Method of manufacturing an impact resistant and insulated glass unit composite with solar control and low-E coatings

1. A method of forming an insulated impact-resistant composite, the steps comprising;

coating an inside surface of a first glass pane with a solar control coating;

laminating a first safety film over the coating, the first safety film extending to all edges of the first glass pane;

coating an outside surface of a second glass pane with a low-E coating;

laminating a second safety film on an inside surface of the second glass pane;

facing the first and second safety films of the first and second glass panes towards each other while inserting a spacer between the first glass pane and the second glass pane; and

backfilling a structural adhesive from an outboard edge of the spacer to the safety film side of the first and second glass panes to form a two glass pane composite while filling with an inert gas.

2. The method according to claim 1 , wherein the solar control coating applied to the first glass pane is applied by a sputtering process or a chemical vapor deposition process.

3. The method according to claim 1 , wherein the low-E coating on the second glass pane is applied by a chemical vapor deposition process, the emissivity reading being between 0.03-0.30.

4. The method according to claim 3 , wherein the process provides a visible light transmission of the low-E coated glass between 35-91%.

5. The method according to claim 1 , wherein the laminated first and second safety films are provided as polyethylene terphthalate films.

6. The method according to claim 5 , wherein the polyethylene terephthalate films are provided in multi-layers, the safety film having a thickness from 0.004 to 0.025 inches.

7. The method according to claim 6 , wherein an acrylic based pressure sensitive adhesive is applied between the film layers.

8. The method according to claim 6 , wherein the safety film is provided at a thickness of 0.008 to 0.018 inches.

9. The method according to claim 8 , wherein the safety film is provided at a thickness of about 0.015 inches.

10. A method of forming an insulated impact-resistant composite for use in a window frame, the steps comprising:

coating an inside surface of a first window pane with a predetermined thickness of a solar control coating;

laminating a first safety film over the coating, the first safety film extending to all edges of the first window pane;

coating an outside surface of a second window pane with a predetermined thickness of low-E coating;

laminating a second safety film on a reverse surface of the second window pane;

facing the safety film of the first and second window panes towards each other while inserting a spacer between the first and second window panes; and

backfilling a structural adhesive from an outboard edge of the spacer to the safety film side of the first and second window panes to form a two window pane composite while filling with an inert gas.

11. The method according to claim 10 , wherein the safety films are applied with an acrylic based pressure sensitive adhesive.

12. The method according to claim 10 , wherein the low-E coating on the second window pane is applied by a vapor deposition process.

13. The method according to claim 10 , wherein the solar control coating applied on the first window pane is applied by a sputtering process or chemical vapor deposition process.

14. The method according to claim 10 , wherein the two window pane composite is mounted in a window frame.

15. The method according to claim 10 , wherein the laminated first and second safety films are provided as polyethylene terephthalate films.

16. The method according to claim 15 , wherein the polyethylene terephthalate films are provided in multi-layers having a thickness from 0.004 to 0.025 inches.