Thermally insulating fenestration devices and methods.

(54) Title: THERMALLY INSULATING DEVICES AND METHODS OF FENESTRATION. (54) Title: THERMALLY INSULATING FENESTRATION DEVICES AND METHODS.

(57) Summary

Some embodiments provide a fenestration apparatus that includes at least one sheet of glass suitable to be installed in the opening of a building enclosure and a tiled structure arranged adjacent to the at least one sheet of glass. The tessellated structure can include at least one partition that has a first face and a second face. The at least one partition can define a plurality of spatially separated cells within a substantially contiguous region of the opening. Each of the plurality of spatially separated cells can have a cell width and a cell depth. Each of the plurality of spatially separated cells may be at least partially surrounded by the first face of the at least one partition, the second face of the at least one partition, or a combination of the first face and the second face of the at least one partition.

(57) Abstract

Some realizations provide a fenestration apparatus including at least one glazing pane capable of being installed in an opening of a building envelope and a tessellated structure disposed adjacent to the at least one glazing pane. The tessellated structure can inelude at least one partition having a first face and a second face. The at least one partition can defines a plurality of spatially separated cells within a substantially contiguous region of the opening. Each of the plurality of spatially separated cells can have a cell width and a cell depth. Each of the plurality of spatially separated cells can be at least partially surrounded by the first face of the at least one partition, the second face of the at least one partition, or a combination of the first face and the second face of the at least one partition.

i

THERMALLY INSULATING FENESTRATION DEVICES AND METHODS

FIELD OF THE INVENTION

The present invention is generally concerned with penetration and more in particular. with penetration devices and methods that provide thermal insulation.

BACKGROUND OF THE INVENTION

Many buildings have walls, ceilings, and / or roofs that at least partially prevent light from the outside environment from entering such buildings. Fenestration devices and methods can be used to allow some of the outside light to pass into a building. They can also allow construction occupants to see the outside environment and / or allow daylight to substantially illuminate the interior of the construction.

Penetration devices include windows, skylights, and other types of apertures and aperture covers. A window is commonly placed in an opening in the construction wall, while a skylight is commonly placed in an opening in a construction roof or ceiling. There are numerous types of skylights, including, for example, plastic glazed skylights, glass glazed skylights, light wells, and tubular daylight devices (TDDs). Light wells and tubular daylight fixtures transport exterior light from the roof to the ceiling inside the building.

BRIEF DESCRIPTION OF THE INVENTION

Exemplary modalities described herein have several elements, none of which are indispensable or solely responsible for their desirable attributes. Without limiting the scope of the claims, some of the advantageous elements of some modalities are now summarized.

Some embodiments provide a fenestration apparatus having at least one glazed sheet apt to be installed in an opening of a building enclosure and a tessellated (eg spatially delineated) structure arranged adjacent to the at least one glazed sheet. The tessellated structure can include at least one partition that has a first face and a second face. The at least one partition can delineate, at least in part, a plurality of spatially spaced paths within a substantially continuous region of the opening. The volume within each cell may or may not be completely isolated from the volumes in the other cells. Cells may or may not share one or more common walls. Each of the plurality of cells spatially separated. it has a cell width and a cell depth. Each of the plurality of spatially spaced cells is at least partially surrounded by the first face of the at least one partition, the second face of the at least one partition, or a combination of the first face and the second face of the at least one partition.

In certain embodiments, the light reflectance of the first face of the at least one partition is greater than or equal to about 95%. In some embodiments, the light reflectance of the second face of the at least one partition is greater than or equal to about 95%. In some embodiments, the light reflectance of each of the first face and the second face of the at least one partition may be greater than or equal to about 99%. The at least one partition can include a plurality of reflective film segments. In some modalities, fenestration devices. they can include a plurality of partitions.

The tessellated structure may include a honeycomb structure, such as for example a cubic prismatic honeycomb structure. or a hexagonal prismatic honeycomb structure or any other appropriate structure.

The apparatus may include a second glazed sheet. The tessellated structure can be arranged between at least a first glazed sheet and the second glazed sheet. In some embodiments, the fenestration apparatus is positioned such that external light passes through the second glazed sheet after passing through the tessellated structure. In some embodiments, the fraction of visible light leaving the second glazed sheet may be greater than or equal to about 85% of the visible light entering the fenestration apparatus.

The cell depth of each of the plurality of spatially separated cells may be greater than or equal to about 1.3 cm (0.5 inch). The cell width of each of the plurality of spatially separated cells can be less than or equal to about 5 cm (2 inches).

The building enclosure may include a roof, a wall, and / or other building elements. The opening in the construction enclosure may include an internally reflective tube that extends between an opening in the roof and an interior construction site.

Certain modalities provide a method of providing light to the interior of a building. The method may include the steps of placing at least one glazed sheet into an opening in the building enclosure and placing a tessellated structure adjacent to the at least one glazed sheet. The tessellated structure can include at least one partition that has a first face and a second face. The at least one partition can define a plurality of spatially separated cells within a substantially contiguous region of the opening. Each of the plurality of spatially separated cells has a cell width and a cell depth. Each of the plurality of spatially separated cells is at least partially surrounded by the first face of the at least one partition, the second face of the at least one partition, or a combination of the first face and the second face of the at least one partition. The light reflectance of the first face of the at least one partition may be of any appropriate value, such as, for example, greater than or equal to about 95%.

The method may include providing a double glazing unit that incorporates the at least one glazed sheet and a second glazed sheet. The tessellated structure can be arranged between the at least one glazed sheet and the second glazed sheet. The method may include providing a diffuser and placing the diffuser adjacent to or near the tiled structure. The diffuser may be configured to refract or reflect light that propagates through the diffuser in a manner that alters or obscures the view of the fenestration device from within the construction.

Some modalities provide a method of manufacturing a fenestration apparatus. The method may include the steps of dividing a sheet of reflective film into a plurality of segments having a length of segments; forming at least a first film loop, a second film loop and a third film loop, from the plurality of segments; inserting a first mandrel into the first film loop and expanding the first mandrel until the first loop reaches a desired shape; inserting a second mandrel into the second film loop and expanding the second mandrel until the second loop reaches a desired shape; adhere the second loop to the first loop while the first mandrel is inserted into the first loop and the second mandrel is inserted into the second loop; inserting the first mandrel or a third mandrel into the third film loop and expanding the third mandrel until the third loop reaches a desired shape; adhering the third loop to the second loop while the first mandrel or third mandrel is inserted into the third loop and the second mandrel is inserted into the second loop. The first loop, the second loop, and the third loop can form an assembled cell structure. Additional loops can be adhered to the assembled cell structure until the assembled cell structure substantially fills an opening in the fenestration apparatus. In some embodiments, the assembled cell structure can form a honeycomb structure. The segment length of each of the plurality of segments may be greater than or equal to the perimeter of a cell and an assembled cell structure.

Certain modalities provide a method of manufacturing a fenestration apparatus with a tessellated structure comprising a plurality of polygonal cells. The method may include the steps of providing a first film strip and a second film strip; crimping the first film strip and the second film strip in increments equal to the lengths of the sides of the polygonal cells; glue the first film strip to the second film strip together at points that are selected to create a crimped cell structure comprising individual cells having desired polygonal shapes and create additional assembled cell structures until the assembled cell structures fill substantially all or a portion of the opening of the fenestration apparatus.

In some embodiments, the assembled cell structures can be secured between the first and second glazed sheets. At least one of the first film strip and the second film strip may include a material that has a light reflectance of greater than or equal to about 95% when measured relative to a CIE D illuminant.₆58

BRIEF DESCRIPTION OF THE FIGURES

Various embodiments are illustrated in the accompanying figures for illustrative purposes and should not be construed in any way as limiting the invention. In addition, various elements of different revealed modalities can be combined to form modalities.

t) additional that are part of this disclosure. Any element or structure can be removed or omitted. In all the figures, the reference numbers can be reused to indicate correspondence between reference elements.

Figure 1 is a partial perspective view of a double-glazed fenestration device.

Figure 2 is a schematic ray diagram showing the spread of light through the fenestration device shown in Figure 1.

Figure 3 is a schematic diagram showing another double-glazed fenestration device.

FIG. 4A is a perspective view of an unformatted tessellated structure cell.

Figure 4B is a schematic diagram of an apparatus for forming tessellated cells.

Figure 4C is a schematic diagram showing the operation of an apparatus for forming tessellated structure cells.

Figure 4D is a schematic diagram showing the operation of an apparatus for forming tessellated cells.

Figure 5 is a schematic diagram showing the operation of another apparatus for cell shapes of tessellated structures.

Figure 6 is an example of a diagram showing examples of proportions between the film area used to form tessellated cells and the area of ​​a glazed opening.

Figure 7 is a schematic diagram of an exemplary TDD facility incorporating a thermally insulating fenestration device.

Figure 8 is a perspective view of a thermally insulating fenestration device.

Figure 9 is a partial perspective view of an exemplary TDD installation incorporating the thermally insulating fenestration device shown in Figure 8.

DETAILED DESCRIPTION OF PREFERRED MODALITIES

Although certain preferred embodiments and examples are disclosed herein, the subject matter of the invention extends beyond the examples in the specifically disclosed embodiments to other alternative embodiments and / or uses and modifications and equivalents thereof. Thus, the scope of the claims appended hereto is in no way limited to the particular embodiments described below. For example, in any method or process disclosed herein, the acts or operations of the method or process may be performed in any appropriate sequence and are not necessarily limited to any particular disclosed sequence. Several operations can be described as multiple discrete operations in turn, in a way that can be helpful in understanding certain modalities; however, the order of description should not be interpreted to imply that these operations are order dependent. Additionally, the structures, systems and / or devices described herein can be implemented as integrated components or as separate components. For purposes of comparing various modalities, certain aspects and advantages of these modalities are described. Not necessarily all of such aspects or advantages are obtained by any particular modality. Thus, for example, various modalities can be carried out in a way that obtains or optimizes an advantage or groups of advantages as taught herein without necessarily obtaining other aspects or advantages as can also be taught or suggested herein.

Fenestration products can be designed to allow occupants inside a pipeline to see the outside environment. Such products may also allow sunlight to illuminate the interior of the building. In some embodiments, a fenestration device is placed in a chest opening or roof of the building. As used herein, the terms fenestration, fenestration device, fenestration apparatus, fenestration method, and the like are used in their broad and ordinary sense. For example, fenestration devices can include skylights, windows, walls, panels, blocks, doors, meshes, shots, openings, tubes, other structures that are not completely opaque, or a combination of structures.

Fenestration devices that are installed in an opening in a roof or roof of a building are often called skylights, while fenestration devices installed vertically or in a wall opening are often called windows. Skylights and windows can include a transparent or translucent glaze, which can be manufactured from a variety of materials, such as plastic, glass, clear material, prismatic material, translucent material, other material that is not completely opaque, a combination of non-opaque materials. opaque or a combination of one or more non-opaque materials and one or more opaque materials. Tubular daylight fixtures and light wells are examples of skylights that can transport light from the roof of a building to the roof and inside the building.

A glaze may suffer from one or more performance limitations. For example, the incident angle of the sun to a glazed surface can vary considerably throughout the day and year due to the movement of the sun. A change in the incident angle of sunlight can affect the optical transmission characteristics of the glaze. Transmission characteristics may also vary based on the index or refractive indices of materials used in the glaze.

Non-opaque glazing materials tend to have relatively high thermal conductivity and light transmission compared to opaque building materials used in the remaining building enclosure. For at least this reason, fenestration devices and methods can be major contributors to heat loss or heat gain in a construction.

A fenestration device may be configured to reduce construction heat loss or construction heat gain. For example, one or more glazing sheets may include a spectrally selective coating that has low emissivity properties, such that the transmission of infrared radiation through the sheets is decreased. In a double glazing system, the inner sheet can be coated with a spectrally selective coating to reduce energy emission at infrared wavelengths of the inner sheet heated out during cold weather. Low emissivity coatings can also reflect sunlight entering the glaze, thereby reducing the building's solar heat gain during warmer months. However, a glaze with a low emissivity coating may have lower visible light transmission compared to an uncoated glaze.

As another example, filling the space between sheets of a multi-sheet glaze with an inert gas can reduce conduction heat losses because inert gases generally have a lower thermal conductivity than air. This technique can also reduce losses by convection because inert gases are generally heavier than air and can suppress gas movement. However, it may be difficult for a glazing unit to maintain a good seal to prevent leakage of these gases.

As a further example, filling the gap between sheets of a multiple sheet glaze with airgel can reduce heat loss and heat gain. Airgel can reduce conduction and convection losses due to the large number of very small air cavities in it. Air cavities can reduce thermal conductivity because stationary air is a good thermal insulator. Airgel is generally translucent and can reduce visible light transmission through the glaze.

In the embodiment shown in Figure 1, a double glazing fenestration device 100 includes a structure 106 configured to reduce the transfer of thermal energy between two glazed sheets 102, 104. Only a portion of device 100 is shown in Figure 1, such that details can be better displayed. The overall dimensions of device 100 can be selected to partially fill, substantially fill, or completely fill a fenestration. A tessellated structure, such as for example the cubic honeycomb structure 106 shown in Figure 1, may have certain properties that are useful for suppressing thermal radiation and convection when placed between two sheets 102, 104 that are at different temperatures. As used herein, the term tessellated structure is used in its broad and ordinary sense. For example, tessellated structures encompass structures with a mosaic in cross section, structures that are generally cells, structures that resemble a honeycomb, honeycomb structures, 'prismatic honeycomb structures, hexagonal prismatic honeycomb structures, prismatic honeycomb structures cubicles, irregular honeycomb structures, a structure that is at least partially a honeycomb structure, other polygonal structures, a combination of structures, etc.

In some embodiments, the tessellated structure 106 of a glaze 100 includes a plurality of cells 110 defined at least partially by one or more walls

112. The longwave infrared radiation can be emitted from a sheet 104 of a glaze 100 in a hemispherical pattern and can intercept with the walls 112 of the tessellated structure 106 based on the depth h and distance w between the walls 112. If the walls 112 absorb radiation and have a high emissivity, the walls 112 can radiate at least a portion of the radiation energy back to the sheet 104 and to other walls 112 of the tessellated structure 106. Walls 112 can be configured to absorb a substantial amount of radiation at infrared wavelengths, including wavelengths at which thermal energy is commonly transferred at temperatures that occur at the earth's surface. Absorption and re-irradiation of thermal energy by tessellated structure 106 can reduce the amount of radiation that intercepts the other sheet of glaze 102 and radiates out into the atmosphere. In some embodiments, the walls 112 of the tessellated structure 106 include a material system that absorbs a substantial amount of radiation at infrared wavelengths, has high emissivity at infrared wavelengths, and is highly reflective at visible wavelengths of the light.

In certain embodiments, glaze 100 is configured to reduce thermal energy transfer between sheets 102, 104 due to convection. The tessellated structure 106 between the sheets 102 can reduce convection because the distance w between the walls 112 surrounding a cell 110 can be much less than the opening of the fenestration. Heat transfer between sheets 102 by convection can also be influenced by the distance h between the glazed sheets 102, 104. In certain embodiments, an increased distance h between the glazed sheets 10.2, 104 can cause a reduction in heat loss by means of convection. The Raleygh number of the fenestration device 100 can be influenced at least in part by the width w of the cell 110 and the depth h of the cells of the tessellated structure 106. The cell width w and depth h can be selected to reduce , minimizing or substantially eliminating air movement between the bottom glazed sheet 104 and the top glazed sheet 102, as described in further detail herein. When the bottom sheet 104 is hotter than the top sheet 102, reducing air movement from the bottom sheet 104 to the top sheet 102 can reduce heat loss through fenestration.

The tessellated structure 106 of the fenestration device 100 can be constructed of any suitable material system. At least a portion of the material may be substantially transparent in at least the visible range, may be substantially reflective in at least the visible range, or may be partially transparent and partially reflective. The tessellated structure 106 can allow visible light to spread between the glazing sheets 102, 104. The light transfer efficiency between the sheets 102, 104 may depend on the transmission qualities or reflective qualities of the material system, the dimensions and geometry of the tessellated structure 106, and the incident angle of light entering the device 100 relative to the optical elements of the device 100.

In some embodiments, the walls 112 of the tessellated structure 106 are. Substantially vertical and wall pairs 112 within structure 106 can be substantially parallel. Structure 106 can be arranged between two substantially horizontal glazing sheets 102, 104. Walls 112 can be made substantially reflective using any appropriate technique. For example, walls 112 can be constructed of reflective film. The film can form a plurality of honeycomb-like closed cells 110. Many other variations are possible. For example, walls 112 may be covered with a reflective film or coating, or they may be constructed of a rigid material, such as a rigid reflective material. Cells 110 can have any appropriate geometry, including a box, a hexagon, a triangle, a circle, another multi-sided shape, a shape with curved or irregular sides, or a combination of geometries. In some embodiments, the tessellated structure material system 106, cell depth h, cell width w, and cell geometry can be selected to reduce thermal heat transfer between sheets 102, 104.

In certain embodiments, cells 110 of tessellated structure 106 are at least partially constructed from DF2000MA Daylighting film available from the 3M of the Maplewood, Minnesota Company. DF2000MA Daylighting film has greater than 99% visible light wavelength reflectivity and less than 10% long wavelength infrared reflectivity (between 1,000 nm and

3,000 nm). DF2000MA film also has emissivity greater than 0.90, thermal conductivity of approximately 1.5 BTU / hp²- ° F / inch and has a thickness that is less than or equal to 0.0069 cm (0.0027 inches). By way of example, the thickness of a cell wall may be substantially less than the thickness of a glazed layer in the fenestration device and / or substantially less than the cell width.

Cells 110 can be constructed of many other films or materials. In some embodiments, the film or material used to form or cover the walls 112 of cells 110 can be highly reflective. For example, the film may have a light reflectance greater than or equal to about 95, greater than or equal to about 98%, or greater than or equal to about 99%. The film or material can be selected to reduce radiation losses. For example, the film or material may be configured to absorb and emit a substantial portion (or substantially all) of long-wavelength infrared radiation. Cells 110 can be constructed of a coated material, a rigid material, a flexible material, another material, or a combination of materials. Cells 110 can be formed and dimensioned to reduce heat transfer due to convection. The geometry of the cells 110 can have a great influence on the thermally insulating capacities of the fenestration device 100 by reducing, minimizing or substantially eliminating convection.

As an example, a computer model was created to simulate thermal losses due to convection and conduction in a double glazed fenestration device having a honeycomb structure arranged between an upper glazed sheet and a lower glazed sheet. Honeycomb structures with several. Dimensional and geometric configurations were simulated. The model also simulated the thermal losses of the same double glazed fenestration device without the honeycomb structure. Test conditions included applying a temperature difference of 39 ° C (70 ° F) through the device. The bottom sheet was exposed to a stagnant air temperature of 21 ° C (70 ° F) and the top sheet was exposed to -18 ° C (0 ° F) at a speed of 20 km per hour (12.3 mph) across its surface. Timbas leaves were on a horizontal plane (eg parallel to the ground). The simulation results are shown in Table 1.

Table 1

<td>Configuration of honeycomb (HC)</td><td>Separation of glaze (centimeters)</td><td>Dimensions HC Side length / area of . cell (centimeters) (inches / cm2 (inches2))</td><td>U factor (BTU / Hr-Ft²- ° F)</td>

<td>Without HC</td><td> 2.5(1.0)</td><td></td><td> 0.70</td>

<td>Square</td><td> 2.5 (1.0)</td><td> 3.8 (1.5/2.25 (2.25))</td><td> 0.46</td>

<td>Square</td><td> 2.5 (1.0)</td><td> 2.5(1.0/6.45(1,0))</td><td> 0.41</td>

<td>Square</td><td> 2.5 (1.0)</td><td> 1.3 (0.5/1.6(0.25))</td><td> 0.33</td>

<td>Hexagonal</td><td> 2.5(1.0)</td><td> 2.4 (0.93/14.5(2.25))</td><td> 0.46</td>

<td>Triangle</td><td> 2.5(1.0)</td><td> 5.8 (2.28/14.5(2.25))</td><td> 0.52</td>

<td>Without HC</td><td> 3.8(1.5)</td><td></td><td> 0.67</td>

<td>Square</td><td> 3.8(1.5)</td><td> 3.8(1.5/14.5(2.25))</td><td> 0.36</td>

<td>Square</td><td> 3.8 (1.5)</td><td> 1.3 (0.5/1.6(0.25))</td><td> 0.26</td>

The results in Table 1 show that a substantial reduction in the rate of heat transfer due to convection can occur when an appropriate tessellated structure, such as a honeycomb structure, is arranged between the glazed sheets. In some embodiments, the reduction in heat transfer rate may be greater than or equal to about 25%, greater than or equal to about 35%, greater than or equal to about 40%, greater than or equal to about 50% or greater than or equal to about 60%. The simulations evaluated the speed of thermal energy transfer due to conduction and convection; however, the transfer of thermal energy due to radiation may also vary depending on the configuration of a tiled structure between glazed sheets. The simulated honeycomb configuration was constructed from a film having a thickness of 0.025 cm (0.010 inches) and a thermal conductance 7.5 times greater than the air conductance. Therefore, when comparing the thermal loss of the configurations without the honeycomb structure with the configurations with the honeycomb structure, the loss due to conduction was greater in the configurations with the honeycomb. This indicates that significant reductions in heat transfer rate in configurations including a honeycomb structure can result in a large reduction in heat transfer due to convection. The cell dimensions of a tessellated structure can be selected to reduce or minimize the rate of heat transfer through a fenestration device. For example, if the tessellated structure is a honeycomb that has a generally square cell configuration, the results in Table 1 show that convection loss performance can be improved by reducing cell sizes, by increasing cell depth. or by reducing cell sizes and increasing cell depth. Configurations of the fenestration device that have different distances between sheets can however be designed to have similar convection loss performance characteristics when selecting an appropriate cell width. For example, if two double glazed devices have sheet separations

2.5 cm (1 inch) and 3.8 cm (1.5 inches), respectively, and if the minimum U-factor overlay is 0.33, the honeycomb structure could have square cells with a width of 1.3 cm (0.5 inch) for the configuration with 2.5 cm (1 inch) sheet gap. Configuration with

3.8 cm (1.5 inch) sheet gap could have

<td>performance</td><td>of</td><td>lost</td><td>by</td><td>similar convection</td><td>with a</td>

<td>structure</td><td>of</td><td>honeycomb</td><td>has</td><td>square cells with</td><td>a width</td>

<td>2.5 cm</td><td> (1</td><td>inch).</td><td>In</td><td>some modalities,</td><td>multiple</td>

Sheet glazed units having different amounts of sheet spacing can be modified to obtain the same thermal requirements without changing the sheet spacing of any glaze unit.

The geometry or topology of cells in the tessellated structure can be selected to reduce or minimize the rate of heat transfer through a fenestration device. For example, the results in Table 1 show that in some embodiments, changing the cell topology from a square to a hexagon and maintaining the same cell area can result in a negligible change in U-factor performance. Changing the cell topology to a triangle while maintaining the same cell area reduced convection loss performance. The elevation of a tessellated structure having triangular cells may require more wall material per opening area than does a tessellated structure having square or hexagonal cells.

Constructing the cells of the tessellated structure from a material with high visible reflectivity can improve convective loss performance without substantially reducing the transmission of visible light through the tessellated structure. For example, if the cells are made of a film with high visible reflectivity, the cells may be configured to have a high ratio of cell depth to cell area (for example, at least around 2.0 or at least around 2.5 or at least about 7.5, etc.) with negligible light loss over a wide range of incident angles. In the embodiment shown in Figure 2, tessellated structure 106 includes cells 110 with walls 112 constructed of a material with high visible reflectivity. A ray of light A entering device 100 at an angle θ_Α60 ° on top sheet 102 spreads through sheet 102 and reflects off walls 112 of tessellated structure 106 three times before spreading through bottom sheet 104 and to the opposite side of device 100. Lightning of light B entering device 100 with an incident angle Θ_Β 30 ° on top sheet 102 spreads through sheet 102 and reflects off walls 112 of tessellated structure 106 once before spreading through bottom sheet 104 and to the opposite side of device 100. In some In modalities, the fraction of visible light incident on the top sheet 102 leaving the bottom sheet 104 of the device 100 is substantially the same for both light rays A, B when the walls 112 have high reflectivity.

The data shown in Table 2 provides the light transfer efficiency for two fenestration device configurations that have a honeycomb structure with hexagonal cells. Configurations having two different cell depths were simulated using a reflective material with a reflectivity of 99%. In the simulation, the cell width was 1.1 cm (0.42 inches), the cell side length was 0.7 cm (0.28 inches), and the cell area was 1.4 cm² (0.20 square inches).

Table 2

<td>Incident angle (degrees)</td><td>Cell depth of 1.3 cm (0.5 inch) Depth / area of ​​2.5</td><td>Cell depth of 3.8 cm (1.5 inch) Depth / area of ​​7.5</td>

<td> 30</td><td> 99%</td><td> 97%</td>

<td> 45</td><td> 99%</td><td> 96%</td>

<td> 60</td><td> 97% '</td><td> 93%</td>

<td> 75</td><td> 95%</td><td> 85%</td>

In the embodiment illustrated in Figure 3, the fenestration device 200 has a tessellated structure 206 having walls 212 that are partially, substantially, or almost completely transparent or translucent in the visible range. The tessellated structure 206 is arranged between transparent sheets 202, 204. In the illustrated embodiment, the incident light fraction C on the top sheet 202 of the device 200 leaving the bottom sheet 204 can be substantially lower than the light fraction that would come out of the bottom sheet 104 of the device 100 of Figure 2 The difference in the fraction of light leaving the device can be caused by surface reflections, absorption, and scattering that occurs when light C propagates through transparent walls 212. The light losses that occur as light C propagates through many layers of transparent material in tessellated structure 206 can result in reduced or eliminated thermal insulation benefits when compared to a fenestration device 100 having a tessellated structure 106 with highly reflective walls 112.

Translucent or translucent walled tessellated structure configurations 212 can suppress heat loss from glazing or solar collectors by absorbing radiation at infrared wavelengths or by reducing convection. In such configurations, light is transmitted through walls 212 of tessellated structure 206. When light is incident on such a configuration at a high incidence angle, the fraction of visible light exiting tessellated structure 206 can be substantially reduced compared to the fraction of visible light exiting tessellated structure 106 with highly reflective walls

112.

In order to mitigate the loss of visible light in such configurations, some embodiments include transparent side walls 212 that absorb a relatively small fraction of visible light. For example, a highly transmitting side wall 212 may have a light transmittance greater than or equal to about 27%, greater than or equal to about 99%, or almost 100%. In order to obtain high transmittance, at least a portion of the side wall 212 may be very thin (for example, less than or equal to about 3 mm, less than or equal to about 1 mm, less than or equal to about 600 gm or less or equal to around 300 pm), can include at least one high strength material, It can be constructed of highly transparent material (s). It can be manufactured to be free of absorbent materials or impurities or include a combination of elements that improve transmittance. In certain embodiments, the side wall 212 includes an anti-reflective coating, film, or layer configured to substantially reduce or eliminate light reflectance at one or more interfaces between the side wall 212 and the surrounding medium (or media). As used herein, light transmittance and light reflectance can be measured with respect to a standard daylight illuminant, such as the CIE Dg illuminant.₅.

In some embodiments, a fenestration device has a tessellated structure arranged between two separate transparent glazed sheets, where the distance between the glazed sheets is greater than or equal to about 1.3 cm (half an inch). Such a fenestration device can be used in conventional skylights, tubular daylight devices, windows, or any product where high light transmission and low heat loss are desired. The fenestration device can reduce convective losses between a hot side of the product and a colder side of the product. Thus, the device can be beneficial during hot or cold periods of the year.

In some embodiments, a tessellated structure as described herein is incorporated into a flat solar thermal plate and concentrating collectors. The honeycomb can be arranged between a thermal collection plate and an end glaze on the flat plate. The concentrating collector can focus light with a reflective or refractive optical device on a smaller heat collection tube or plate. In some embodiments, the tessellated structure can be placed between the heat collection reflector and a transparent cover. The back side or non-optical portion of this reflector can be coated with opaque insulation material to reduce heat loss.

Certain modalities provide methods of manufacturing a tessellated structure as described herein. In some modalities, the tessellated structure. It is constructed using a thin reflective film. The film can be manufactured as a continuous tape and wound on a core. The fabric can be divided into bands that have a width equal to the depth dimension of the honeycomb. Adhesive material or other bonding material can be coated or applied to one side of the film. The film strips can be cut into segments that have a length greater than or equal to the perimeter of one or more of the cells of the tessellated structure. The lengths of the segments may be somewhat greater than the perimeter of the cells, such that some of the length of the segment can be used to form an overlapping bond.

One end of the band segment can be glued to the opposite end of the band segment to form a film loop 300 with a reflective side 302 facing inward and an adhesive side 304 facing outward, as shown in Figure 4A. An expandable mandrel 310 can be inserted into the film loop 300 and expanded to cause the film loop to conform to a desired cell shape. The expandable mandrel 310 can include two or more paddles that are together when inserted into the loop as shown in Figure 4B. A plurality of expandable mandrels configured to shape film loops to the cell shapes in the tessellated structure can be used. As shown in Figure 4C, a first expandable mandrel 310a can be used to form a film loop 300a, while a second expandable mandrel 310b temporarily remains within a previously formed loop 300b to provide support for adhering the film loop 300a. to the previously formed loop 300b. As shown in Figure 4B, the newly formed loop 300a can be coupled with previously formed loops 300b, 300c by pressing the newly formed loop 300a against the other formed loops 300b, 300c, which are supported by the second mandrel 310b. The adhesive sides 304 of the formed loops are glued together when pressed together. This process can be repeated until the desired tiled structure configuration is obtained.

In the embodiment shown in Figure 5, a tessellated structure is made from rolls of film 400a, 400b without using adhesive. Film strips 402a, 402b can be stretched through a series of compression rollers 404a, 404b configured to undulate or crimp film 402a, 402b in increments equal to the length of the cell sides (hexagon, square, etc.), the corrugated or crimped film 402a, 402b can continue through another set of compression rollers 406a, 406b that are configured for heat welding, Solvent glue or mechanically fasten two strips of film 402a, 402b together at points that are selected to create individual cells having desired shapes. For example, the bonding rollers 406a, 406b may include sharp tips 408a, 408b that are heated to a temperature that causes the film strips 402a, 402b to melt together. The bonding rollers 406a, 406b can emit a group of assembled film cells 410. A plurality of assembled film cell groups 410 can be created by repeating the process until enough cells are created to form the tessellated structure.

In certain embodiments, a tessellated structure formed using the mandrel process shown in Figures 4A4D is stiffer than the tessellated structure formed using the corrugated roll process shown in Figure 5. In some embodiments, the mandrel process uses about 2 Sometimes as much film material to create a tessellated structure as the corrugated roll process would. The Table shown in Figure 6 shows the relationship between the area of ​​film used compared to the area of ​​a glazed opening filled by the tessellated structure. Area ratios are provided for exemplary cell configurations that have cell widths of 1.3 cm (0.5 inch), 2.5 cm (1 inch) and 3.8 cm (1.5 inches), and cell depths of 1.3 cm (0.5 inch), 2.5 cm. (1 inch), 3.8 cm (1.5 inches) or 5 cm (2 inches). The graph shows proportions of film area to aperture area in one example when the mandrel process shown in Figure 4A-4D is used to prepare the assembled cell structure. In some embodiments, the ratio of cell depth to cell width can be at least about 1.0 or greater, such as at least around 1.5 or at least around 2.0. In some embodiments, each of the proportions can be substantially lower, such as when a corrugated roll process as shown in Figure 5 is used, resulting in approximately half ratio intervals as large as those provided above.

In some embodiments, a fenestration device with a tessellated structure is incorporated into a device

<td>light of</td><td>day</td><td>tubular.</td><td>A</td><td>TDD is configured</td><td>for</td>

<td>transport</td><td>the</td><td>light of</td><td>Sun</td><td>from the roof of</td><td>a</td>

<td>building</td><td>to the</td><td>inside</td><td>via</td><td colspan="2">a tube with a surface</td>

reflective on the inside of the tube. A TDD can sometimes also be referred to as a tubular skylight. A TDD installation may include a transparent cover over the roof of a building or other appropriate site. A tube with a reflective surface on the inside of the tube extends between the cover and a diffuser installed at the base of the tube. The transparent cover can

<td>be dome-shaped or can have another</td><td>shape</td><td colspan="2">appropriate and</td>

<td>can be configured to capture the</td><td>light</td><td>of the</td><td>Sun. In</td>

<td>certain modalities, the cover prevents</td><td>than</td><td>the</td><td>humidity</td>

<td>environmental and other materials enter the</td><td>tube.</td><td>The</td><td>diffuser</td>

<td colspan="2">scatters the tube light into the space or area in</td><td>the</td><td>who</td>

<td>diffuser is located. The cover can allow light</td><td colspan="2">Exterior,</td><td>such as</td>

daylight enters the tube. In some embodiments, the cover includes a light collection system configured to improve or increase the daylight entering the tube. In certain embodiments, a TDD includes a light mixing system. For example, the light mixing system can be placed on the tube or integrated with the tube and can be configured to transfer light in the direction of the diffuser. The diffuser can be configured to distribute or configure the light in general of a room or area inside the construction. Various diffuser designs are possible. An auxiliary lighting system can be installed in a TDD to provide tube light to the target area when daylight is not available in sufficient quantity to provide a desired level of interior lighting.

The direction of light reflected through the tube can be affected by various light propagation factors. Light Propagation Refractors include the angle at which light enters the TDD, which can sometimes be called the entry angle. The angle of entry can be affected by, among other things, the solar elevation, the optical elements in the transparent cover, and the angle of the cover with respect to the ground. Other light propagation factors include the slope of one or more portions of the tube side wall and the specularity of the internal reflective surface of the side wall. The large number of possible combinations of light propagation factors in a single day can result in light leaving the TDD at an interval. Wide-angle and continuously variable.

Figure 7 shows a sectional view of an example of a TDD 10 installed in a construction 16 to illuminate, with natural light, an interior room 12 of the construction 16. The TDD 10 includes a transparent cover 20 mounted on the roof 18 of construction 16 allowing natural light to enter tube 24. Cover 20 can be mounted to roof 18 using a rain boot. The boot may include a flange 22a that is attached to the roof 18 and a flange 22b that rises upward from the flange 22a and is angled to where appropriate for the edge of the roof 18 to engage and retain-cover 20 in a generally vertical orientation. Other orientations are also possible.

Tube 24 can be connected to boot 22 and can extend from roof 18 through ceiling 15 of interior room 12. Tube 24 can direct light L_D which enters tube 24 downwards into a light diffuser 26 that scatters light from room 12. The bottom surface 25 of tube 24 may be reflective. In some embodiments, tube 24 has at least one section with substantially parallel side walls (a generally cylindrical surface). As illustrated, tube 24 can include multiple angle sections connected in a way that forms angles between adjacent sections. Many other tube shapes and configurations are possible. Tube 24 can be made of metal, fiber, plastic, a rigid material, an alloy, another appropriate material, or a combination of materials. For example, tube 24 can be constructed of 1150 aluminum alloy. The shape, position, configuration, and materials of tube 24 can be selected to increase or maximize the daylight portion L_D or other types of light entering tube 24 that propagates into the room

12.

Tube 24 may terminate in or be operatively coupled to a light diffuser 26. Light diffuser 26 may include one or more devices that scatter light in an appropriate manner across a larger area than would result without the diffuser 26 or devices therefor. In some embodiments, diffuser 26 allows most or substantially all of the visible light traveling through tube 24 to propagate into room 12. The diffuser may include one or more lenses, ground glass, holographic diffusers, other diffusing materials, or a combination of materials.

Diffuser 26 can be connected to tube 24 using any appropriate connection technique. For example, a tube ring 28 may be surrounding coupled with tube 24 'and connected to light diffuser 26 in order to hold diffuser 26 over the end of tube 24. In some embodiments, diffuser 26 is located in the same general plane as the ceiling 15, generally parallel to the plane of the ceiling or close to the ceiling frame 15.

In certain embodiments, the diameter of diffuser 26 is substantially equal to the diameter of tube 24, slightly larger than the diameter of tube 24, slightly less than the diameter of tube 24, or substantially larger than the diameter of tube 24. Diffuser 26 can distribute incident light on the diffuser to a lower surface (eg, floor 11) below the diffuser and in some room configurations, to an upper surface (eg, at least one wall 13 or ceiling 15 ) of room 12. Diffuser 26 can scatter light such that light from a diffuser area of ​​at least one square foot and / or less than or equal to about 4 square feet can be distributed over a floor area and / or wall of at least about 60 square feet and / or less, or equal to about 200 square feet in a typical room configuration.

In the embodiment shown in Figure 7, TDD 10 includes a fenestration device 30 to reduce the rate of transfer of thermal energy between the interior of TDD 10 and room 12. In the illustrated embodiment, fenestration device 30 is station adjacent to diffuser 26, between diffuser 26 and tube 24. The fenestration device 30 can be placed in any other appropriate position, such as near the top of the tube 24, near the level of the roof 18, near the level of the ceiling 15 or near the level of the dome 20. In some embodiments, the fenestration device 30 can be placed on the same level as an insulating layer found in construction. For example, in a construction with an insulation layer 14 directly above the ceiling 15, the fenestration device 30 can be placed at or near the level of the insulation layer 145 in order to provide a substantially continuous layer of insulation. The TDD 10 may also have fenestration devices arranged in a combination of positions. The position (s) of the fenestration device (s) 30 can be selected to produce any desired thermal energy transfer characteristics.

The fenestration device 30 can have a tessellated structure as shown in Figure 8. The illustrated tessellated structure includes hexagonally shaped cells 32 with reflective walls 34. A ring 36 surrounding the tessellated structure can allow the fenestration device 30 to be secured within tube 24 of a TDD 10, at one end of tube 24, or within another type of fenestration opening. The fenestration device 30 may have an integral glazing sheet 38b arranged on one side of the tessellated structure or glazing sheets 38a, 38b on both sides of the tessellated structure. In certain embodiments, a fenestration device 30 with only one glazing sheet 38b is configured to be installed in an opening such that the leafless side is adjacent to a substantially flat transparent surface, such as a diffuser. In other embodiments, the fenestration device 30 does not have a glazing sheet but is configured to be placed in the inter-blade space of a multi-sheet glazing unit.

In the embodiment illustrated in Figure 9, the fenestration device 30 shown in Figure 8 is installed in a

TDD 10 directly above a diffuser 26. The illustrated diffuser 26 includes a plurality of lens elements that can at least partially affect the appearance of the fenestration device 30 when viewed from an observer's point of view from the room. Diffuser 26 may be configured to refract or reflect light that propagates through the diffuser in a manner that alters or obscures the vision of the fenestration device. This

<td>way the</td><td>diffuser</td><td> 26</td><td>can be</td><td>used to improve</td><td>the</td>

<td>appearance</td><td>esthetic</td><td>of the</td><td>device</td><td>fenestration 30.</td><td>In</td>

<td colspan="2">some modalities,</td><td>the</td><td>device</td><td>fenestration 30</td><td>is</td>

horizontally oriented when installed in an opening of the building enclosure.

Discussion of the various modalities disclosed herein have generally followed the modalities illustrated in the figures. However, it is contemplated that particular elements, structures, or features of any modalities discussed herein may be combined in any appropriate manner into one or more separate modalities not illustrated or expressly described. For example, it will be understood that a fenestration device may not include a glazing sheet, may include a glazing sheet, or more than one glazing sheet. A fenestration device may also include optical elements, reflective surfaces, diffusing surfaces, absorbent surfaces, refractive surfaces, and other elements in addition to the elements disclosed herein. In many cases, structures that are described or illustrated as unitary or contiguous may be separated while still performing the function (s) of the unitary structure (s). In many instances, structures that are described or illustrated as separate can be joined or combined while still performing the function (s) of the separate structures. It will be understood that in addition that the tessellated structures disclosed herein can be used in at least some daylight systems, fenestration devices and / or other lighting facilities in addition to TDD.

It should be appreciated that the above discussion of modalities, various elements are sometimes grouped together into a single modality, figure, or illustration thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various aspects. of the invention. This disclosure method, however, will not be construed to reflect the intention that any claim requires elements that are expressly cited in that claim. Furthermore, any components, elements, or steps illustrated and / or described in a particular embodiment herein, may be applied to or used with any other embodiment (s). Thus, it is intended that the scope of the invention disclosed herein should not be limited by the particular embodiments described above, but should be determined only by a fair reading of the claims that follow.