U.S. patent application number 11/491332 was filed with the patent office on 2006-11-16 for window sash, glazing insert, and method for manufacturing windows therefrom.
This patent application is currently assigned to Sashlite, LLC. Invention is credited to John S. France.
Application Number | 20060254203 11/491332 |
Document ID | / |
Family ID | 27364219 |
Filed Date | 2006-11-16 |
United States Patent
Application |
20060254203 |
Kind Code |
A1 |
France; John S. |
November 16, 2006 |
Window sash, glazing insert, and method for manufacturing windows
therefrom
Abstract
A window sash frame has a glazing insert receiving channel. A
glazing insert provides a spacing structure for at least two
glazing panes. The spacing structure has at least two glazing
surfaces adapted to protrude into a viewing opening of the sash
frame and hold a respective one of the glazing panes. The glazing
insert includes a base for receipt in the receiving channel of the
sash frame. The base extends away from the glazing surfaces such
that the glazing panes will be isolated from the sash frame when
the base is received in the channel and the glazing panes are
mounted on the glazing surfaces.
Inventors: |
France; John S.; (Cuyahoga
Falls, OH) |
Correspondence
Address: |
Lipsitz & McAllister, LLC
755 MAIN STREET
MONROE
CT
06468
US
|
Assignee: |
Sashlite, LLC
Westport
CT
|
Family ID: |
27364219 |
Appl. No.: |
11/491332 |
Filed: |
July 21, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10974230 |
Oct 26, 2004 |
7100343 |
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11491332 |
Jul 21, 2006 |
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10349555 |
Jan 23, 2003 |
6823643 |
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10974230 |
Oct 26, 2004 |
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|
09907528 |
Jul 17, 2001 |
6536182 |
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10349555 |
Jan 23, 2003 |
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09307825 |
May 7, 1999 |
6286288 |
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09907528 |
Jul 17, 2001 |
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08935924 |
Sep 23, 1997 |
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09307825 |
May 7, 1999 |
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60032776 |
Dec 5, 1996 |
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Current U.S.
Class: |
52/786.1 |
Current CPC
Class: |
E06B 3/6675 20130101;
E06B 3/6604 20130101; E06B 3/24 20130101; E06B 3/64 20130101 |
Class at
Publication: |
052/786.1 |
International
Class: |
E04C 2/54 20060101
E04C002/54 |
Claims
1. A method for making windows, comprising: providing a sash frame
having a glazing insert receiving channel; inserting a glazing
insert into said receiving channel, said insert (i) having a base
for receipt in said receiving channel and (ii) providing a spacing
structure for at least two glazing panes, said spacing structure
having at least two glazing surfaces adapted to protrude into a
viewing opening of said sash frame; and mounting said glazing panes
to respective ones of said glazing surfaces; said base extending
away from said glazing surfaces such that said glazing panes will
be isolated from said sash frame when the base is received in said
channel and the glazing panes are mounted on said glazing
surfaces.
2. The method of claim 1, wherein each of said glazing surfaces is
adapted to hold a respective one of said glazing panes entirely
within at least a portion of said viewing opening such that said
glazing panes remain outside of said receiving channel.
3. The method of claim 1, comprising using an adhesive sealant to
mount said glazing panes to said glazing surfaces.
4. The method of claim 1, wherein said glazing insert comprises a
separate leg for each glazing pane.
5. The method of claim 1, comprising providing said base with sides
that slope away from said legs.
Description
[0001] This application is a divisional of co-pending U.S. patent
application Ser. No. 10/974,230 filed on Oct. 26, 2004 which was a
continuation of U.S. patent application Ser. No. 10/349,555 filed
on Jan. 23, 2003, now U.S. Pat. No. 6,823,643; which was a
continuation of U.S. patent application Ser. No. 09/907,528 filed
on Jul. 17, 2001, now U.S. Pat. No. 6,536,182; which was a
continuation of U.S. patent application Ser. No. 09/307,825 filed
on May 7, 1999, now U.S. Pat. No. 6,286,288; which was a
continuation-in-part of U.S. patent application Ser. No. 08/935,924
filed on Sep. 23, 1997, now abandoned; all claiming priority from
U.S. provisional application 60/032,776 filed on Dec. 5, 1996.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to commercial,
residential and architectural windows and, more particularly, to an
integrated multipane window unit and sash assembly and a method for
manufacturing the same.
[0004] 2. Description of the Related Art
[0005] As is currently well-known in the art, insulating glass
units, or IG units, are currently widely used as elements of
windows and doors. Such units are used in windows and doors to
reduce heat loss from building interiors in winter, and reduce heat
gain into air-conditioned buildings in summer. The insulating glass
units are typically formed separate from the sash, and then in a
separate step the insulating glass unit is installed in a sash.
[0006] IG units generally consist of two parallel sheets of glass
which are spaced apart from each other and which have the space
between the panes sealed along the peripheries of the panes to
enclose an air space between them. Spacer bars are placed along the
periphery of the space between the two panes. The spacers are
assembled into generally rectangular-shaped frames either by
bending or by the use of corner keys.
[0007] As has evolved in the present commercially successful
technology, insulating glass units form only the internal
components of a sash element used in a window unit. A sash element
forms the working element of the window, and forms a perimeter
called a sash frame that holds necessary working hardware to allow
the sash element to slide, lock, crank, etc.
[0008] Although many materials of construction are conventionally
utilized for manufacturing sash elements, such as wood and
aluminum, presently available insulating window units that utilize
a sash element formed of extruded polyvinyl chloride polymers are
known to provide superior insulating qualities in conventional
commercial and residential applications.
[0009] In the manufacture of a conventional sash, one starts with
an extrusion called a "profile." These extrusions can be purchased
from an extrusion manufacturer in different styles each having a
certain aesthetic. Extrusions can be made generally available to
the marketplace; however, a general practice that has developed is
to provide a partial exclusivity by region, market, etc. in order
to allow a particular window manufacturer to associate a certain
aesthetic with that manufacturer's product. Therefore, although
many extrusion profiles are of an original design, they are treated
in the marketplace as a quasi-commodity.
[0010] Another aspect of the extrusion profile is that since the
exterior surface must mate with the main frame, the profile is also
functional as well as aesthetic. In order to accomplish this
functionality, changes are made in internal grooves, channels,
etc.
[0011] A further step in the manufacture of a sash is to cut corner
miters in the sash profile elements used to fabricate the sash
frame. These cuts are made in an oversized manner, by 1/4 to 1/8
inch. This additional material is to allow for a process called
vinyl welding, in which both seams are heated to a point wherein
the PVC material softens and the joint is pressed together and
cooled in place to form a cohesive bond. This process forms a
corner joint that is stronger than the original extrusion.
[0012] The manufacture of the sash results, e.g., in a four-sided
sash frame. However, a flash buildup or `swath` is formed by the
vinyl welding process, which must be milled, cut, scraped, or
otherwise removed. This process is called corner cleaning, and is
generally accomplished by a separate piece of manufacturing
equipment called a corner cleaner.
[0013] At this point the sash frame is ready for glazing. Glazing
is typically accomplished by one of two processes. The first
readily used process is when an adhesive strip called a glazing
tape is attached to a structure on the profile called the glazing
leg. Next, an IG unit (comprising a prefabricated assembly having
at least two glazing panes separated by a spacer) is adhered to the
other side of the glazing tape. Glazing stops are then placed over
the IG unit in order to hold the exterior of the IG unit. This
process has advantages, in that the equipment and technology to
accomplish this is skewed toward the glazing strip manufacturer,
and the window manufacturer can form the window with less equipment
and capital outlays. However, the drawbacks to this method lie in
the increased cost of and limited materials that can be formed into
glazing tapes.
[0014] The alternative method of glazing is by a process called
back-bedding sealing. In this method, a sash frame is placed
horizontally on an X-Y back-bedding machine that will lay down a
continuous bead of fluid back bedding sealant along the glazing
leg. The prefabricated IG unit is then adhered to the back bedding,
and glazing stops are attached. In this method, the back bedding
material creates a seal between IG unit and the sash frame.
Although additional equipment is required, this process allows the
use of a variety of materials, including silicone adhesives, that
have advantageous price and/or performance characteristics.
[0015] In all cases, IG units must necessarily be manufactured
separately, and many times are made by a separate company. The
trend is to move this step in-house to control costs, size,
availability, etc. Also, by more directly controlling the IG unit
manufacture, both retrofit (custom) and standard size (new
installation) markets can be addressed.
[0016] The manufacturing of conventional IG units, as utilized in
the manufacture of PVC insulating windows, has been thoroughly
addressed within the art, and is meant to be incorporated herein.
For purposes of identifying structures and for providing a frame of
reference for the present invention, this manufacture shall be
briefly discussed. First, a spacer bar is formed, generally of a
hollow, roll-formed flat metal, into a hollow channel. Generally, a
desiccant material is placed within the hollow channel, and some
provisions are made for the desiccant to come into fluid
communication with or otherwise affect the interior space of the IG
unit. The spacer bar is then notched in order to allow it to be
formed into a rectangular frame. Due to the nature and geometry of
this frame, the IG unit at this point has very little structural
rigidity. At this point a sealant is applied to the outer three
sides of the spacer bar in order to bond a pair of glass panes to
either opposite side of the spacer bar. There are a variety of
sealants well known in the art that can be used for this purpose.
After application of the glass panes and curing of the sealant, the
IG unit finally has structural integrity. The current state of the
art is represented by U.S. Pat. No. 5,313,761, issued in the name
of Leopold, in which hot melt butyl is directly applied to a spacer
element that incorporates a folding corner key. Such a method is
embodied in a very difficult and clumsy manufacturing process that
incorporates a number of inherent manufacturing problems.
[0017] A number of other problems exist with the current state of
the art in IG unit performance. The use of polyurethane or
polysulfide sealants, because of their non-pliable nature when
cured, can cause stress fractures of the glass after periods of
thermal cycling that cause expansion and contraction of the
elements. This leads to fog or moisture intrusion into the interior
air space. The use of polyisobutelene sealants have been attempted
due to their excellent moisture barrier properties. However, poor
structural integrity results. And, although silicone is a strong
sealant material, it is porous to moisture intrusion and cannot be
used by itself, and must be used as part of a double seal unit
(dual seal).
[0018] Other recent issues have arisen that have yet to be
addressed by the art, and can be characterized by a standard called
the "warm edge test." The warm edge test is a thermal conductivity
test that rates the insulating properties the IG unit, and is a
method of quantifying the insulating capacity of an assembled
insulating window, and not just of the component parts. The driving
force for this characterization is governmental regulations that
require structures to have certain outside thermal envelope
characteristics. However, because of the metal spacer necessary and
the inevitable increase in thermal conductance caused by such a
structure, conventional IG units perform poorly in this regard.
This is mainly due to the fact that conventional IG units were
designed to provide insulating properties along the viewable glass
area and not increase insulating properties along the perimeter
sash and frame areas.
[0019] The current state of the art for this technology is also
represented by U.S. Pat. No. 5,313,761, issued in the name of
Leopold, in which "U" shaped spacers without corner keys are used
such that conduits for conductive heat transfer are reduced. The
elimination of corner keys also eliminates a natural leak point in
the system.
[0020] A need has been felt for an improved but less complex
mechanism that provides a thermally sealed and structurally sealed
air pocket bounded on two sides by a glazing pane, for use in
otherwise conventional functioning windows.
SUMMARY OF THE INVENTION
[0021] It has been found that the qualities of well performing
thermal air space allow for glazing materials such as glass or
plastic (e.g., Plexiglas, a thermoplastic polymer of methyl
methacrylate) to expand and contract without stress on the glazing
pane to a point where stress fractures would occur; or, to allow
sealant to deform to a point where it fails to maintain structural
integrity.
[0022] Further, it has been found that stresses between the glazing
pane and sealant will inevitably take place, and therefore the
design of a window sash must allow such stress and movement to
occur in a manner that diminishes the full load of such forces on
the glazing pane and sealant.
[0023] Further, it has been found that the contact of an IG unit
with the sash causes the sash to function as a radiator of heat,
and consequently, a transmitter of vibration and sound.
[0024] Further still, it has been found that the expansion
coefficient of glass is less than that of the sash profile
extrusion; therefore, any assembly should preferably keep any glass
(or other glazing material with a different coefficient of
expansion than the sash profile) from making substantial direct
contact with the extrusion material, e.g., vinyl.
[0025] It would be advantageous to provide methods for fabricating
devices of the type disclosed above, which avoid the disadvantages
inherent in the state of the art.
[0026] It is therefore an object of the invention to provide an
improved integrated multipane window unit and sash assembly.
[0027] It is another object of the invention to provide an improved
method for manufacturing such a multipane window unit.
[0028] It is a feature of the present invention to provide an
integrated multipane window unit and sash assembly that forms both
a thermally sealed and structurally sealed air pocket bounded on
two sides by glazing panes, e.g., of glass or plastic, and around
its periphery by an internal glazing leg.
[0029] It is another feature of the present invention to provide a
method for assembling an integrated multipane window unit and sash
that allows for glass to expand and contract without stresses that
result in failure on either the glass or the sealant.
[0030] It is another feature of the present invention to provide an
integrated multipane window unit and sash assembly that allows the
glazing pane to rest above any extrusion shelf structure, thereby
eliminating any stress against the edge of the glass that could
cause cracking and providing for water drainage away from the
sealant, thereby lessening the opportunity for the sealant to come
into contact with water.
[0031] It is another feature of the present invention to provide an
integrated multipane window unit and sash assembly that includes an
offset section in the sash profile that is downward sloping to
assist in evacuation of moisture.
[0032] It is another feature of the present invention to provide an
integrated multipane window unit and sash assembly that allows for
the use of a glazing bead (sometimes referred to herein as a
glazing clip) in a manner that holds glass in place temporarily
while allowing the sealant to cure during the manufacturing
process.
[0033] It is another feature of the present invention to provide an
integrated multipane window unit and sash assembly that utilizes a
sealant for both adhesive purposes as well as to form a vapor
barrier.
[0034] It is another feature of the present invention to provide an
integrated multipane window unit and sash assembly that allows the
glazing panes to "float" on sealant, thereby preventing direct
contact of glass to the sash profile material.
[0035] It is another feature of the present invention to provide an
integrated multipane window unit and sash assembly that allows
desiccant to be truly isolated from any exterior source, thereby
preventing the loading of the desiccant with moisture.
[0036] It is another feature of the present invention to provide an
integrated multipane window unit and sash assembly that provides
added sound deadening characteristics.
[0037] It is another feature of the present invention to provide an
integrated multipane window unit and sash assembly that allows for
the elimination of separately manufactured and installed
conventional type IG units.
[0038] It is another feature of the present invention to provide a
process for manufacturing such an integrated multipane window unit
and sash assembly.
[0039] Briefly described according to one embodiment of the present
invention, an integrated multipane window unit and sash combination
is disclosed having a sash frame that incorporates an integral
spacing structure formed integrally with the sash frame and
protruding toward the viewing opening. The integral spacing
structure incorporates internal glazing surfaces upon which
adhesive is affixed. In this configuration, the portions of sealant
connecting each pane to the sash element are isolated from each
other, thereby allowing each piece of glass to function
separately.
[0040] An advantage of the present apparatus can be readily seen
from the present disclosure; however, they can be summarized in the
providing of both a superior performing multipane window unit, and
an improved method of manufacturing the same.
[0041] Briefly described according to one method of manufacturing
such an embodiment of the present invention, the use of an
integrated multipane window unit and sash combination having
integral spacing structure formed integrally with the sash frame
and protruding toward the viewing opening allows for an efficient
manufacturing process in which the sash can be formed initially in
an otherwise conventional manner. Subsequent to the initial forming
of a structurally rigid sash member, sealant, either of a
structural type, vapor barrier type, a combined type, or both
types, can be applied directly to the vertical internal glazing
surfaces of the finished sash frame. Next, because the internal
glazing surfaces and spacing structure protrude toward the viewing
opening, the glass panes can then be affixed to the sealant. At
this point, a glazing clip can optionally be affixed in a manner
that holds the glass in place temporarily while allowing the
sealant to cure during the manufacturing process.
[0042] Advantages of the present method can be readily seen from
the present disclosure; however, they can be summarized in the
providing of such a window unit in a manner that is less capital
intensive and requires fewer manufacturing steps, equipment and
personnel than what is required to manufacture windows using
exiting IG units.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] The advantages and features of the present invention will
become better understood with reference to the following more
detailed description and claims taken in conjunction with the
accompanying drawings, in which like elements are identified with
like symbols, and in which:
[0044] FIG. 1 is an exploded perspective view of a window sash
frame according to the prior art;
[0045] FIG. 2 is an exploded perspective view of a window sash
frame according to a first preferred embodiment of an integrated
multipane window unit and sash assembly according to the present
invention;
[0046] FIG. 3a is a partial cross sectional view of a sash frame
element according to a first configuration of the present
invention;
[0047] FIG. 3b a partial cross sectional view of a sash frame
element according to a second configuration of the present
invention;
[0048] FIG. 3c is a partial cross sectional view of a sash frame
element according to a third configuration of the present
invention;
[0049] FIG. 3d is a partial cross sectional view of a sash frame
element according to a fourth configuration of the present
invention;
[0050] FIG. 4a is a partial exploded perspective view of a muntin
assembly connection shown in combination with the present
invention;
[0051] FIG. 4b is a partial exploded perspective view of an
alternate design for a muntin assembly connection shown in
combination with the present invention;
[0052] FIG. 5 is a partial cross sectional view of a sash frame
element incorporating the teachings of the present invention for
use with a wood-frame, aluminum, or other sash material; and
[0053] FIG. 6 is a partial cross sectional view of a sash frame
element similar to that of FIG. 3a, wherein the sealant material
provides vapor barrier characteristics in a configuration that
allows the internal cavity to have contact with the internal
surface of the sealant.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0054] 1. Detailed Description of the Apparatus
[0055] Referring now to FIG. 1, a conventional IG unit 10, as
utilized in the manufacture of PVC insulating windows, is shown. A
spacer bar 11, formed generally of a hollow, roll-formed flat
metal, forms a hollow channel 12. A desiccant material 14 is placed
within the hollow channel 12, and fluid conduits 16 are provided
for the desiccant to come into fluid communication with or
otherwise affect the interior space of the IG unit 10. Sealant 18
is applied to the outer three sides of the spacer bar 11 in order
to bond a pair of glass panes 19 to opposite sides of the spacer
bar 11.
[0056] Referring to FIG. 2, an integrated multipane window unit and
sash combination 20 is disclosed having a sash frame 22 that
incorporates an integral spacing structure 24 formed integrally
with the sash frame and protruding toward the viewing opening
(generally, 25). The integral spacing structure 24 incorporates at
least two vertical internal glazing surfaces 26 upon which
adhesive, or sealant 28 is affixed. Sealant strips or beads 28,
connecting respective glazing panes 30 to the integral spacing
structure 24, are isolated from each other, thereby allowing each
pane 30 to function independently.
[0057] As noted above, a well performing thermal air space will
allow for glazing panes to expand and contract without stress to
point where stress fractures would occur, or where sealant would
deform and fail to maintain structural integrity. Since stresses
between the glazing panes and sealant will inevitably take place,
the present invention allows for the stresses of the pane 30 (which
can be, e.g., glass, plastic or the like) to act directly upon the
sash element via the vertical glazing surface through the sealant,
and not be transferred to the opposing pane, thereby allowing such
stress and movement to occur in a manner that diminishes the full
load of such forces on the glazing panes and sealant. This is done
by providing the integrated spacing structure that allows the
glazing panes to "float" on sealant, thereby substantially
preventing direct contact with the sash profile. The term "float"
as used herein is not intended to preclude occasional or accidental
contact of the glazing panes with the sash profile, but only to
indicate that along the majority of the glazing pane periphery, the
glazing pane contacts the sealant, and not the sash profile.
[0058] Further detail is shown in FIG. 3a. As described, the sash
frame 22 directly incorporates an integral spacing structure 24.
The spacing structure 24 is formed integrally with the sash frame.
The sash frame 22 itself is formed in a rigid, structural manner,
and provides all the necessary or required structural rigidity of
the completed sash frame. Unlike with conventional windows, there
is no rigid IG unit that inevitably must function to provide a
certain amount of structural rigidity to the system. The function
of the integral spacing structure 24 is two-fold: first, to provide
a separation space "D" between glazing panes 30 in order to form an
insulating air space 32; and second, to provide a pair of glazing
surfaces, shown as internal glazing surfaces 26, upon which to
mount each glazing pane 30.
[0059] Each PVC profile that forms a sash frame element 22 also
includes an inner sash frame surface 34. The integral spacing
structure 24 extends inwardly, above the level of the inner sash
frame surface 34, and protrudes into the viewing opening
(generally, 25). The integral spacing structure 24 incorporates at
least two vertical internal glazing surfaces 26 upon which
adhesive, or sealant 28 is affixed. Each strip or bead of sealant
28 connecting the respective glazing panes 30 to the integral
spacing structure 24 is isolated from the other such strip or bead.
The protrusion of the integral spacing structure 24 allows for a
number of manufacturing benefits, which are described below, and
also allows the sash frame 22 itself to be formed and designed to
provide all the necessary structural rigidity that is required by
the completed sash assembly. With the sash frame 24 completed and
having the internal glazing surfaces 26 being accessible above the
inner sash frame surface 34, the glazing panes 30 can be fitted
onto the finished sash frame 24. Otherwise, the sash frame would be
required to be built onto the glazing pane 30, resulting in the
pane 30 being required to provide the structural integrity during
the manufacturing process. Although such an embodiment is
envisioned, and may exhibit some of the benefits anticipated by the
present disclosure, such an embodiment is not considered to
incorporate the best mode of the present invention.
[0060] Finally, a bead of sealant 28 is shown affixed to both the
internal glazing surface 26 as well as the glazing pane 30. Since
the expansion coefficient of the glazing pane is typically less
than that of a PVC extrusion, such a sealant configuration prevents
the glazing pane 30 from making direct contact with the extrusion
vinyl. This structure avoids the disadvantages inherent in the
state of the art, yet forms both a thermally sealed and
structurally sealed space bounded on two sides by a glazing pane
(e.g., a glass or plastic panel), and sealed around its periphery
by an internal glazing structure. Further, it is anticipated that
the dimensions of the glazing pane 30 would be overall less than
that of the inner sash frame surface 34, thereby allowing for the
glass to expand and contract without stresses that result in
failure on either the glass or the sealant. Further still, any
glass (or other glazing pane material) preferably rests above this
extrusion shelf structure, thereby eliminating any stress against
the edge of the glass that could cause cracking, as well as
providing for water drainage away from the sealant, thereby
lessening the opportunity for the sealant to come into contact with
water.
[0061] Also envisioned is the otherwise conventional use of glazing
clips or beads 36, for providing an aesthetic visual barrier to the
glazing elements of the unit. Further, glazing clip 36 can also be
used in a manner such as to hold the glazing 30 in place
temporarily while allowing the sealant 28 to cure during the
manufacturing process.
[0062] FIG. 3b shows a second preferred embodiment of the present
invention utilizing an integral spacing structure 24 that further
provides a separation space "D" between a pair of parallel,
vertically spaced internal glazing legs 35. Each glazing leg 35
provides a glazing surface upon which to mount a corresponding
glazing pane 30. Further, each glazing leg allows for each pane to
expand and contract independently without stresses that result in
failure on either the glass or the sealant, and diminishes the full
load of such forces on glass and sealant. This allows for each
glazing pane to expand and contract independently without stresses
that result in failure of either the glass or the sealant. Also,
such a configuration provides added sound deadening characteristics
in that the minimal possible surface area is shared between glass
and spacer.
[0063] Finally, FIG. 3b shows a configuration wherein multiple
beads of sealant 28 are shown affixed to both the internal glazing
surface 26 as well as the glazing pane 30. Such multiple beads
would allow for the use of separate structural adhesive and vapor
barrier sealants.
[0064] FIG. 3c shows a third embodiment of the present invention,
and depicts an integral spacing structure 24 that further provides
a separation space and a plurality of internal cavities and
external feature surfaces. A pair of parallel, vertically spaced
internal glazing legs 35 further form a desiccant receiving cavity
40. In this manner, desiccant (not shown), as well as desiccant of
an otherwise conventional type can be incorporated into such a
receiving cavity 40 and provided with air conduits 42 which provide
fluid communication between the receiving cavity 42 and the
internal, thermally sealed air space formed between the glazing
panels 30. Each glazing leg 35 provides a glazing surface upon
which to mount each glazing pane 30, as well as provides for
lateral flexibility for receiving stresses communicated by the
glazing panes 30 as they expand and contract.
[0065] Also shown formed within the sash frame profile are a
plurality, in this case two, of internal frame cavities. In
addition to manufacturing convenience, such cavities provide
increased structural rigidity to the assembled sash frame. Further,
it is envisioned that many such cavity designs can be incorporated
to provide for various structural needs, as well as to receive
other materials, such as desiccant, insulative material, or the
like.
[0066] An additional feature disclosed in FIG. 3c is a sealant
receiving recess 46, shown as a trough or notch recess below the
outermost surface of the external glazing surface of each internal
glazing leg. Such a structure allows for increased surface area
contact between the sealant and glazing surface, increased volume
availability for sealant material, as well as easier manufacturing
in the application of sealant to the glazing surface.
[0067] Finally, a number of additional features are disclosed in
the embodiment shown in FIG. 3c. These include: an internal offset
surface 50, for accommodating the thickness of the glazing pane 30;
an internal drainage slope 52 formed as a downwardly sloping
surface along the top of the internal offset surface 50 for aiding
in the drainage of moisture into a moisture collection channel 56;
and, a glazing clip retaining channel 58 that provides for the dual
functionality of retaining a glazing clip by frictional impingement
as well as providing a drainage conduit for accumulated
moisture.
[0068] As shown in FIG. 3d, an alternate embodiment of the present
invention is provided depicting the capability of triple glazing.
Such an embodiment is depicted simply in order to communicate the
essence of the teachings of the present invention. In such an
embodiment, a sash frame is provided having a first internal
glazing leg 60 formed integrally with the sash frame. The sash
frame itself is formed in a rigid, structural manner, and provides
all the necessary or required structural rigidity of the completed
sash frame. A second internal glazing leg 62 is further formed
integrally with the sash frame, and in a similar manner as and
parallel to said first internal glazing leg. Additionally, a third
internal glazing leg 64 is provided, located in the space formed
between the first internal glazing leg and the second internal
glazing leg. In this manner, a first separation space 66, between
the first internal glazing leg and the third internal glazing leg,
and a second separation space 67 between the second internal
glazing leg and the third internal glazing leg, are formed. Each
glazing leg incorporates a glazing surface upon which to mount a
glazing pane 30. Each internal glazing leg extends inwardly, above
the level of the inner sash frame surface 34 and protrudes into the
viewing opening (generally, 25). In keeping with the manufacturing
methods taught hereinbelow wherein the sash frame is fully
assembled prior to glazing, it would be necessary for the third
internal glazing leg to extend inwardly, above the level of one of
the other internal glazing legs, and is shown herein as extending
inwardly above the level of the second internal glazing leg. In
this manner, the triple glazing integral spacing structure allows
for three vertical internal glazing surfaces 26 upon which
adhesive, or sealant 28 can be affixed and can thereby form a
triple pane insulating unit.
[0069] Other adaptations of the present teachings can be
envisioned. For purposes of example, and not by way of limitation,
several variations are described herein:
1. In a two-internal glazing leg configuration, providing one
glazing leg extending upward above the other in a manner that
allows the user to affix glazing panes to both surfaces, thereby
allowing for an alternate triple glazing configuration;
2. Incorporate muntin retaining clips or receiving notches 72
within the sash profile, and more particularly, within the
separation space formed in the integral spacing structure formed of
the vertically spaced internal glazing legs;
[0070] 3. The use of a desiccant sealant material that provides
conventional structural and vapor barrier characteristics along
with desiccant properties, made possible in a configuration that
allows the internal cavity 31 to have contact with the internal
surface 29 of the sealant as shown, e.g., in FIG. 6;
4. The use of traditional IG units in place of single glass glazing
panes, thereby allowing the combined benefits of the two
technologies; and
[0071] 5. Incorporation of tempered, stained, plate, bullet proof,
or other specialty glasses that could not otherwise be subject to
the heat and pressures necessary for curing of traditional IG units
as glazing panes, thereby allowing for the expanded use of
insulating glass windows into a variety of areas where such use is
currently unavailable.
[0072] Additional benefits of the designs generated by the present
invention, in all its variations, embodiments, and improvements,
include the ability to include muntin bars between the sealed
insulating space and affixed directly to the sash frame. As best
shown in FIG. 4a, it is envisioned that a separate muntin retaining
clip 70, having a frame affixment point 71, shown as an otherwise
conventional friction fit, snap lock fastener element that is
received within a clip receiving slot 73 formed by and within the
sash frame member 24. In this configuration, it is envisioned that
a muntin grid comprising hollow type grid members can thereby
receive the opposite end of the clip 70. Use of a plurality of such
clips 70 would result in the muntin assembly being retained within
the insulative space and yet affixed directly to the sash frame. By
way of merely one further example of many possible, and not meant
in limitation, as shown in FIG. 4b, a muntin grid element 75 can
incorporate a sash frame receiving notch 76 directly within the
grid element. Such a configuration can then be received and
retained directly by a clip receiving slot 73 formed by and within
the sash frame member 24. Use of a plurality of such notches and
slots would again result in the muntin assembly being retained
within the insulative space and yet affixed directly to the sash
frame.
[0073] One final example of the utilization of the teachings of the
present disclosure is further shown in FIG. 5, wherein the
technology taught and described is adapted for use in the
manufacture of windows made with wood, aluminum, or other sash
material. Such a configuration is made possible by use of an
internal glazing insert 80, formed in a manner similar to that
anticipated above with respect to the sash frame, except made in a
manner to be incorporated or inserted into a conventional window
(e.g., wood, aluminum, etc.) in a manner that would otherwise be
done with a conventional IG unit.
[0074] As such, an integrated multipane window insert 80 is
disclosed having an insert frame that incorporates an integral
spacing structure 24 formed integrally with the insert frame and
protruding toward the viewing opening. The integral spacing
structure 24 incorporates at least two vertical internal glazing
surfaces 26 upon which adhesive, or sealant 28 is affixed. Sealant
strips or beads 28 connecting each glazing pane 30 to the integral
spacing structure 24 are isolated from each other, thereby allowing
each pane 30 to function independently. In this manner, the
qualities of well performing thermal air space are achieved while
allowing the glass to expand and contract without stress on the
glass to the point where stress fracture would occur. This
structure also prevents the sealant from deforming to a point where
it fails to maintain structural integrity, and can be added to an
otherwise conventional wood or aluminum, etc. sash frame. In this
manner, stresses between the glass and sealant, which will
inevitably take place, will be transferred to the PVC insert,
rather than against the sash frame.
2 Detailed Description of the Method of Producing the Apparatus
[0075] In addition to the functional and performance advantages
resulting from the features of an apparatus configured according to
the present disclosure, numerous improvements to the manufacturing
process can also result. As such, the manufacture of an integrated
multipane window unit and sash combination, having an integral
spacing structure formed integrally with the sash frame and
protruding toward the viewing opening, allows for an efficient
manufacturing process in which the sash can be formed initially in
an otherwise conventional manner. Subsequent to the initial forming
of a structurally rigid sash member, sealant, either of a
structural type, vapor barrier type, a combined type, or both
types, can be applied directly to the vertical internal glazing
surfaces of the finished sash frame. Next, because the internal
glazing surfaces and spacing structure protrude into the viewing
opening, the glazing panes can then be affixed to the sealant. At
this point a glazing clip can be affixed in a manner that holds
glass in place temporarily while allowing the sealant to cure
during the manufacturing process.
[0076] Advantages of the present method can be readily seen from
the present disclosure; however, they can be summarized in the
providing of such a window unit in a manner that is less capital
intensive and requires fewer manufacturing steps, equipment and
personnel than what is required to manufacture windows using
exiting IG units.
[0077] As designed, a device embodying the teachings of the present
invention is easily applied. The foregoing description is included
to illustrate the operation of the preferred embodiment and is not
meant to limit the scope of the invention. As one can envision, an
individual skilled in the relevant art, in conjunction with the
present teachings, would be capable of incorporating many minor
modifications that are anticipated within this disclosure.
Therefore, the scope of the invention is to be broadly limited only
by the following claims.
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