulating element 5 in the mould for the encasing process.

[0060] A still further embodiment of the pane module is shown in FIG. 6. Here there is no stiffening and connector element, and the insulating element 5 is of a simple rectangular design, but the inclined inner side 21 of the border element 2 described with reference to FIG. 2 is maintained.

[0061] The thermal insulating element 5 may be provided in the form of an uninterrupted frame extending along all sides of the pane element 1, but it is also possible to use several separate insulating members. For a rectangular pane module it will often be preferable to use four insulating members each extending along one edge of the pane element, but for use in a centre-hung window is may be considered advantageous to have a section without thermal insulation at the position of the hinges (not shown) in order to provide a stiffer section better able to transmit loads to the hinges. The stiffening and connector element 3, if any, may also be embodied differently in the vicinity of hinges or other elements attached to the pane module. The stiffening and connector element 3 may also be directly connected to the hinges.

[0062] When using several separate insulating members for the insulating element 5, these members may be arranged at a distance from each other in order to provide a flow passage for the moulding material used for the border element 2. One such embodiment is shown in FIG. 7, where the width w of the flow passage 7 is exaggerated for illustration purposes. It will normally suffice if the width of the flow passage is approximately 10 mm, but the exact dimensions will depend on the moulding material used, the size of the pane, the number of passages etc. Flow passages may also be provided as holes (not shown) extending through the insulating element(s) 5 or grooves (not shown) in the interior or exterior side of the insulating element 5. Seen from a moulding perspective it will generally be advantageous to have flow passages at the corners of a rectangular pane module, but other considerations may require a different design. As an example it may be considered expedient or even necessary from an insulation perspective to have uninterrupted sections of insulating material at the corners.

[0063] It is to be understood that the different embodiments of the stiffening and connector element 3, the insulating element 5, the border element 2, and the pane element 1 described with reference to the embodiments shown in the drawing may be combined in different ways without departing from the scope of the claim. As an example the stiffening and connector element 3 in FIG. 2 may be combined with the insulating element 5 in FIG. 5, or the beads 25 and feathers 23 from FIG. 3 may be provided on the FIG. 4 embodiment. Likewise, the insulating element 5 may extend only on the outer side of the pane element 1, i.e. extending neither along the interior side of the pane element nor along the exterior side.