When multiple glass panes or "lites" are assembled into units, they are commonly referred to as insulated glass, double glazing, Double Glazed Units (UK and Europe) or Insulating Glass Units (IGU) (North America and Australia).
These units use the thermal and acoustic insulating properties of a gas (or vacuum) contained in the space formed by the unit. They can provide good insulation without sacrificing transparency (visual transmittance (VT)). Single glazed tinted and reflective glasses can provide similar thermal insulation, but for the same insulation performance are harder to see through and provide little protection against unwanted sound.
Most IGUs are double glazed, but IGUs with three sheets or more, i.e. "triple glazing" are becoming more common due to higher energy costs. Insulated glazing may be framed in a sash, frame or in a curtain wall.
Comparison of IGU characteristics
IGUs are manufactured to varying degrees of performance, as shown in the table below.)
Components
Glass
Glass is used to provide light and allow vision of things outside the place that is viewed from. While the composition and manufacturing of glass is covered elsewhere, for the purposes of this article, its importance to the construction is its dimensional stability over a wide temperature range. IGUs are manufactured with glass in range of thickness from 3 mm to 10 mm or more in special applications. Laminated or tempered glass may also be used as part of the construction. Most units are manufactured with the same thickness of glass used on both panes but special applications such as acoustic attenuation or security may require wide ranges of thicknesses to be incorporated in the same unit.
To reduce shear effects on the sealed unit (a major cause of premature failure), manufacturers use a rule of thumb that permits a difference of 1 mm between panes of glass used in the unit and still maintain the warranty for the unit. For example, a unit may be ordered with a 4 mm pane on the exterior and a 3 mm pane on the interior. These variations are allowed for architectural and cost reasons. Other combinations can be specified and produced but the manufacturer may reserve the right to limit the term of the warranty or refuse to warranty the unit altogether.
For ease of description the surfaces of a double paned unit are named according to the following convention: Surface #1 (facing outside), Surface #2 (inside of outside pane), Surface #3 (outside of inside pane) and Surface #4 (inside surface of inside pane). Applying the corresponding nomenclature for triple paned units results in surfaces #1 through #6.
The performance of glass can be modified through the use of the following:
Tinted glass
While clear glass is the most common glass component of IGUs, tinted glass may be used to reduce solar heat gain or as an architectural feature. The principle colors available are bronze, gray and green . The degree of tint depends on both the composition of the glass and the thickness of the lite. Tinted glass is usually placed on the exterior of the IGU. Tinted glass almost always requires heat-treatment to reduce potential thermal stress and breakage and tends to reradiate the absorbed heat.
Coated glass
The heat and sound insulation of glazing may also be improved by the use of a film or coating applied to its surface. This film is typically made of polyester or metal, and may give the window a reflective appearance or a one-way mirror effect. It may be used on single-glazed windows as an alternative to insulated glazing, or on surfaces #1, #2 or #3 (or combinations thereof) of insulated glazing to further improve its effectiveness. Such coatings may reduce fading of fabric and improve safety in case of breakage.. Glass performance is measured in two ways: Solar Heat Gain Co-efficient (SHGC), which expresses the proportion of incidental solar thermal radiation that is transmitted by the glass and Visible Transmittance, which describes the amount of visible light that is conducted through the glass between the exterior and interior surfaces. Both of these properties can be independently altered by different coatings.
Low-emissivity glass
Low-emissivity (Low-E) glass has a thin coating, often of metal, on the glass within its airspace that reflects thermal radiation or inhibits its emission reducing heat transfer through the glass.
A basic low-e coating allows solar radiation to pass through into a room. Thus, the coating helps to reduce heat loss but allows the room to be warmed by direct sunshine. The low-e coating is usually on surface #3; if solar control is required then the coated surface is moved to surface #2 to reflect or absorb solar radiation. The change in location of the coating does not affect the insulating properties of the IGU, only the percentage of solar heat gain.
Further solar radiation control can be added through the use of tinted glass and/or metallic coatings . Low-e glass reflects the radiation rather than absorbing it improving performance compared to the glass in a simple greenhouse. Its effect can be noticed by an increase in temperature of the inside glass surface and the reduction of condensation that would normally form on the unit because of a change in the dew point.
There are two types of low-e coatings available, "hard-coat" or pyrolytic and "soft-coat" or sputtered. Hard-coat glass is manufactured using the Atmospheric Pressure Chemical Vapor Deposition (APCVD) method of applying a doped tin composition to the glass surface as the glass sheets are being manufactured in the hot tin bath of a glass float plant, or alternatively in an offline furnace process. The tin bonds to the surface of the glass and forms a relatively thick coating. Hard-coat glass is considered a low to medium performance coating since the emissivity is greater (about 10 times) compared to the sputtered coating. The advantage of hard-coat glass is that it does not require special handling in the IGU assembly process to maintain the surface's coating integrity and does not scratch easily. It does require that the glass surface in contact with the spacer be abraded to improve adhesion of the sealant.
MSVD, or Magnetron Sputterering Vacuum Deposition (also known as "sputtering"), is the other technology used to manufacture Low-E glass. In MSVD, a metal or ceramic target bombarded with ions releases atoms to form a thin coating on a sheet of glass under high vacuum. The latest sputtered products are engineered to be increasingly more durable, approaching the durability of "hard coat" products.
Sputter coated high performance low-e glass offers better performance when compared to hard coat glass. The sputtered coating is often less durable compared to pyrolytic coated glass, and may require special handling and storage for both the manufacturing process and IGU fabrication. Choosing a high performance low-e glass over a hard-coat glass improves thermal performance of the IGU by about 13%.
Spacer
The glass panes are separated by a "spacer". A spacer is the component, or piece, used in window manufacturing that separates the two panes of glass in an insulating glass (IG) system, and seals the airspace between them. Historically, spacers were made primarily of metal, which manufacturers thought provided more durability for their windows. However, metal spacers act as a heat conductor, undermining the ability of the IGU to reduce heat flow. This may result in water or ice forming at the bottom of the sealed unit because of the heating/cooling loss through the window. To reduce heat transfer through the spacer and increase overall thermal performance, the spacer may be constructed of a less-conductive material such as structural foam.
Typically, spacers are filled with or contain desiccant to remove moisture trapped in the air space during manufacturing, preventing condensation from forming on surface #2 when the temperature falls below the dew point.
Construction
IGUs are manufactured on a made to order basis on factory production lines. The width and height dimensions, the thickness of the glass panes and the type of glass for each pane as well as the overall thickness of the unit must be supplied to the manufacturer. On the assembly line, spacers of specific thicknesses are cut and assembled into the required overall width and height dimensions and filled with desiccant. On a parallel line, glass panes are cut to size and washed to be optically clear. An adhesive sealant (polyisobutylene or PIB for short)is applied to the face of the spacer on each side and the panes pressed against the spacer. If the unit is gas filled, two holes are drilled into the spacer of the assembled unit, lines are attached to draw out the air out of the space and replaced with the desired gas - however the more modern technique is with the introduction of an online gas filler, which removes the need to drill holes in the spacer - The lines are then removed and holes sealed to conta
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