Assembly of insulating glass structures on an integrated sash

Abstract

A sash frame is provided having a first mounting surface for a first glazing pane and a second mounting surface for mounting a second glazing pane substantially parallel to the first glazing pane. The first and second mounting surfaces are spaced apart to provide an insulating space between the glazing panes. An evacuation opening is provided in communication with the insulating space. The first glazing pane is adhesively mounted to the first mounting surface and the second glazing pane is adhesively mounted to the second mounting surface. Air is allowed to exhaust through the evacuation opening as the insulating space is formed between the glazing panes. A vacuum is drawn from the evacuation opening to draw the first and second glazing panes closer together after the panes have been mounted on their respective mounting surfaces. Mounting of the glazing panes may also be facilitated using a roll press.

What is claimed is:  
     
         1 . A method for fabricating an integrated sash insulating glass unit, comprising: 
 providing a sash frame having a first mounting surface for a first glazing pane and a second mounting surface for mounting a second glazing pane substantially parallel to said first glazing pane, said first and second mounting surfaces being spaced apart to provide an insulating space between said first and second glazing panes with an evacuation opening communicating with said insulating space;    adhesively mounting said first glazing pane to said first mounting surface and said second glazing pane to said second mounting surface;    allowing air to exhaust through said evacuation opening as said insulating space is formed between said glazing panes; and    drawing a vacuum from said evacuation opening to draw the first and second glazing panes closer together after the panes have been mounted on their respective mounting surfaces.    
     
     
         2 . A method in accordance with  claim 1 , wherein: 
 said glazing panes are mounted to their respective mounting surfaces using an adhesive sealant; and    said vacuum is drawn until edges of the glazing panes are at least partially embedded into the sealant.    
     
     
         3 . A method in accordance with  claim 1 , comprising: 
 plugging said evacuation opening after said vacuum has been drawn.    
     
     
         4 . A method in accordance with  claim 1 , comprising: 
 filling said insulating space with an insulating gas via said evacuation opening, after said vacuum has been drawn; and    plugging said evacuation opening after said gas filling step.    
     
     
         5 . A method in accordance with  claim 1 , wherein: 
 said glazing panes are mounted to their respective mounting surfaces using an adhesive sealant;    stops are provided on said mounting surfaces to limit whet-out of said sealant; and    said vacuum is drawn until the glazing panes contact said stops.    
     
     
         6 . A method in accordance with  claim 5 , comprising: 
 plugging said evacuation opening after said vacuum has been drawn.    
     
     
         7 . A method in accordance with  claim 5 , comprising: 
 filling said insulating space with an insulating gas via said evacuation opening, after said vacuum has been drawn; and    plugging said evacuation opening after said gas filling step.    
     
     
         8 . A method in accordance with  claim 1 , comprising: 
 applying said glazing panes to their respective mounting surfaces using at least one roller.    
     
     
         9 . A method in accordance with  claim 8 , wherein a roll press with multiple rollers is used to apply the glazing panes to their respective mounting surfaces.  
     
     
         10 . A method in accordance with  claim 8 , wherein said at least one roller is used to attach a glazing bead for at least one of the glazing panes.  
     
     
         11 . A method in accordance with  claim 10 , wherein said glazing bead is attached simultaneously with the mounting of the respective glazing pane to its respective mounting surface.  
     
     
         12 . A method in accordance with  claim 10 , wherein pressure from the at least one roller is applied to the at least one glazing pane via the respective glazing bead.  
     
     
         13 . A method in accordance with  claim 1  wherein said evacuation opening comprises a hole or a breather tube.  
     
     
         14 . A method for fabricating an integrated sash insulating glass unit, comprising: 
 providing a sash frame having a first mounting surface for a first glazing pane and a second mounting surface for mounting a second glazing pane substantially parallel to said first glazing pane, said first and second mounting surfaces being spaced apart to provide an insulating space between said first and second glazing panes;    mounting said first glazing pane to said first mounting surface via an adhesive sealant;    mounting said second glazing pane to said second mounting surface via an adhesive sealant; and    pressing surfaces of said first and second glazing panes adjacent their respective mounting surfaces into the respective adhesive sealant using at least one roller.    
     
     
         15 . A method in accordance with  claim 14 , comprising: 
 providing stops on said mounting surfaces to limit whet-out of the sealant; and    pressing said surfaces of the glazing panes with said at least one roller to a point at which the glazing panes contact said stops.    
     
     
         16 . A method in accordance with  claim 14 , wherein said at least one roller is used to attach a glazing bead for at least one of the glazing panes.  
     
     
         17 . A method in accordance with  claim 16 , wherein said glazing bead is attached simultaneously with the mounting of the respective glazing pane to its respective mounting surface.  
     
     
         18 . A method in accordance with  claim 16 , wherein pressure from the at least one roller is applied to the at least one glazing pane via the respective glazing bead.  
     
     
         19 . A method in accordance with  claim 14 , wherein: 
 said glazing pane surfaces are pressed by the at least one roller via respective glazing beads; and    pressure applied to the glazing beads by said at least one roller attaches the glazing beads to the sash frame.    
     
     
         20 . A method in accordance with  claim 14 , wherein a roll press with multiple rollers is used to apply the glazing panes to their respective mounting surfaces.  
     
     
         21 . A method in accordance with  claim 20 , wherein said roll press simultaneously presses said surfaces of the first and second glazing panes toward their respective mounting surfaces.  
     
     
         22 . A method in accordance with  claim 20 , wherein said roll press comprises successive roller sets that are spaced progressively closer together as said sash frame and glazing panes are transported therebetween.  
     
     
         23 . A method in accordance with  claim 14 , wherein an evacuation opening is provided in communication with said insulating space, to allow the escape of air as said glazing panes are mounted to their respective mounting surfaces and pressed by said roll press.  
     
     
         24 . A method in accordance with  claim 23 , comprising: 
 plugging said evacuation opening after said glazing panes have been mounted and pressed.    
     
     
         25 . A method in accordance with  claim 23 , comprising: 
 filling said insulating space with an insulating gas via said evacuation opening, after said glazing panes have been mounted and pressed; and    plugging said evacuation opening after said gas filling step.