U.S. patent application number 12/270362 was filed with the patent office on 2009-05-14 for sealed unit and spacer with stabilized elongate strip.
This patent application is currently assigned to INFINITE EDGE TECHNOLOGIES, LLC. Invention is credited to Paul Trpkovski.
Application Number | 20090120018 12/270362 |
Document ID | / |
Family ID | 40219375 |
Filed Date | 2009-05-14 |
United States Patent
Application |
20090120018 |
Kind Code |
A1 |
Trpkovski; Paul |
May 14, 2009 |
SEALED UNIT AND SPACER WITH STABILIZED ELONGATE STRIP
Abstract
A sealed unit includes at least two sheets of material separated
by a spacer. In one example, a spacer includes an elongate strip
having a first longitudinal edge and a second longitudinal edge and
defines a plane extending between at least portions of the first
and second longitudinal edges. The spacer also includes at least a
first stabilizer connected to the elongate strip adjacent the first
longitudinal edge. The first stabilizer has a first surface
arranged substantially perpendicular to the plane. The first
surface is adapted to support the elongate strip against a first
sheet of material. Some embodiments include a second stabilizer
adapted to support the elongate strip against the second sheet of
material.
Inventors: |
Trpkovski; Paul; (Buffalo,
WY) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Assignee: |
INFINITE EDGE TECHNOLOGIES,
LLC
Avoca
WI
|
Family ID: |
40219375 |
Appl. No.: |
12/270362 |
Filed: |
November 13, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60987681 |
Nov 13, 2007 |
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61049593 |
May 1, 2008 |
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61049599 |
May 1, 2008 |
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61038803 |
Mar 24, 2008 |
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Current U.S.
Class: |
52/204.593 ;
52/309.1; 52/745.19; 52/786.13 |
Current CPC
Class: |
E06B 3/66323 20130101;
E06B 3/66304 20130101; E06B 3/66314 20130101; E06B 3/66309
20130101; Y10T 156/10 20150115; Y10T 428/24628 20150115; E06B
3/66361 20130101; Y10T 29/49623 20150115; E06B 2003/6639 20130101;
E06B 3/66342 20130101; Y10T 428/24174 20150115; Y10T 428/24331
20150115; E06B 3/6733 20130101; Y10T 428/2848 20150115; Y10T
428/192 20150115 |
Class at
Publication: |
52/204.593 ;
52/745.19; 52/786.13; 52/309.1 |
International
Class: |
E06B 7/23 20060101
E06B007/23 |
Claims
1. A spacer comprising: an elongate strip having a first
longitudinal edge and a second longitudinal edge and defining a
plane extending between at least portions of the first and second
longitudinal edges; and a first stabilizer connected to the
elongate strip adjacent the first longitudinal edge, the first
stabilizer having a first surface arranged substantially
perpendicular to the plane, the first surface adapted to support
the elongate strip against a first sheet of material.
2. The spacer of claim 1, further comprising a second stabilizer
connected to the elongate strip adjacent the second longitudinal
edge, the first stabilizer having a second surface arranged
substantially perpendicular to the plane, the second surface
adapted to support the elongate strip against a second sheet of
material, wherein the spacer is adapted to maintain a space between
the first and second sheets when arranged therebetween.
3. The spacer of claim 2, wherein the elongate strip has an
undulating shape.
4. The spacer of claim 3, wherein the undulating shape is regular
and repeating.
5. The spacer of claim 2, wherein the elongate strip includes an
external surface and an internal surface.
6. The spacer of claim 5, wherein the first stabilizer includes an
external portion connected to the external surface and an internal
portion connected to an internal surface.
7. The spacer of claim 6, wherein the first and second stabilizers
are plastic.
8. The spacer of claim 2, wherein the first and second stabilizers
include a plurality of stabilizers, each stabilizer being separated
from an adjacent stabilizer by a space.
9. The spacer of claim 1, wherein the first surface includes a
trough, the trough arranged and configured to support at least one
bead of sealant thereon.
10. The spacer of claim 1, wherein the spacer further comprises a
desiccant connected to an interior surface of the elongate
strip.
11. A method of making a spacer, the method comprising: forming an
undulating shape in a first elongate strip, the undulating shape
having a regular and repeating pattern, wherein the first elongate
strip has a first longitudinal edge and a second longitudinal edge;
and forming a first stabilizer on the elongate strip adjacent the
first longitudinal edge.
12. The method of claim 11, further comprising forming a second
stabilizer on the elongate strip adjacent the second longitudinal
edge.
13. The method of claim 12, wherein forming further comprises
extruding.
14. The method of claim 13, wherein the first and second
stabilizers are made of plastic.
15. The method of claim 11, wherein forming the first and second
stabilizers further comprises: pre-forming the first and second
stabilizers; and connecting the first and second stabilizers to the
elongate strip after pre-forming.
16. The method of claim 15, wherein connecting comprises adhering
the pre-formed first and second stabilizers using an adhesive.
17. A sealed unit comprising: a first sheet having a first surface;
a second sheet having a second surface; a spacer arranged between
the first and second sheets to maintain a gap between the first and
second sheets, the spacer comprising: an elongate strip having a
first edge and a second edge; a first stabilizer connected to the
elongate strip adjacent the first edge of the elongate strip, the
first stabilizer including a first sealant trough; and a second
stabilizer connected to the elongate strip adjacent the second edge
of the elongate strip, the first stabilizer including a second
sealant trough; a first sealant bead arranged in the first sealant
trough and connecting the spacer to the first sheet; and a second
sealant bead arranged in the second sealant trough and connecting
the spacer to the second sheet.
18. The sealed unit of claim 17, wherein the elongate strip has an
undulating shape.
19. The sealed unit of claim 18, wherein the undulating shape has a
period in a range from about 0.005 inches to about 0.1 inches and
an amplitude from about 0.005 inches to about 0.1 inches.
20. The sealed unit of claim 17, further comprising a desiccant
connected to an interior surface of the elongate strip.
21. The sealed unit of claim 17, further comprising secondary
sealant beads arranged adjacent the first and second sealant
beads.
22. The sealed unit of claim 17, wherein the elongate strip has a
material thickness in a range from about 0.0001 inches to about
0.010 inches.
23. The sealed unit of claim 17, wherein the elongate strip has a
material thickness in a range from about 0.0001 inches to about
0.005 inches.
24. The sealed unit of claim 17, wherein the elongate strip has a
material thickness in a range from about 0.0003 inches to about
0.004 inches.
25. The sealed unit of claim 17, wherein the first and second
stabilizers are plastic.
Description
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 60/987,681, filed on Nov. 13, 2007, titled "WINDOW
ASSEMBLY AND WINDOW SPACER"; and to U.S. Provisional Application
No. 61/049,593, filed on May 1, 2008, titled "WINDOW ASSEMBLY AND
WINDOW SPACER"; and to U.S. Provisional Application No. 61/049,599,
filed on May 1, 2008, titled "MANUFACTURE OF WINDOW ASSEMBLY AND
WINDOW SPACER"; and to U.S. Provisional Application No. 61/038,803,
filed on Mar. 24, 2008, titled "WINDOW ASSEMBLY AND WINDOW SPACER";
the disclosures of which are each hereby incorporated by reference
in their entirety.
BACKGROUND
[0002] Windows often include two facing sheets of glass separated
by an air space. The air space reduces heat transfer through the
window to insulate the interior of a building to which it is
attached from external temperature variations. As a result, the
energy efficiency of the building is improved, and a more even
temperature distribution is achieved within the building. A rigid
pre-formed spacer is typically used to maintain the space between
the two facing sheets of glass.
SUMMARY
[0003] In general terms, this disclosure is directed to a sealed
unit and a spacer. In one possible configuration and by
non-limiting example, a sealed unit includes a first sheet, a
second sheet, and a spacer arranged between the first sheet and the
second sheet. The spacer includes an elongate strip and two sets of
stabilizers. The first set of stabilizers is arranged along a first
edge of the elongate strip and the second set of stabilizers is
arranged along a second edge of the elongate strip.
[0004] One aspect is a spacer comprising: an elongate strip having
a first longitudinal edge and a second longitudinal edge and
defining a plane extending between at least portions of the first
and second longitudinal edges; and a first stabilizer connected to
the elongate strip adjacent the first longitudinal edge, the first
stabilizer having a first surface arranged substantially
perpendicular to the plane, the first surface adapted to support
the elongate strip against a first sheet of material.
[0005] Another aspect is a method of making a spacer, the method
comprising: forming an undulating shape in a first elongate strip,
the undulating shape having a regular and repeating pattern,
wherein the first elongate strip has a first longitudinal edge and
a second longitudinal edge; and forming a first stabilizer on the
elongate strip adjacent the first longitudinal edge.
[0006] Yet another aspect is a sealed unit comprising: a first
sheet having a first surface; a second sheet having a second
surface; a spacer arranged between the first and second sheets to
maintain a gap between the first and second sheets, the spacer
comprising: an elongate strip having a first edge and a second
edge; a first stabilizer connected to the elongate strip adjacent
the first edge of the elongate strip, the first stabilizer
including a first sealant trough; and a second stabilizer connected
to the elongate strip adjacent the second edge of the elongate
strip, the first stabilizer including a second sealant trough; a
first sealant bead arranged in the first sealant trough and
connecting the spacer to the first sheet; and a second sealant bead
arranged in the second sealant trough and connecting the spacer to
the second sheet.
[0007] There is no requirement that an arrangement include all of
the features characterized herein to obtain some advantage
according to the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a schematic front view of an example window
assembly including a windows spacer according to the present
disclosure.
[0009] FIG. 2 is a perspective view of a portion of the window
assembly shown in FIG.
[0010] FIG. 3 is a top view of a portion of the window assembly
shown in FIG. 1.
[0011] FIG. 4 is a cross-sectional view of a portion of the window
assembly shown in FIGS. 1-3.
[0012] FIG. 5 is a schematic front view of an example embodiment of
an elongate strip according to the present disclosure.
[0013] FIG. 6 is a perspective view of a portion of the spacer
shown in FIG. 1.
[0014] FIG. 7 is a top view of the portion of the spacer shown in
FIG. 6.
[0015] FIG. 8 is a front view of the portion of the spacer shown in
FIG. 6.
[0016] FIG. 9 is a cross-sectional view of the portion of the
spacer shown in FIG. 6.
[0017] FIG. 10 is a cross-sectional view of another embodiment of a
window spacer according to the present disclosure including sealant
and desiccant.
[0018] FIG. 11 is a perspective view of a portion of the spacer
shown in FIG. 10.
[0019] FIG. 12 is a front view of another example embodiment of a
spacer according to the present disclosure arranged in a corner
configuration and including a standard stabilizer
configuration.
[0020] FIG. 13 is perspective view of the portion of the spacer
shown in FIG. 12 including a modified stabilizer configuration.
[0021] FIG. 14 is a front view of the portion of the spacer shown
in FIG. 13.
[0022] FIG. 15 is a perspective view of a portion of another
example embodiment of a spacer according to the present
disclosure.
[0023] FIG. 16 is a top view of the portion of the spacer shown in
FIG. 15.
[0024] FIG. 17 is a cross-sectional view of the spacer shown in
FIG. 15.
[0025] FIG. 18 is a perspective view of a portion of another
example embodiment of a spacer according to the present disclosure
in an unbent configuration and including notches.
[0026] FIG. 19 is a bottom view of the portion of the spacer shown
in FIG. 18.
[0027] FIG. 20 is a top view of the portion of the spacer shown in
FIG. 18.
[0028] FIG. 21 is a front view of the portion of the spacer shown
in FIG. 18.
[0029] FIG. 22 is a front perspective view of the portion of the
spacer shown in FIG. 18 and arranged in a corner configuration.
[0030] FIG. 23 is a front view of the portion the spacer shown in
FIG. 22.
[0031] FIG. 24 is a cross-sectional view of another example
embodiment of a window assembly according to the present
disclosure.
[0032] FIG. 25 is a perspective view of a portion of another
example spacer according to the present disclosure and further
including an example muntin bar.
DETAILED DESCRIPTION
[0033] Various embodiments will be described in detail with
reference to the drawings, wherein like reference numerals
represent like parts and assemblies throughout the several views.
Reference to various embodiments does not limit the scope of the
claims attached hereto. Additionally, any examples set forth in
this specification are not intended to be limiting and merely set
forth some of the many possible embodiments for the appended
claims.
[0034] Although some of the examples discussed herein are directed
to a window assembly and a window spacer, such embodiments can
alternatively be used in any of various types of sealed units to
form yet other embodiments according to the present disclosure. A
sealed unit typically includes at least two sheets of material
separated by a spacer, where the spacer provides a gap between the
two sheets of material.
[0035] FIG. 1 is a schematic front view of example window assembly
100 according to the present disclosure. In some embodiments,
window assembly 100 includes sheet 102, sheet 104, and spacer 106.
Sheets 102 and 104 are made of a material that allows at least some
light to pass through. Typically, sheets 102 and 104 are made of a
transparent material, such as glass, plastic, or other suitable
materials. Alternatively, a translucent or semi-transparent
material is used, such as etched, stained, or tinted glass or
plastic.
[0036] Ends of spacer 106 can be connected together with one or
more fasteners to form a closed loop in some embodiments. Spacer
106 and sheets 102 and 104 together define an interior space 120 of
window assembly 100. Interior space 120 reduces heat transfer
through window assembly 100.
[0037] A gas is typically sealed within interior space 120. In some
embodiments, the gas is air. Other embodiments include oxygen,
carbon dioxide, nitrogen, or other gases. Yet other embodiments
include an inert gas, such as helium, neon or a noble gas such as
krypton, argon, and the like. Combinations of these or other gases
are used in other embodiments.
[0038] In some embodiments, spacer 106 is flexible and can be bent
to form corner configurations such as described herein. An example
embodiment of a corner is corner 122. Example embodiments of corner
122 will be discussed in further detail below in FIGS. 12-14 and
22-23. In other embodiments, spacer 106 is not flexible and another
fastener, such as a corner key, is used with rigid spacers to form
corner 122.
[0039] FIGS. 2-4 illustrate a portion of another example window
assembly 100. FIG. 2 is a perspective view. FIG. 3 is a top view.
FIG. 4 is a cross-sectional view. In this example, spacer 106
includes elongate strip 210 and a plurality of stabilizers 212.
Spacer 106 is disposed between sheets 102 and 104 to keep sheets
102 and 104 spaced from each other. Typically, spacer 106 is
arranged to form a closed loop near to the perimeter of sheets 102
and 104. Spacer 106 is able to withstand compressive forces applied
to sheets 102 and/or 104 to maintain a desired space between sheets
102 and 104. An interior space 120 is defined within window
assembly 100 by spacer 106 and sheets 102 and 104.
[0040] Elongate strip 210 is typically a long and thin strip of a
solid material, such as metal or plastic. An example of a suitable
metal is stainless steel. An example of a suitable plastic is a
thermoplastic polymer, such as polyethylene terephthalate. A
material with low or no permeability is preferred in some
embodiments. Other embodiments include a material having a low
thermal conductivity.
[0041] Elongate strip 210 is typically flexible, including both
bending and torsional flexibility. Bending flexibility allows
spacer 106 to be bent to form corners. Bending and torsional
flexibility also allow for ease of manufacturing. Such flexibility
includes either elastic or plastic deformation such that elongate
strip 210 does not fracture during installation into window
assembly 100.
[0042] A benefit of some embodiments having a single elongate strip
210 is increased flexibility of spacer 106. Another benefit of some
embodiments having a single elongate strip 210 is reduced thickness
of spacer 106. In some embodiments, spacer 106 has more than one
elongate strip 210 (e.g. two, three, four, or more).
[0043] Another benefit of some embodiments having a single elongate
strip 210 is reduced thermal transfer through spacer 106. In
another example embodiment, the thermal properties of spacer 106
are further enhanced by dividing elongate strip 210 into two strips
that are separated by thermal break. The separation of elongate
strip 210 by thermal breaks further reduces heat transfer through
elongate strip 210 to improve the insulating properties of spacer
106. For example, if sheet 102 is adjacent a relatively cold space
and sheet 104 is adjacent a relatively warm space, less heat
transfer will occur through elongate strip 210 due to the presence
of the thermal break.
[0044] The thermal break is preferably made of a material with low
thermal conductivity. In one embodiment, thermal break is a fibrous
material, such as paper or fabric. In other embodiments, thermal
break is an adhesive, sealant, paint, or other coating. In yet
other embodiments, the thermal break is a polymer, such as plastic.
Further embodiments include other materials, such as metal, vinyl,
or any other suitable material. In some embodiments, the thermal
break is made of multiple materials, such as paper coated with an
adhesive or sealant material on both sides to adhere the paper to
elongate strip 210. Another alternative embodiment divides elongate
strip 210 into at least three strips, and includes more than one
thermal break.
[0045] Plurality of stabilizers 212 help stabilize elongate strip
210 between sheet 102 and sheet 104. Due to the flexibility of
elongate strip 210, the added support of stabilizers 212 aids in
the installation and improves the stability of spacer 106. The
plurality of stabilizers 212, reduce the change that the thin
elongate strip 210 will bend, buckle, or displace such a
compressive force is applied to one or both of sheets 102 and 104.
Plurality of stabilizers 212 help keep elongate strip 210 in a
generally perpendicular orientation to sheets 102 and 104,
promoting strength and stability of elongate strip 210. Plurality
of stabilizers 212 further allow spacer 106 to maintain appropriate
spacing between sheets 102 and 104 and help reduce the change of
buckling, bending, or breaking of elongate strip 210. An advantage
of some embodiments using plurality of stabilizers 212 is that the
material thickness (e.g., T1 shown in FIG. 4) of elongate strip 210
can be reduced. In doing so, material costs are reduced.
Furthermore, thermal transfer through elongate strip 210 is also
reduced.
[0046] FIG. 4 is a cross sectional view of a portion of window
assembly 100. In this embodiment, window assembly 100 includes
sheet 102, sheet 104, and spacer 106.
[0047] Sheet 102 includes outer surface 410, inner surface 412, and
perimeter 414. Sheet 104 includes outer surface 420, inner surface
422, and perimeter 424. In one example, WI is the thickness of
sheets 102 and 104. WI is typically in a range from about 0.05
inches (about 0.15 centimeter) to about 1 inch (about 2.5
centimeters), and preferably from about 0.1 inches (about 0.25
centimeter) to about 0.5 inches (about 1.5 centimeters). Other
embodiments include other dimensions. In some embodiments, the
thickness of sheet 102 is the same as the thickness of sheet 104.
In other embodiments, the thickness of sheet 102 is different from
the thickness of sheet 104. Sheets 102 and 104 are not required in
all embodiments.
[0048] In some embodiments, spacer 106 is arranged between inner
surface 412 and inner surface 422. Spacer 106 is typically arranged
near perimeters 414 and 424. In one example, D1 is the distance
between and connected to perimeters 414 and 424 and elongate strip
210 of spacer 106. D1 is typically in a range from about 0 inches
(about 0 centimeter) to about 2 inches (about 5 centimeters), and
preferably from about 0.1 inches (about 0.25 centimeter) to about
0.5 inches (about 1.5 centimeters). However, in other embodiments
spacer 106 is arranged in other locations between sheets 102 and
104.
[0049] Spacer 106 maintains a space between sheets 102 and 104. In
one example, W3 is the overall width of spacer 106 and the distance
between sheets 102 and 104. W3 is typically in a range from about
0.1 inches (about 0.25 centimeter) to about 2 inches (about 5
centimeters) and preferably from about 0.3 inches (about 0.75
centimeter) to about 1 inch (about 2.5 centimeters). Other
embodiments include other spaces.
[0050] Spacer 106 is connected to sheets 102 and 104. In some
embodiments, stabilizers 212 connect spacer 106 to sheets 102 and
104. In other embodiments, stabilizers 212 are connected to sheets
102 and 104 by any suitable fastener. An example of a fastener is a
sealant or adhesive, as described in more detail below. In yet
other embodiments, a frame, sash, or the like is constructed around
window assembly 100 to support spacer 106 between sheets 102 and
104. In some embodiments, spacer 106 is connected to the frame or
sash by a fastener, such as adhesive. In example embodiments,
spacer 106 is fastened to the frame or sash prior to installation
of sheets 102 and 104.
[0051] FIG. 5 is a schematic front view of an example embodiment of
elongate strip 210 according to the present disclosure. In this
embodiment, elongate strip 210 has an undulating shape. In some
embodiments, elongate strip 210 is formed of a metal ribbon, such
as stainless steel, which is then bent into the undulating shape.
Some possible embodiments of the undulating shape include
sinusoidal, arcuate, square, rectangular, triangular, and other
desired shapes.
[0052] One benefit of stainless steel is that it is resistant to
ultraviolet radiation. Other metals are used in other embodiments,
such as titanium. Titanium has a lower thermal conductivity, a
lower density, and better corrosion resistance than stainless
steel. Other embodiments include other materials, such as aluminum.
Some embodiments are formed by other processes, such as
molding.
[0053] In some embodiments, elongate strip 210 has bending
flexibility and torsional flexibility. Bending flexibility allows
spacer 106 to be formed around a corner of a window, for example.
In addition, bending flexibility allows elongate strip 210 to be
made from rolled stock. Rolled stock saves space during
transportation and is therefore easier and less expensive to
transport. Portions of elongate strip 210 are then unrolled during
assembly. In some embodiments a tool is used to guide elongate
strip 210 into the desired arrangement and to attach plurality of
stabilizers 212 to form spacer 106. In other embodiments, a machine
or robot is used to automatically manufacture spacer 106 and window
assembly 100.
[0054] One of the benefits of the undulating shape is that the
flexibility of elongate strip 210 is increased, including bending
and torsional flexibility. The undulating shape resists permanent
deformation, such as kinks and fractures. This allows elongate
strip 210 to be more easily handled during manufacturing without
damaging elongate strip 210. The undulating shape also increases
the structural stability of elongate strip 210 to improve the
ability of spacer 106 to withstand compressive and torsional loads.
Some embodiments of elongate strip 210 are also able to extend and
contract, which is beneficial, for example, when spacer 106 is
formed around a corner. In some embodiments, the undulating shape
reduces the need for notching or other stress relief.
[0055] In one example, elongate strip 210 has material thicknesses
T1. T1 is typically in a range from about 0.0001 inches (about
0.00025 centimeter) to about 0.010 inches (about 0.025 centimeter),
and preferably from about 0.0003 inches (about 0.00075 centimeter)
to about 0.004 inches (about 0.01 centimeter). Such thin material
thickness reduces material costs and reduces thermal conductivity
through elongate strip 210. The undulating shape of elongate strip
210 defines a waveform having a peak-to-peak amplitude and a
peak-to-peak period. The peak-to-peak amplitude is also the overall
thickness T3 of elongate strip 210. T3 is typically in a range from
about 0.005 inches (about 0.015 centimeter) to about 0.1 inches
(about 0.25 centimeter), and preferably from about 0.02 inches
(about 0.05 centimeter) to about 0.04 inches (about 0.1
centimeter). P1 is the peak-to-peak period of undulating elongate
strip 210. P1 is typically in a range from about 0.005 inches
(about 0.015 centimeter) to about 0.1 inches (about 0.25
centimeter), and preferably from about 0.02 inches (about 0.05
centimeter) to about 0.04 inches (about 0.1 centimeter).
[0056] Other embodiments include other dimensions. For example,
some embodiments have an elongate strip 210 with a larger waveform.
Elongate strips with larger waveforms have increased stability
because the overall thickness is increased. This thickness resists
torsional forces and in some embodiments provides increased
resistance to compressive loads. Elongate strip 210 can be expanded
and compressed, such as to form a corner. In one embodiment, an
elongate strip 210 with a larger waveform is expandable between a
first length (having the large undulating shape) and a second
length (in which elongate strip 210 is substantially straight and
substantially lacking an undulating shape) or any length there
between. In some embodiments, the second length is in a range from
25 percent to about 60 percent greater than the first length, and
preferably from about 30 percent to about 50 percent greater.
[0057] When elongate strip 210 has a larger waveform it also
includes greater surface area. The greater surface area provides a
stronger bond with a sealant or adhesive and one or more sheets.
The greater surface area also provides increased strength and
stability. In other embodiments, elongate strip 210 is generally
flat and smooth (e.g. having an amplitude of about 0 inches (about
0 centimeter) and a period of about 0 inches (about 0 centimeter))
without an undulating shape.
[0058] FIGS. 6-9 illustrate another example spacer 106 according to
the present disclosure. FIG. 6 is a perspective view of a portion
of spacer 106. FIG. 7 is a top view of the portion of spacer 106.
FIG. 8 is a front view of the portion of spacer 106. FIG. 9 is a
cross-sectional view of spacer 106.
[0059] Spacer 106 includes elongate strip 210. Elongate strip 210
includes edge 632 and an edge 634. When installed in example window
assembly 100, edge 632 of spacer 106 typically contacts and extends
generally perpendicular to a surface of sheet 102. When installed
in example window assembly 100, edge 634 typically contacts and
extends generally perpendicular to a surface of sheet 104. Elongate
strip 210 also includes an external surface 636 and an internal
surface 638. Internal surface 638 is adjacent to interior space 120
when assembled into a window assembly. In some embodiments internal
surface 638 of elongate strip 210 is visible by a person when
looking through window assembly 100. Internal surface 638 of
elongate strip 210 provides a clean and finished appearance to
spacer 106.
[0060] In example embodiments, stabilizers 212 include a first set
of stabilizers 642 and a second set of stabilizers 644. First set
of stabilizers 642 is attached to elongate strip 210 near edge 632.
When installed in example window assembly 100, first set of
stabilizers 642 is adjacent to sheet 102. First set of stabilizers
642 is attached to the external surface 636 and internal surface
638 near edge 632 of elongate strip 210. Second set of stabilizers
644 is attached to elongate strip 210 near edge 604. When installed
in example window assembly 100, second set of stabilizers 642 is
adjacent to sheet 104. Second set of stabilizers 644 is attached to
the external surface 636 and internal surface 638 near edge 634 of
elongate strip 210.
[0061] First set of stabilizers 642 and second set of stabilizers
644 are typically made of a strong, rigid material such as metal or
plastic. In example embodiments, plastic stabilizers are preferable
to metal because they are cheaper to manufacture and easier to
install, while still providing the necessary strength to stabilize
the elongate strip 210.
[0062] FIGS. 7-8 illustrate dimensions for one example of spacer
106. In this example, each of stabilizers 212 of example spacer 106
has a length L1. L1 is typically in a range from about 0.01 inches
(about 0.025 centimeter) to about 1 inch (about 2.5 centimeters),
and preferably from about 0.05 inches (about 0.15 centimeter) to
about 0.5 inches (about 1.5 centimeters). Additionally, each of
stabilizers 212 of example spacer 106 is separated from its closest
adjacent stabilizer by a length L3. L3 is typically in a range from
about 0.01 inches (about 0.025 centimeter) to about 1 inch (about
2.5 centimeters), and preferably from about 0.05 inches (about 0.15
centimeter) to about 0.5 inches (about 1.5 centimeters). Other
embodiments include other dimensions.
[0063] Looking to FIG. 9, spacer 106 is shown in further detail in
a cross-sectional view. Spacer 106 includes elongate strip 210,
stabilizer 920 (of first set of stabilizers 642), and stabilizer
940 (of second set of stabilizers 644).
[0064] In some embodiments, stabilizer 920 includes an external
stabilizer portion 922 and an internal stabilizer portion 924.
External stabilizer portion 922 is attached to external surface 636
near edge 632 of elongate strip 210. Internal stabilizer portion
924 is attached to internal surface 638 near edge 632 of elongate
strip 210. External stabilizer portion 922 and internal stabilizer
portion 924 are shaped so that when both are connected to elongate
strip 210, external stabilizer portion 922 and internal stabilizer
portion 924 create a trough 926. In specific embodiments, trough
926 has an arcuate shape with a radius RI. In this embodiment, RI
is the distance between edge 632 and the surface of stabilizer 920
that forms trough 926. In example embodiments, trough 926 is
divided into two areas by edge 632 of elongate strip 210. The area
of trough 926 created between external surface 636 and external
stabilizer portion 922 is external trough area 928. The area of
trough 926 created between internal surface 638 and internal
stabilizer portion 924 is internal trough area 930. External trough
area 928 and internal trough area 930 are cavities into which
material, such as sealants and desiccants, can be placed during
installation of spacer 106, as discussed in more detail below.
[0065] As with stabilizer 920, stabilizer 940 includes an external
stabilizer portion 942 and an internal stabilizer portion 944.
External stabilizer portion 942 is attached to external surface 636
near edge 634 of elongate strip 210. Internal stabilizer portion
944 is attached to internal surface 638 near edge 634 of elongate
strip 210. External stabilizer portion 942 and internal stabilizer
portion 944 are shaped so that when both are connected to elongate
strip 210, external stabilizer portion 942 and internal stabilizer
portion 944 create a trough 946. In specific embodiments, trough
946 has an arcuate shape with a radius RI. In this embodiment, RI
is the distance between edge 634 and the surface of stabilizer 940
that forms trough 946. In example embodiments, trough 946 is
divided into two areas by edge 634 of elongate strip 210. The area
created between external surface 636 and external stabilizer
portion 942 is external trough area 948. The area created between
internal surface 638 and internal stabilizer portion 944 is
internal trough area 950. External trough area 948 and internal
trough area 950 are cavities into which material, such as sealant,
can be placed during installation of spacer 106, as discussed in
more detail below.
[0066] In some embodiments, each of external stabilizer portion
922, internal stabilizer portion 924, external stabilizer portion
942, and internal stabilizer portion 944 have a width w5. Looking
to external stabilizer portion 922 as an example, W5 is the width
of external stabilizer portion 922 from a surface 932 nearer edge
632 of elongate strip 210 to a surface 934 at an opposite side of
stabilizer portion 922. W5 is typically in a range from about 0.01
inches (about 0.025 centimeter) to about 1 inch (about 2.5
centimeters), and preferably from about 0.05 inches (about 0.15
centimeter) to about 0.5 inches (about 1.5 centimeters). Internal
stabilizer portion 924, external stabilizer portion 942, and
internal stabilizer portion 944 have W5 values equal to or similar
to external stabilizer portion 922 in some embodiments. In example
embodiments, W5 values are approximately the same for each
individual stabilizer of plurality of stabilizers 212. In other
embodiments, W5 varies.
[0067] In some embodiments, each of external stabilizer portion
922, internal stabilizer portion 924, external stabilizer portion
942, and internal stabilizer portion 944 have a height H1. Looking
again to external stabilizer portion 922 as an example, H1 is the
height of external stabilizer portion 922 from a surface 936 of
external stabilizer portion 922, where external stabilizer portion
922 is attached to external surface 636 of elongate strip 210, to a
distal surface 938 of external stabilizer portion 922, farthest
from surface 636 of elongate strip 210. H1 is typically in a range
from about 0.01 inches (about 0.025 centimeter) to about 1 inch
(about 2.5 centimeters), and preferably from about 0.05 inches
(about 0.15 centimeter) to about 0.5 inches (about 1.5
centimeters). Internal stabilizer portion 924, external stabilizer
portion 942, and internal stabilizer portion 944 have H1 values
equal to or similar to external stabilizer portion 922 in some
embodiments. In example embodiments, H1 values are approximately
the same for each individual stabilizer of plurality of stabilizers
212. In other embodiments, H1 varies.
[0068] First set of stabilizers 642, including external stabilizer
portion 922 and internal stabilizer portion 924, and second set of
stabilizers 644, including external stabilizer portion 942 and
internal stabilizer portion 944, are attached to elongate strip
210. In one example, first set of stabilizers 642 and second set of
stabilizers 644 are made of plastic and extruded directly onto
elongate strip 210. As the plastic contacts elongate strip 210 and
cools, the plastic bonds to elongate strip 210. In other
embodiments, first set of stabilizers 642 and second set of
stabilizers 644 are preformed and subsequently attached to elongate
strip 210 with an adhesive.
[0069] In other embodiments, external stabilizer portion 922 of
first set of stabilizers 642 and internal stabilizer portion 924 of
first set of stabilizers 642 are attached together with a fastener,
thus sandwiching elongate strip 210 in between. Specifically, a
metal fastener such as a screw, nail, or pin can connect external
stabilizer portion 922 to internal stabilizer portion 924 by
puncturing through elongate strip 210. This same method is used to
connect external stabilizer portion 942 of second set of
stabilizers 644 and internal stabilizer portion 944 of second set
of stabilizers 644 to each other and to elongate strip 210 in some
embodiments.
[0070] FIGS. 10-11 illustrate another example spacer 106 further
including sealant and desiccant. FIG. 10 is a cross-sectional view
of spacer 106 including sealant and desiccant. FIG. 11 is a
perspective view of spacer 106 including sealant and desiccant.
[0071] In example embodiments, sealants 1002 and 1004 are used to
connect spacer 106 to sheets 102 and 104 of window assembly 100.
Examples of sealants 1002 and 1004 include polyisobutylene (PIB),
butyl, curable PIB, reactive hot melt beutal (such as D-2000
manufactured by Delchem, Inc. located in Wilmington, Del.),
curative hot melt (such as HL-5153 manufactured by H.B. Fuller
Company), hot melt silicon, copolymers of silicon and
polyisobutylene, acrylic adhesive, acrylic sealant, and other Dual
Seal Equivalent (DSE) type materials.
[0072] In one embodiment, sealant 1002 is filled into external
trough area 928 and internal trough area 930 of trough 926 until it
covers edge 632 of elongate strip 210. The sealant covered edge 632
and sealant filed trough 926 are then pressed against inner surface
412 of sheet 102. Sealant 1004 is also filled into external trough
area 948 and internal trough area 950 of trough 946 until it covers
edge 634 of elongate strip 210. The sealant covered edge 634 and
sealant filed trough 926 are then pressed against inner surface 422
of sheet 104. In other embodiments, beads of sealant 1002 and 1004
are applied to sheets 102 and 104, and spacer 106 is then pressed
into the beads. Edges 632 and 634 are covered with sealants 1002
and 1004 and troughs 926 and 946 are filled with sealants 1002 and
1004.
[0073] In some embodiments, once spacer 106 is installed into a
window assembly (e.g. 100 shown in FIG. 1), first set of
stabilizers 642, edge 632 of elongate strip 210, and sealant 1002
sit flush against sheet 102 and second set of stabilizers 644, edge
634 of elongate strip 210, and sealant 1004 sit flush against sheet
104.
[0074] In some embodiments, sealants 1002 and 1004 are a material
having adhesive properties, such that sealants 1002 and 1004 act to
fasten spacer 106 to sheets 102 and 104. Typically, sealant 1002
and 1004 is arranged to support spacer 106 is an orientation
generally normal to inner surfaces 412 and 422 of sheets 102 and
104. Sealants 1002 and 1004 also act to seal the joint formed
between spacer 106 and sheets 102 and 104 to inhibit gas or liquid
intrusion into interior space 120.
[0075] In some embodiments, a desiccant 1006 is applied to internal
surface 638 of elongate strip 210. Desiccant 1006 acts to remove
moisture from interior space 120. Desiccants include molecular
sieve and silica gel type desiccants. One example of a desiccant is
a beaded desiccant, such as PHONOSORB.RTM. molecular sieve beads
manufactured by W. R. Grace & Co. of Columbia, Md. If desired,
an adhesive is used to attach beaded desiccant to internal surface
638 of elongate strip 210. A matrix desiccant is used in some
embodiments, such as those manufactured by W.R. Grace & Co. and
H.B. Fuller Corporation. In some embodiments, desiccant 1006 also
provides thermal insulation. Thermal insulation reduces heat
transfer through spacer 106 both between sheets 102 and 104, and
between the interior space 120 and an exterior side of spacer
106.
[0076] FIG. 12 is a front view of a portion of an example spacer
106 arranged in a corner configuration with a standard stabilizer
configuration. In some embodiments, the spacer shown in FIG. 12 is
the same as the spacer shown in FIG. 6 after a bending operation.
Spacer 106 includes elongate strip 210 and plurality of stabilizers
212. In this embodiment, elongate strip 210 has an undulating
shape. The portion of spacer 106 is shown arranged as a corner,
such that a first region 1202 of the spacer 106 is oriented at
approximately a 90 degree angle from a second region 1204 of spacer
106. Some embodiments of spacer 106 are able to be arranged to form
a corner without kinking or breaking.
[0077] Elongate strip 210 includes an undulating shape. As a
result, elongate strip 210 is arranged to expand and compress as
necessary. The undulating shape is able to expand by stretching. In
some embodiments, the undulating shape of elongate strip 210 is
expandable from a first length (having an undulating shape) to a
second length (at which point the elongate strip is substantially
flat and without an undulating shape). The second length is
typically in a range from about 5 percent to about 25 percent
longer than the first length, and is preferably from about 10
percent to about 20 percent longer than the first length. In some
embodiments, the undulating shape of elongate strip 210 is also
compressible. The illustrated embodiment shows elongate strip 210
slightly compressed. In some embodiments, however, elongate strip
210 bends without significant compression or expansion of the
undulating shape.
[0078] Spacer 106 has bending flexibility. For example, a radius of
curvature (as measured from a centerline of spacer 106, is
typically in a range from about 0.05 inches (about 0.15 centimeter)
to about 0.5 inches (about 1.5 centimeters), and preferably from
about 0.05 inches (about 0.15 centimeter) to about 0.25 inches
(about 0.65 centimeter) without undesired kinking, fracture, or
damage to spacer 106.
[0079] In the example embodiment illustrated in FIG. 12, all of
plurality of stabilizers 212 have approximately the same size and
shape. Thus, the corner configuration of FIG. 12 has a standard
stabilizer configuration. Lengths L1 and L3 are such that spacer
106 can be arranged in corner configuration without any of the
plurality of stabilizers 212 prohibiting the bending of spacer 106,
even in the standard configuration. Because the stabilizer
configuration has not been modified, the L3 value between the
stabilizers in the corner is changed from the standard L3 value
found between the others of the plurality of stabilizers 212. In
other embodiments, such as the embodiment illustrated in FIGS.
13-14, the stabilizer configuration can be modified.
[0080] FIGS. 13-14 illustrate an example spacer 106 arranged in a
corner configuration with a modified stabilizer configuration. FIG.
13 is perspective view of a portion of spacer 106 arranged in a
corner configuration with a modified stabilizer configuration. FIG.
14 is a front view of a portion of spacer 106 arranged in a corner
configuration with a modified stabilizer configuration.
[0081] In the example embodiment illustrated by FIGS. 13-14, spacer
106 includes elongate strip 210 and plurality of stabilizers 212.
Elongate strip 210 has an undulating shape. The portion of spacer
106 is shown arranged as a corner, such that a first region 1202 of
the spacer 106 is oriented at approximately a 90 degree angle from
a second region 1204 of the spacer 106. Spacer 106 is able to be
arranged to form a corner without kinking or breaking.
[0082] As described above, the undulating shape of elongate strip
210 allows elongate strip 210 to expand and compress as necessary
to form a corner 122. The example embodiment of spacer 106
illustrated in FIGS. 13-14 differs from that illustrated in FIG. 12
in its stabilizer shape and size. In this embodiment, the
stabilizer configuration of spacer 106 has been modified. Modified
corner stabilizers 1310 have been modified from the standard
stabilizer size and shape to better suit usage in corner 122.
[0083] Looking to FIG. 14, modified corner stabilizers 1310 include
internal stabilizer portions 1402 on the inside of the window
assembly 100 in the interior space 120 and external stabilizer
portion 1404 on the exterior of window assembly 100. Internal
stabilizer portions 1402 of modified corner stabilizers 1310 have
been reduced slightly in size, while external stabilizer portions
1404 of modified corner stabilizers 1310 have been enlarged
slightly in size. In specific embodiments, the modified corner
stabilizers 1310 taper from being slightly smaller than the others
of plurality of stabilizers 212 at internal stabilizer portions
1402 to being slightly larger than the others of plurality of
stabilizers 212 at the external stabilizer portions 1404. In
example embodiments, the distance between each individual
stabilizer and the next individual stabilizer is kept constant by
the modifications to the size of internal stabilizer portions 1402
and external stabilizer portions 1404 on modified corner
stabilizers 1310.
[0084] Although FIGS. 12-14 illustrate bending in only one
direction, spacer 106 is capable of bending in multiple directions
at once. Furthermore, spacer 106 is also capable of stretching and
twisting without causing permanent damage to spacer 106, such as
buckling, cracking, or breaking.
[0085] FIGS. 15-17 illustrate another example spacer 1502 according
to the present disclosure. FIG. 15 is a perspective view of spacer
1502. FIG. 16 is a top view of spacer 1502. FIG. 17 is a
cross-sectional view of spacer 1502.
[0086] Example spacer 1502 can be designed to further enhance the
aesthetics of window assembly 100 compared to other spacers. Spacer
1502 includes elongate strip 210 and a plurality of stabilizers
1504.
[0087] Elongate strip 210 includes edge 632 and an edge 634. When
installed in example window assembly 100, edge 632 of spacer 1502
is adjacent and perpendicular to sheet 102. When installed in
example window assembly 100, edge 634 is adjacent and perpendicular
to sheet 104. Elongate strip 210 also includes an external surface
636 and an internal surface 638. Internal surface 638 is adjacent
to interior space 120. In some embodiments internal surface 638 of
elongate strip 210 is visible by a person when looking through
window assembly 100. Internal surface 638 of elongate strip 210
provides a clean and finished appearance to spacer 1502.
[0088] Plurality of stabilizers 1504 includes a first stabilizer
1510 and a second stabilizer 1520. First stabilizer 1510 is a
single piece of material attached to elongate strip 210 near edge
632. First stabilizer 1510 is approximately the same length as
elongate strip 210. When installed in example window assembly 100,
first stabilizer 1510 is adjacent to sheet 102. First stabilizer
1510 is attached to the external surface 636 and internal surface
638 near edge 632 of elongate strip 210. Second stabilizer 1520 is
a single piece of material attached to elongate strip 210 near edge
604. Second stabilizer 1520 is approximately the same length as
elongate strip 210. When installed in example window assembly 100,
second stabilizer 1520 is adjacent to sheet 104. Second stabilizer
1520 is attached to the external surface 636 and internal surface
638 near edge 634 of elongate strip 210.
[0089] In example embodiments, first stabilizer 1510 and second
stabilizer 1520 are arcuate in shape, each forming a semicircle.
First stabilizer 1510 and second stabilizer 1520 are made of a
strong, rigid material such as metal or plastic. In example
embodiments, plastic is preferable to metal because it is cheaper
to manufacture and easier to install, while still providing the
necessary strength to stabilize the elongate strip 210.
[0090] In example embodiments, stabilizer 1510 includes a plurality
of apertures 1512 and stabilizer 1520 includes a plurality of
apertures 1522. Apertures 1512 and 1522 will be detailed further
below.
[0091] Looking to the cross-sectional view of spacer 1502 in FIG.
17, stabilizer 1510 has two parts, an external stabilizer portion
1702 and an internal stabilizer portion 1704. External stabilizer
portion 1702 is attached to external surface 636 near edge 632 of
elongate strip 210. Internal stabilizer portion 1704 is attached to
internal surface 638 near edge 632 of elongate strip 210. External
stabilizer portion 1702 and internal stabilizer portion 1704 are
shaped so that when both are connected to elongate strip 210,
external stabilizer portion 1702 and internal stabilizer portion
1704 create a trough 1706. In specific embodiments, trough 1706 has
an arcuate shape with a radius R3. In this embodiment, R3 is the
distance between edge 632 and the surface of stabilizer 1510 that
forms trough 1706. In example embodiments, trough 1706 is divided
into two areas by edge 632 of elongate strip 210. The area of
trough 1706 created between external surface 636 and external
stabilizer portion 1702 is external trough area 1708. The area of
trough 1706 created between internal surface 638 and internal
stabilizer portion 1704 is internal trough area 1710. External
trough area 1708 and internal trough area 1710 are cavities into
which material, such as sealants and desiccants, can be placed
during installation of spacer 106. Sealants and desiccants can be
applied to spacer 1502 in a manner similar to that shown in FIGS.
10-11 and described above.
[0092] In example embodiments, plurality of apertures 1512 are
included in internal stabilizer portion 1704 of stabilizer 1510.
Apertures 1512 allow gas and moisture to pass through internal
stabilizer portion 1704 of stabilizer 1510. As a result, moisture
located within interior space 120 is allowed to pass through
internal stabilizer portion 1704 of stabilizer 1510 and into
internal trough area 1710, where it is removed by a desiccant
placed within inner trough area 1710. In another embodiment,
apertures 1512 are used for registration. In yet another
embodiment, apertures provide reduced thermal transfer. In one
example, apertures 1512 have a diameter in a range from about 0.002
inches (about 0.005 centimeter) to about 0.050 inches (about 0.15
centimeter). Apertures 1512 are made by any suitable method, such
as cutting, punching, drilling, laser forming, or the like.
[0093] As with stabilizer 1510, stabilizer 1520 has two parts, an
external stabilizer portion 1722 and an internal stabilizer portion
1724. External stabilizer portion 1722 is attached to external
surface 636 near edge 634 of elongate strip 210. Internal
stabilizer portion 1724 is attached to internal surface 638 near
edge 634 of elongate strip 210. External stabilizer portion 1722
and internal stabilizer portion 1724 are shaped so that when both
are connected to elongate strip 210, external stabilizer portion
1722 and internal stabilizer portion 1724 create a trough 1726. In
specific embodiments, trough 1726 has an arcuate shape with a
radius R3. In this embodiment, R3 is the distance between edge 634
and the surface of stabilizer 1520 that forms trough 1726. In
example embodiments, trough 1726 is divided into two areas by edge
634 of elongate strip 210. The area of trough 1726 created between
external surface 636 and external stabilizer portion 1722 is
external trough area 1728. The area of trough 1726 created between
internal surface 638 and internal stabilizer portion 1724 is
internal trough area 1730. External trough area 1728 and internal
trough area 1730 are cavities into which material, such as sealants
and desiccants, can be placed during installation of spacer 106.
Sealants and desiccants can be applied to spacer 1502 in a manner
similar to that shown in FIGS. 10-11 and described above.
[0094] In example embodiments, plurality of apertures 1522 are
included in internal stabilizer portion 1724 of stabilizer 1520.
Apertures 1522 allow gas and moisture to pass through internal
stabilizer portion 1724 of stabilizer 1520. As a result, moisture
located within interior space 120 is allowed to pass through
internal stabilizer portion 1724 of stabilizer 1520 and into
internal trough area 1730, where it is removed by a desiccant
placed within inner trough area 1730. In another embodiment,
apertures 1522 are used for registration. In yet another
embodiment, apertures provide reduced thermal transfer. In one
example, apertures 1522 have a diameter in a range from about 0.002
inches (about 0.005 centimeter) to about 0.050 inches (about 0.15
centimeter). Apertures 1522 are made by any suitable method, such
as cutting, punching, drilling, laser forming, or the like.
[0095] First stabilizer 1510, including external stabilizer portion
1702 and internal stabilizer portion 1704, and second stabilizer
1520, including external stabilizer portion 1722 and internal
stabilizer portion 1724, can be attached to elongate strip 210 by
various means and methods. In example embodiments, first stabilizer
1510 and second stabilizer 1520 are made of plastic extruded
directly onto elongate strip 210. In other embodiments, first
stabilizer 1510 and second stabilizer 1520 are attached to elongate
strip 210 with an adhesive.
[0096] As with the example embodiment previously described,
external stabilizer portion 1702 of first stabilizer 1510 and
internal stabilizer portion 1704 of first stabilizer 1510 may also
be attached together with a fastener, thus sandwiching elongate
strip 210 in between. Specifically, a metal fastener such as a
screw or nail can connect external stabilizer portion 1702 to
internal stabilizer portion 1704 by puncturing through elongate
strip 210. This same method can be used to connect external
stabilizer portion 1722 of second stabilizer 1520 and internal
stabilizer portion 1724 of second stabilizer 1520 to each other and
to elongate strip 210.
[0097] In some embodiments, each of external stabilizer portion
1702, internal stabilizer portion 1704, external stabilizer portion
1722, and internal stabilizer portion 1724 have a width W7. Looking
to internal stabilizer portion 1704 as an example, W7 is the width
of internal stabilizer portion 1704 from a surface 1712 nearer edge
632 of elongate strip 210 to an outer edge 1714 farther from edge
632 of elongate strip 210. W7 is typically in a range from about
0.01 inches (about 0.025 centimeter) to about 1 inch (about 2.5
centimeters), and preferably from about 0.05 inches (about 0.15
centimeter) to about 0.5 inches (about 1.5 centimeters). External
stabilizer portion 1702, external stabilizer portion 1722, and
internal stabilizer portion 1724 have W7 values equal to or similar
to external stabilizer portion 1702 in some embodiments. In example
embodiments, W7 values are approximately the same for both first
stabilizer 1510 and second stabilizer 1520. In other embodiments,
W7 varies.
[0098] In some embodiments, each of external stabilizer portion
1702, internal stabilizer portion 1704, external stabilizer portion
1722, and internal stabilizer portion 1724 also have a height H3.
Looking again to internal stabilizer portion 1704 as an example, H3
is the height of internal stabilizer portion 1704 from a surface
1716 of internal stabilizer portion 1704, where internal stabilizer
portion 1704 is attached to internal surface 638 of elongate strip
210, to a surface 1718 of internal stabilizer portion 1704,
farthest from surface 638 of elongate strip 210. H3 is typically in
a range from about 0.01 inches (about 0.025 centimeter) to about 1
inch (about 2.5 centimeters), and preferably from about 0.05 inches
(about 0.15 centimeter) to about 0.5 inches (about 1.5
centimeters). External stabilizer portion 1702, external stabilizer
portion 1722, and internal stabilizer portion 1724 have H3 values
equal to or similar to internal stabilizer portion 1704. In example
embodiments, H3 values are approximately the same for each
individual stabilizer of plurality of stabilizers 212. In other
embodiments, H3 varies.
[0099] FIGS. 18-21 illustrate another example spacer 1802 according
to the present disclosure. FIG. 18 is a perspective view of spacer
1802. FIG. 19 is a bottom view of spacer 1802. FIG. 20 is a top
view of spacer 1802. FIG. 21 is a front view of spacer 1802. Spacer
1802 includes elongate strip 210 and a plurality of stabilizers
1504.
[0100] Unlike spacer 106, spacer 1502 of FIGS. 15-17 cannot be
easily bent into corner 122 because first stabilizer 1510 and
second stabilizer 1520 are rigid and span the entire length of
elongate strip 210. Example spacer 1802 solves this problem by
including several notches in first stabilizer 1510 and second
stabilizer 1520. Notch 1810 is included in external stabilizer
portion 1702 of first stabilizer 1510 and notch 1812 is included in
internal stabilizer portion 1704 of first stabilizer 1510. Notch
1814 (not visible in FIG. 18) is included in external stabilizer
portion 1722 of second stabilizer 1520 and notch 1816 is included
in internal stabilizer portion 1724 of second stabilizer 1520.
[0101] Notches 1810, 1812, 1814, and 1816 allow spacer 1802 to be
bent to form the 90 degree angles necessary for corner 122. Notches
1810, 1812, 1814, and 1816 can be created in a number of ways. In
example embodiments, notches 1810, 1812, 1814, and 1816 are cut out
of first stabilizer 1510 and second stabilizer 1520.
[0102] Looking to the bottom view of spacer 1802 in FIG. 19, notch
1810 is cut out of external stabilizer portion 1702 creating two
surfaces 1910 and 1912. Surfaces 1910 and 1912 converge at a point
1914 on elongate strip 210 and extend in opposite directions to
points 1916 and 1918 on the edge of external stabilizer portion
1702. Notch 1814 is cut out of external stabilizer portion 1722
creating two surfaces 1920 and 1922. Surfaces 1920 and 1922
converge at a point 1924 on elongate strip 210 and extend in
opposite directions to points 1926 and 1928 on the edge of external
stabilizer portion 1722.
[0103] Looking to the top view of spacer 1802 in FIG. 20, notch
1812 is cut out of internal stabilizer portion 1704 creating two
surfaces 2010 and 2012. Surfaces 2010 and 2012 converge at a point
2014 on elongate strip 210 and extend in opposite directions to
points 2016 and 2018 on the edge of internal stabilizer portion
1704. Notch 1816 is cut out of internal stabilizer portion 1724
creating two surfaces 2020 and 2022. Surfaces 2020 and 2022
converge at a point 2024 on elongate strip 210 and extend in
opposite directions to points 2026 and 2028 on the edge of internal
stabilizer portion 1724.
[0104] With notches 1810, 1812, 1814, and 1816 created, spacer 1802
can now be bent along the line between points 1914 and 1924 and
2014 and 2024. In example embodiments, spacer 1802 can be bent
approximately 90 degrees so that surfaces 2010 and 2012 come into
contact with one another and so that surface 2020 and 2022 come
into contact with one another. This corner configuration of spacer
1802 is shown in further detail in FIG. 21-22.
[0105] FIG. 22-23 illustrate example spacer 1802 in corner
configuration. FIG. 22 is a perspective view of spacer 1802 in
corner configuration. FIG. 23 is a front view of spacer 1802 in a
corner configuration. As noted above, example spacer 1802 includes
elongate strip 210 and a plurality of stabilizers 1504.
[0106] With notches 1810, 1812, 1814, and 1816 created as described
above, spacer 1802 is now bent along the line between points 1914
and 1924 and 2014 and 2024. Spacer 1802 is bent approximately 90
degrees so that surface 2010 comes into contact with surface 2012
and so that surface 2020 comes into contact with surface 2022. When
spacer 1802 is installed in window assembly 100, surface 2010 is
flush against surface 2012 and surface 2020 is flush against
surface 2022. Thus, the aesthetics of installed spacer 1802 and
window assembly 100 as a whole are enhanced due to the clean
finished look of stabilizers 1510 and 1520 in combination with
elongate strip 210.
[0107] Apertures 1512 of stabilizers 1510 and apertures 1522 of
stabilizer 1520 allow desiccant to be hidden in internal trough
area 1710 and internal trough area 1730 behind the clean finished
look of stabilizers 1510 and 1520. The sealant is also hidden in
trough 1706 of first stabilizer 1510 and trough 1726 of second
stabilizer 1520 so that installed spacer 1802 in window assembly
100 is aesthetically appealing while maintaining the functional
benefits of the stabilizers and hidden desiccant.
[0108] FIG. 24 is a cross-sectional view of another embodiment of
window assembly 100 according to the present disclosure. Window
assembly 100 includes sheet 102, sheet 104, and spacer 106. Spacer
106 is similar to the spacer shown in FIG. 6-9 in that it includes
elongate strip 210 and plurality of stabilizers 212. In this
embodiment, spacer further includes sheet attachment means 2402 for
attachment of a sheet 2404. This third sheet of window material
forms a triple paned window. In example embodiments, sheet
attachment means 2402 is a continuation of interior stabilizer
portion 944. Interior stabilizer portion 944 extends in front of
elongate strip 210 on interior surface 638. This embodiment is
advantageous, because it allows for an additional sheet 2404 to be
attached in between sheets 102 and 104. The addition of sheet 2404
potentially increases the insulating properties of window assembly
100. The inclusion of sheet attachment means 2402 is advantageous
because elongate strip 210 by itself might not be rigid enough to
support sheet 2404.
[0109] In certain embodiments, sheet 2404 is a film or plate. For
example, sheet 2404 is a film or plate of material that absorbs or
reflects ultraviolet radiation, thereby warming interior space 120.
In some embodiments, sheet 2404 divides interior space 120 into two
or more regions. Sheet 2404 can incorporate a Mylar film in some
embodiments. A benefit of some embodiments is that the addition of
sheet 2404 does not require additional spacers or sealants.
[0110] FIG. 25 is a perspective view of another example spacer 1502
according to the present disclosure. Example spacer 1502 is similar
to that shown in FIGS. 15-17 in that it includes elongate strip 210
and plurality of stabilizers 1504. In this embodiment, spacer 1502
includes a plurality of muntin bar clips 2502 and a plurality of
muntin bars 2504 (only one is visible in FIG. 25). Plurality of
muntin bar clips 2502 are connected to spacer 1502 by a series of
muntin bar connector supports 2506. In example embodiments, muntin
bar connector supports 2506 are permanently attached to muntin bar
clips 2502. Next, muntin bar connector supports 2506 are connected
to spacer 1502 through apertures 1512 and apertures 1522. In
specific embodiments, muntin bar connector supports can be added
and removed from spacer 106 after plurality of stabilizers 1504 are
attached to elongate strip 210. In other embodiments, muntin bar
connector supports 2506 must be added before spacer 106 is
assembled. Plurality of muntin bars 2504 are connected to plurality
of muntin bar clips 2502 as shown in FIG. 24. The use of muntin
bars 2504 in addition to the clean look of plurality of stabilizers
1504 in spacer 1502 make spacer 1502 of FIG. 25 particularly
advantageous for use in applications where aesthetics are
paramount.
[0111] The various embodiments described above are provided by way
of illustration only and should not be construed to limit the
claims attached hereto. Those skilled in the art will readily
recognize various modifications and changes that may be made
without following the example embodiments and applications
illustrated and described herein, and without departing from the
intended scope of the following claims.
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