U.S. patent application number 17/150576 was filed with the patent office on 2021-05-13 for thermally efficient window frame.
The applicant listed for this patent is GED INTEGRATED SOLUTIONS, INC.. Invention is credited to William A. Briese, Timothy B. McGlinchy.
Application Number | 20210140228 17/150576 |
Document ID | / |
Family ID | 1000005348557 |
Filed Date | 2021-05-13 |
United States Patent
Application |
20210140228 |
Kind Code |
A1 |
McGlinchy; Timothy B. ; et
al. |
May 13, 2021 |
THERMALLY EFFICIENT WINDOW FRAME
Abstract
A spacer frame for use in fabricating a window and a method of
fabrication thereof is disclosed. The spacer frame for separating
first and second glass lites from each other in window. The spacer
frame includes a frame forming a multi-sided form comprising a
first outwardly facing surface for supporting a first glass lite
that is contiguous with a first intermediate wall portion and a
second outwardly facing surface for supporting a second glass lite
that is contiguous with a second intermediate wall portion. The
first and second intermediate wall portions comprise a first
material and are linked to each other and spaced from each other by
a thermal interruption strip. The first and second intermediate
wall portions and the thermal interruption strip comprise an
intermediate wall that bridges the first and second outwardly
facing surfaces. The spacer frame further includes a film
overlaying the intermediate wall portion.
Inventors: |
McGlinchy; Timothy B.;
(Twinsburg, OH) ; Briese; William A.; (Hinckley,
OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GED INTEGRATED SOLUTIONS, INC. |
Glenwillow |
OH |
US |
|
|
Family ID: |
1000005348557 |
Appl. No.: |
17/150576 |
Filed: |
January 15, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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15881114 |
Jan 26, 2018 |
10920480 |
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17150576 |
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62554201 |
Sep 5, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29L 2031/7782 20130101;
E06B 2003/66395 20130101; B29C 48/12 20190201; B29C 48/155
20190201; B29C 48/0021 20190201; E06B 3/66323 20130101; E06B
2003/66385 20130101; E06B 3/67313 20130101 |
International
Class: |
E06B 3/663 20060101
E06B003/663; E06B 3/673 20060101 E06B003/673; B29C 48/12 20060101
B29C048/12 |
Claims
1. A spacer frame for separating first and second glass lites from
each other in an insulating glass unit (IGU) for use in fabricating
a window, the spacer frame comprising: an elongated frame forming a
multi-sided form comprising a first outwardly facing surface and a
second outwardly facing surface, the first outwardly facing surface
for supporting the first glass lite, the first outwardly facing
surface is contiguous with a first intermediate wall portion, and
the second outwardly facing surface for supporting the second glass
lite, the second outwardly facing surface is contiguous with a
second intermediate wall portion, wherein the first and second
intermediate wall portions comprise a first material and are linked
to each other and spaced from each other by a thermal interruption
strip, the first and second intermediate wall portions and the
thermal interruption strip comprise an intermediate wall that
bridges the first and second outwardly facing surfaces; and a film
for preventing fluid leakage, overlaying the intermediate wall
portion.
2. The spacer frame of claim 1 wherein the film is applied over the
intermediate wall portion on at least one side of the spacer
frame.
3. The spacer frame of claim 1 wherein: the first material
comprises a first thermal conductivity; the thermal interruption
strip comprises a second thermal conductivity, wherein said second
thermal conductivity is less than the first thermal
conductivity.
4. The spacer frame of claim 1 wherein the thermal interruption
strip comprises a material that is flexible enough to be wound on a
roll.
5. The spacer frame of claim 1 wherein the first and second
intermediate wall portions comprise complementary intruding and
protruding undulations.
6. The spacer frame of claim 1 wherein at least a portion of the
first and second intermediate wall portions comprise
interruptions.
7. The spacer frame of claim 6 wherein said interruptions comprise
at least one of holes and mesh material.
8. Thermal stock for use in forming a spacer frame for use in an
insulating glass unit (IGU), the thermal stock comprising: first
and second frame stock portions comprising a first thermal
conductivity; a thermal interruption strip coupling the first frame
stock portion to the second frame stock portion, the thermal
interruption strip spacing the first frame stock portion a gap
distance from the second frame stock portion, the thermal
interruption strip comprising a second thermal conductivity, said
second thermal conductivity is less than the first thermal
conductivity; and wherein an intermediate wall portion comprising
the thermal interruption strip is covered by a film material for
preventing fluid leakage.
9. The thermal stock of claim 8, wherein the thermal interruption
strip comprises a central portion, an upper portion, and a lower
portion, said central portion spaces the first and second frame
stock portions from each other, said upper portion extend over at
least an upper portion of the first and second frame stock
portions, and said lower portion extend over at least a lower
portion of the first and second frame stock portions.
10. The thermal stock of claim 9, wherein the film is applied over
at least one of the upper and lower portions of the thermal
interruption strip.
11. The thermal stock of claim 10, wherein the film is in direct
contact with at least a portion of the first and second frame stock
portion.
12. A method of forming thermal stock for use in insulating glass
units, the method comprising: forming a first and second frame
stock portion; laterally linking the first and second frame stock
portions via a thermal interruption strip, the thermal interruption
strip spacing the first frame stock portion from the second frame
stock portion, and the thermal interruption strip comprising a
lower thermal conductivity material than the first and second frame
stock portions; and overlaying the thermal interruption strip and
at least a portion of the first and second frame stock portions
with a film.
13. The method of claim 12 wherein the step of laterally linking
comprises adhesively bonding the first and second frame stock
portions to the thermal interruption strip.
14. The method of claim 13 wherein the first and second frame stock
portions are elongated, generally planar strips of a first material
and wherein the thermal interruption strip includes separate layers
having said lower thermal conductivity that are adhesively bonded
to a first and second exposed surfaces of the generally planar
strips.
15. The method of claim 14 wherein the thermal interruption strip
comprises three layers wherein a middle layer is adhesively
attached to two additional layers that are adhesively bonded to the
exposed surfaces of the generally planar strips.
16. The method of claim 15 wherein the step of laterally linking
comprises extruding the thermal interruption strip into contact
with the first and second frame stock portions.
17. The method of claim 16 where the thermal interruption strip is
extruded at an elevated temperature which hardens after coming in
contact with the first and second frame stock portions.
18. The method of claim 12 wherein the step of laterally linking
comprises molding the thermal interruption strip into contact with
the first and second frame stock portions.
19. The method of claim 12 additionally comprising roll forming
first and second frame stock portions to form a channel subsequent
to linking the first and second frame stock portions with the
thermal interruption strip and wherein the film is applied
subsequent to said bending.
20. An insulating glass unit comprising: first and second glass
lites spaced apart from each other having inner facing surfaces
that bound an interior region; a multi-sided channel shaped
composite spacer frame for arranging said first and second glass
lites in a spaced apart, generally parallel relation to each other,
said spacer frame comprising: an elongated thermal interruption
strip forming a middle portion of said composite spacer frame that
extends around a periphery of the interior region bound by the
first and second glass lites; a first elongated metal side wall
member having a first outwardly facing side wall surface for
orienting the first glass lite and a first inwardly facing side
wall surface that bounds the interior region wherein the first
elongated metal side wall member includes a first embedded portion
securing the first metal side wall member to the thermal
interruption strip; and a second elongated metal side wall member
having a second outwardly facing side wall surface for orienting
the second glass lite and a second inwardly facing side wall
surface that bounds the interior region wherein the second
elongated metal side wall member includes a second embedded portion
securing the second metal side wall member to the thermal
interruption strip; an adhesive material interposed between the
outwardly facing side wall surfaces of said first and second metal
side wall members and the first and second glass lites for
arranging the first and second glass lites in spaced relation to
each other; and a vapor barrier overlying at least a portion of the
thermal interruption strip to impede contaminants from reaching the
interior region bounded by the first and second glass lites.
21. (canceled)
22. (canceled)
Description
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] The following application claims priority under 35 U.S.C.
119(e) to co-pending U.S. Provisional Patent Application Ser. No.
62/554,201 filed Sep. 5, 2017 entitled THERMALLY EFFICIENT WINDOW
FRAME. The above-identified provisional application is incorporated
herein by reference in its entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present disclosure relates to insulating glass units and
more particularly to a thermally efficient window frame that
comprises a spacer frame with a thermal barrier to reduce heat
transfer across the spacer frame and through the insulating glass
units.
BACKGROUND OF THE INVENTION
[0003] Insulating glass units (IGUs) are used in windows to reduce
heat loss from building interiors during cold weather and to
prevent the entrance of heat during warm weather. IGUs are
typically formed by a spacer assembly sandwiched between glass
lites. A spacer assembly usually comprises a frame structure
extending peripherally about the unit, a sealant material adhered
both to the glass lites and the frame structure, and a desiccant
for absorbing atmospheric moisture within the unit. The margins of
the glass lites are flush with or extend slightly outwardly from
the spacer assembly. The sealant extends continuously about the
frame structure periphery and its opposite sides so that the space
within the IGUs is hermetic.
[0004] One successful IGU construction has employed tubular, roll
formed aluminum or steel frame elements connected at their ends to
form a square or rectangular spacer frame. The frame sides and
corners were covered with sealant (e.g., a hot melt material) for
securing the frame to the glass lites. The sealant provided a
barrier between atmospheric air and the IGU interior, which blocked
entry of atmospheric water vapor. Particulate desiccant deposited
inside the tubular frame elements communicated with air trapped in
the IGU interior to remove the entrapped airborne water vapor, and
thus, preclude its condensation within the unit. Thus, after the
water vapor entrapped in the IGU was removed, internal condensation
only occurred when the unit failed.
[0005] Alternatively, individual roll formed spacer frame tubes
were cut to length and "corner keys" were inserted between adjacent
frame element ends to form the corners. In some constructions, the
corner keys were foldable so that the sealant could be extruded
onto the frame sides as the frame moved linearly past a sealant
extrusion station. The frame was then folded to a rectangular
configuration with the sealant in place on the opposite sides. The
formed spacer was then placed between glass lites and the IGU
assembly completed.
[0006] A typical insulating glass unit (IGU) 10 is illustrated in
FIG. 1. The IGU 10 includes a spacer assembly 12 sandwiched between
glass sheets, or lites, 14. The assembly 12 comprises a frame
structure 16 and sealant material for hermetically joining the
spacer assembly 12 to the lites 14 to form a closed space 20 within
the IGU 10. The prior art IGU 10 illustrated in FIG. 1 is in
condition for final assembly into a window or door frame.
[0007] The assembly 12 maintains the lites 14 spaced apart from
each other to produce the hermetic insulating "insulating air
space" 20 between them. The typical frame 16 comprises a plurality
of spacer frame segments, or members, 30a-d connected to form a
planar, polygonal frame shape, element juncture forming frame
corner structures 32a-d, and connecting structure 34 for joining
opposite frame element ends to complete the closed frame shape.
Traditionally a frame member 30 is has a channel shaped cross
section defining a peripheral wall 40 and first and second lateral
walls 42, 44 (see FIGS. 2-3). The peripheral wall 40 extends
continuously about the IGU 10 except where the connecting structure
34 joins the frame member ends.
[0008] The frame 16 extends about the unit periphery, such that, in
an installed window, a lite 14 exposed to the external temperature
is thermally connected to a lite 14 that is exposed to an internal
temperature via the peripheral wall 40. This thermal connection
causes a thermal energy flow between the internal and external
regions bound by the window, causing the internal desired
temperature to be altered by the external not-desired
temperature.
[0009] U.S. Pat. No. 5,361,476 to Leopold discloses a method and
apparatus for making IGUs wherein a thin flat strip of sheet
material is continuously formed into a channel shaped spacer frame
having corner structures and end structures, the spacer thus formed
is cut off, sealant and desiccant are applied and the assemblage is
bent to form a spacer assembly. U.S. Pat. No. 5,361,476 to Leopold
is incorporated herein by reference in its entirety for all
purposes.
[0010] U.S. Pat. Pub. No. 2001/0032436 to Riegelman entitled
"Insulated Channel Seal for Glass Panes" and U.S. Pat. Pub. No.
2008/0060290 to McGlinchy concerns a structure having a channel for
a frame which separates window panes to form an insulated window
and has a plurality of openings through a wall of the channel that
faces outward along the periphery of the frame and glass sandwich.
In Riegelman, the openings are designed to prevent significant
passage of sealant from the outside of the channel to the inside of
the channel through the openings. This is done by the cross
sectional area of each opening being so small that it resists
viscous flow of the sealant through the opening, or by a cover over
the opening. U.S. Pat. Pub. No. 2001/0032436 to Riegelman is
incorporated herein incorporated by reference in its entirety for
all purposes. U.S. Pat. Pub. No. 2008/0060290 to McGlinchy is
herein incorporated by reference in its entirety and for all
purposes.
[0011] Companies by the names of Edgetech and Nynex produce window
spacer frames formed entirely of PVC having thermally efficient
insulating characteristics. U.S. Pat. Pub. No. 2008/0134596 to
Brunnhofer et al. entitled "Spacer Profile for a Spacer Frame for
an Insulating Window Unit and Insulating Window Unit" concerns a
mountable spacer profile for forming an intervening space. U.S.
Pat. Pub. No. 2008/0134596 to Brunnhofer et al. is herein
incorporated by reference in its entirety and for all purposes.
SUMMARY
[0012] One aspect of the present disclosure includes a spacer for
separating first and second glass lites from each other in an
insulating glass unit (IGU) for use in fabricating a window or
door. The spacer frame comprising an elongated frame forming a
multi-sided unit comprising a first outwardly facing surface for
supporting the first glass lite. The first outwardly facing surface
is contiguous with a first intermediate wall portion. The spacer
frame further comprises a second outwardly facing surface for
supporting the second glass lite. The second outwardly facing
surface is contiguous with a second intermediate wall portion,
wherein the first and second intermediate wall portions comprise a
first material and are linked to each other and spaced from each
other by a thermal interruption strip. The first and second
intermediate wall portions and the thermal interruption strip
comprise an intermediate wall that bridges the first and second
outwardly facing surfaces. Additionally, the spacer frame comprises
a film for preventing fluid leakage, overlaying the intermediate
wall portion.
[0013] Another aspect of the present disclosure comprises thermal
stock for use in forming a spacer frame for use in an insulating
glass unit (IGU). The thermal stock comprising first and second
frame stock portions comprising a first thermal conductivity value,
and a thermal interruption strip coupling the first frame stock
portion to the second frame stock portion. The thermal interruption
strip spacing the first frame stock portion a gap distance from the
second frame stock portion. The thermal interruption strip
comprising a second thermal conductivity value, the second thermal
conductivity being less than the first thermal conductivity value.
Wherein an intermediate wall portion comprising the thermal
interruption strip is covered by a film material for preventing
fluid leakage.
[0014] Yet another aspect of the present disclosure comprises a
method of forming thermal stock for use in insulating glass units.
The method comprises forming a first and second frame stock
portion, laterally linking the first and second frame stock
portions via a thermal interruption strip. The thermal interruption
strip spacing the first frame stock portion from the second frame
stock portion, and comprising a lower thermal conductivity material
than the material first and second frame stock portions. The method
further comprising overlaying the thermal interruption strip and at
least a portion of the first and second frame stock portions with a
film.
[0015] Yet another aspect of the present disclosure comprises an
insulating glass unit comprising first and second glass lites
spaced apart from each other having inner facing surfaces that
bound an interior region, a multi-sided channel shaped composite
spacer frame for arranging said first and second glass lites in a
spaced apart, generally parallel relation to each other. The spacer
frame comprising an elongated thermal interruption strip forming a
middle portion of said composite spacer frame that extends around a
periphery of the interior region bound by the first and second
glass lites, a first elongated metal side wall member having a
first outwardly facing side wall surface for orienting the first
glass lite and a first inwardly facing side wall surface that
bounds the interior region wherein the first elongated metal side
wall member includes a first embedded portion securing the first
metal side wall member to the thermal interruption strip, and a
second elongated metal side wall member having a second outwardly
facing side wall surface for orienting the second glass lite and a
second inwardly facing side wall surface that bounds the interior
region wherein the second elongated metal side wall member includes
a second embedded portion securing the second metal side wall
member to the thermal interruption strip. The spacer frame further
comprising an adhesive material interposed between the outwardly
facing side wall surfaces of said first and second metal side wall
members and the first and second glass lites for arranging the
first and second glass lites in spaced relation to each other and a
vapor barrier overlying at least a portion of the thermal
interruption strip to impede contaminants from reaching the
interior region bounded by the first and second glass lites.
[0016] While another aspect of the present disclosure comprises
thermal stock for use in forming a spacer frame for use in an
insulating glass unit (IGU), the thermal stock includes first and
second metallic ribbons that are substantially planar comprising
first and second lateral ends, the first and second metallic
ribbons having a first thermal conductivity; a polymeric thermal
interruption strip formed over and between the second lateral ends
of the first and second metallic ribbons, the polymeric thermal
interruption strip spacing the first and second metallic ribbons by
forming a gap between the second lateral ends, the gap being
fixedly within the polymeric thermal interruption strip, the
polymeric thermal interruption strip comprising a second thermal
conductivity, the second thermal conductivity is less than the
first thermal conductivity; the polymeric thermal interruption
strip further comprising spaced first and second mirrored
converging lateral ends forming a sandwich connection with and over
the second lateral ends of the first and second metallic ribbons,
the sandwich connection extending toward the first lateral ends to
cover a portion of the first and second metallic ribbons beyond the
second lateral connection ends, the polymeric thermal interruption
strip further comprising a planar body that connects the first and
second spaced mirrored converging lateral ends, the planar body
covers a portion of the metallic ribbons and the entire gap between
the second lateral ends of the first and second metallic ribbons;
and a film material covering a portion of first and second
longitudinal sides of the first and second metallic ribbons and an
entire first and second longitudinal sides of the polymeric thermal
interruption strip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The foregoing and other features and advantages of the
present disclosure will become apparent to one skilled in the art
to which the present invention relates upon consideration of the
following description of the invention with reference to the
accompanying drawings, wherein like reference numerals refer to
like parts unless described otherwise throughout the drawings and
in which:
[0018] FIG. 1 is perspective view of a typical insulating glass
unit as known in the prior art;
[0019] FIG. 2 is a top view of a typical spacer frame that forms
part of the typical insulating glass unit of FIG. 1 as known in the
prior art;
[0020] FIG. 3 is a left side elevation view of FIG. 2 as known in
the prior art;
[0021] FIG. 4 is perspective view of an insulating glass unit (IGI)
constructed in accordance with one example embodiment of the
present disclosure;
[0022] FIG. 5 is a plan view of flat thermal stock after a punching
operation that will be formed into one or more thermal spacer frame
assemblies before the flat stock is roll formed or has sealant
applied;
[0023] FIG. 5A is a top view of the thermal spacer frame assembly
located in the IGU illustrated in FIG. 4 after a roll forming
operation is performed on the flat thermal stock illustrated in
FIG. 5;
[0024] FIG. 6A is a left side elevation view of FIG. 5A;
[0025] FIG. 6B is cross sectional view of the spacer frame assembly
of FIG. 6A taken along lines 6B-6B;
[0026] FIG. 6C is a fragmentary elevation view of a thermal space
frame formed from the spacer assembly of FIG. 6A, which is
illustrated in a partially constructed condition;
[0027] FIG. 7 is an elevation depiction of a production assembly
for use in producing the thermal spacer frame assemblies of the
present disclosure that are used in an IGU;
[0028] FIG. 8 is a front elevation view of thermal sheet stock
constructed in accordance with one example embodiment of the
present disclosure, the thermal sheet stock used to form a thermal
spacer frame assembly;
[0029] FIG. 9 is a top perspective view of a thermal spacer frame
assembly comprising roll formed thermal sheet stock in accordance
with one example embodiment of the present disclosure;
[0030] FIG. 10 is a top perspective view of thermal sheet
stock;
[0031] FIG. 11 is a front elevation view of thermal sheet stock
being roll formed;
[0032] FIG. 12 is a magnified view of FIG. 11;
[0033] FIG. 13 is a cross-section taken along line 13-13 of FIG.
4;
[0034] FIG. 14 is a top plan view of first and second sheet stock
portions;
[0035] FIG. 14A is a perspective view of a thermal spacer frame
assembly in accordance with one example embodiment of the present
disclosure;
[0036] FIG. 15A is cross-section view of an isotherm of the
traditional IGU of FIG. 1 taken along lines 15A-15A; and
[0037] FIG. 15B is cross-section view of an isotherm of the IGU of
FIG. 4 taken along lines 13-13.
[0038] Skilled artisans will appreciate that elements in the
figures are illustrated for simplicity and clarity and have not
necessarily been drawn to scale. For example, the dimensions of
some of the elements in the figures may be exaggerated relative to
other elements to help to improve understanding of embodiments of
the present disclosure.
[0039] The apparatus and method components have been represented
where appropriate by conventional symbols in the drawings, showing
only those specific details that are pertinent to understanding the
embodiments of the present disclosure so as not to obscure the
disclosure with details that will be readily apparent to those of
ordinary skill in the art having the benefit of the description
herein.
DETAILED DESCRIPTION
[0040] Referring now to the figures generally wherein like numbered
features shown therein refer to like elements throughout unless
otherwise noted. The present disclosure relates to insulating glass
units and more particularly to a thermally efficient window frame
that comprises a spacer frame with a thermal barrier to reduce heat
transfer across the spacer frame and through the insulating glass
units.
[0041] A double pane insulating glass unit (IGU) 333 is illustrated
in FIG. 4. The IGU 333 includes a spacer assembly 312 sandwiched
between glass sheets, or lites 314. The assembly 312 comprises a
frame 316 and sealant material (omitted for clarity) for
hermetically joining the spacer assembly 312 to the lites 314 to
form a closed space 320 within the IGU 333. The IGU 333 is
illustrated in FIG. 4 as in condition for final assembly into a
window or door frame, not illustrated, for ultimate installation in
a building. The IGU 333 as illustrated in FIG. 4 includes muntin
bars "m" that provide the appearance of individual window panes. It
would be appreciated by one having ordinary skill in the art that
multi-pane IGUs were contemplated, and the frame structures used
therein would be substantially the same as the frame 316 described
with regard to the IGU 333. Further discussion of multi-pane IGUs
and their assembly process is found in U.S. Pat. Nos. 9,416,583 and
9,534,439, which are assigned to the assignee of the present
disclosure. Both U.S. Pat. Nos. 9,416,583 and 9,534,439 are
incorporated herein in their entireties for all purposes.
[0042] The assembly 312 maintains the lites 314 spaced apart from
each other to produce the hermetic insulating "insulating air
space" 320 between them. The frame 316 and the sealant body 318
(see FIG. 13) co-act to provide a structure which maintains the
lites 314 properly assembled with the space 320 sealed from
atmospheric moisture over long time periods during which, the IGU
333 is subjected to frequent significant thermal stresses. A
desiccant 319 (see FIG. 13) removes water vapor from air, or other
volatiles, entrapped in the space 320 during construction of the
IGU 333.
[0043] The sealant 318 both structurally adheres the lites 314 to
the spacer assembly 312 and hermetically closes the space 320
against infiltration of airborne water vapor from the atmosphere
surrounding the IGU 333. One suitable sealant is formed from a "hot
melt" material, which is attached to the frame 316 sides and outer
periphery to form a U-shaped cross section.
[0044] The frame 316 extends about the unit periphery to provide a
structurally strong, stable spacer 312 for maintaining the lites
314 aligned and spaced while minimizing heat conduction between the
lites via the frame. The preferred frame 316 comprises a plurality
of spacer frame segments, or members, 330a-d connected to form a
planar, polygonal frame shape, element juncture forming frame
corner structures 332a-d, and connecting structure 334 (see FIG.
6C) for joining opposite frame element ends 362, 364 to complete
the closed frame shape.
[0045] The frame member 330 is elongated and has a channel-shaped
cross section, defining a peripheral wall 340 and first and second
lateral walls 342, 344 (see FIGS. 5A, 9, and 13). The peripheral
wall 340 comprises frame stock 306, 308 spaced from each other and
linked to each other by a thermal interruption strip 302 (see FIGS.
5A, 9, and 13, and 14). A film 304 overlays at least a portion of
the stock 306, 308, and the thermal interruption strip 302 (see,
for example, FIG. 9). The peripheral wall 340 extends continuously
about the IGU 333 except where the connecting structure 334 joins
the frame member ends 362, 364. The lateral walls 342, 344 are
integral with respective opposite peripheral wall edges. The
lateral walls 342, 344 extend inwardly from the peripheral wall 340
in a direction parallel to the planes of the lites 314 and the
frame 316. The illustrated frame 316 has stiffening flanges 346
formed along the inwardly projecting lateral wall edges. The
lateral walls 342, 344 add rigidity to the frame member 330 so it
resists flexure and bending in a direction transverse to its
longitudinal extent. The flanges 346 stiffen the walls 342, 344 so
they resist bending and flexure transverse to their longitudinal
extents.
[0046] Illustrated in FIG. 5 is the continuous metal ribbon or flat
stock 348 that is roll formed into the channel shaped cross section
defining the peripheral wall 340 and first and second lateral walls
342, 344 (see FIGS. 5A, 9, and 13). The flat stock 348 is passed
through a stamping station and punched by a number of dies to form
notches 350 and weakening zones 352 for corner folds 332, a
connecting structure 334, a nose 362, gas fill apertures 371, 372,
and end cut 380. The thermal interruption strip 302 is illustrated
in dashed lines for clarity as the film 304 overlays said thermal
interruption strip. A punch strip 336 of flat thermal stock 310
forms a thermal spacer frame assembly 312 as illustrated in
repeating sections by dimension "L" from the continuous strip 348.
The punch strip 336 is eventually sheared to make a spacer frame
assembly 312 at end 380 and the nose 362, leaving scrap piece 382.
Alternatively, the punching or shearing operation is a single hit
operation in which the width of the shear equals that of scrap
piece 382, leaving no scrap or need for a double hit operation.
Further discussion relating to the shearing or punching operation
is discussed in U.S. Pat. No. 8,720,026, which is incorporated
herein by reference in its entirety. The gas fill apertures 371,
372 comprise holes punched into the flat thermal stock 310.
[0047] The frame 316 is initially formed as a continuous straight
channel constructed from thermal stock 310, wherein the thermal
stock comprises two independent thin ribbons of stock material 306,
308 (e.g., 304 stainless steel having a thickness of 0.006-0.010
inches) linked via the thermal interruption strip 302, and at least
partially overlaid with the film 304. It should be appreciated that
the metal stock 306 could also be 1020 steel, mild steel, hardened
steel, aluminum, CrMo steel, nickel, carbon steel, and the
like.
[0048] In one example embodiment, the frame stock 306, 308
comprises other materials, such as galvanized and/or tin plated
steel, aluminum and/or plastic. The thermal interruption strip 302
in one example embodiment comprises a non-thermally conductive
material such as a polymer (e.g., aliphatic or semi-aromatic
polyamides (Nylon), polyethylene, polyester, epoxy, etc.), a
plastic (e.g., polyethylene terephthalate, high-density
polyethylene, polyvinyl chloride, etc.) rubber, hardening agents
(e.g., calcuim carboniate, talc, barium sulphate, glass fibers,
etc.), bonding agents (e.g., polyvinyl acetate) or a combination
thereof. The thermal interruption strip 302 comprises a durometer
between 70-90 Shore D which has a sufficient rigidity at
temperatures up to below 100.degree. C., to maintain the shape of
the channel, and the walls 342, 344, yet provide the flexibility to
bend when assembled (see FIG. 6C) at the corners C1-C4 without
separation at corners C1-C4. The film 304 comprises an air fight
film such as a metalized polyester film, to prevent loss of
thermally efficient insulating fluids (e.g., He, Ne, Ar, Kr, Xe, or
the like) from the space 320, the flexibility of the film 304 also
provides strength to the spacer frame and thermal interruption
strip 302 to prevent fracturing during the bending at the corners
C1-C4. In one example embodiment, the film 304 comprises a low
moisture vapor transition rate (MVTR) barrier film. Examples of
products that can be used as film 304 include Mylar resin (e.g.,
Polyethylene Terephthalate (PET)), 3M's P Model #850 Polyester
film, and the like.
[0049] As described more fully below, the corner structures 332 are
made to facilitate bending the frame channel to the final,
polygonal frame configuration in the IGU 333 while assuring an
effective vapor seal at the frame corners and properly aligning
apertures 371, 372. The gas fill apertures 371, 372 comprise holes
punched into the thermal interruption strip 302. The gas fill
apertures 371, 372 are used to either inject the space 320 in the
IGU 333 with a liquid and/or solid, or to evacuate the space. In
one example embodiment, the corner structures 332 are manually or
automatically bent when the frame 316 is maintained at an elevated
bending temperature. The bending temperature is determined based
upon a melting temperature and/or a heat distortion temperature of
the thermal interruption strip 302. In this embodiment, the
apertures 371, 372 are formed while the thermal interruption strip
302 is at the bending temperature, to facilitate aperture
formation. In another embodiment, the apertures 371, 372 are formed
through the thermal interruption strip 302 utilizing a punch and/or
screw before or after roll forming.
[0050] In yet another embodiment, the apertures 371, 372 are formed
through the thermal interruption strip 302 via a hot or thermal
punch, cold punch, and/or a hole drilling mechanism. Sealant 318 is
applied and adhered to the channel before the corners 332 are bent.
As shown in the illustrated embodiment of FIGS. 5, 5A, and 6A, the
corner structures 332 initially comprise notches 350 and weakened
zones 352 formed in the walls 342, 344 at frame corner locations.
The notches 350 extend into the walls 342, 344 from the respective
lateral wall edges. The lateral walls 342, 344 extend continuously
along the frame 316 from one end to the other. The walls 342, 344
are weakened at the corner locations 332 because the notches reduce
the amount of lateral wall material, a portion of the film 304, and
eliminate the stiffening flanges 346 and because the walls are
punched and stamped to weaken them at the corners. At the same time
the notches 350 are formed, the weakened zones 352 are formed.
These weakened zones are cut into the strip 310, but not all the
way through. When this strip 310 is rollformed, the weakened zones
352 can spring back and have an outward tendency.
[0051] The connecting structure 334 secures the opposite frame ends
362, 364 together when the frame 316 has been bent to its final
configuration. The illustrated example embodiment of FIG. 6C, the
connecting structure 334 comprises a connecting tongue structure
366 continuous with and projecting from the frame structure end 362
and a tongue receiving structure 370 at the other frame end 364.
The illustrated example embodiment tongue and tongue receiving
structures 366, 370 are constructed and sized relative to each
other to form a telescopic joint 358. When assembled, the
telescopic joint 358 maintains the frame in its final polygonal
configuration prior to assembly of the unit 333.
[0052] In a second embodiment, such as in the illustrated example
embodiments of FIGS. 5A, 6A, 6B, and 6C, the connecting structure
334 comprises a stop 364 that is formed by stamping dies at a
stamping station 104 as described below. The connecting structure
334 is inserted into an opposite frame end 354 or the leg member
330d when the thermal spacer frame assembly 312 has been bent to
its final configuration. That is, rotating the thermal spacer frame
assembly 312 members 330 (from the linear configuration of FIGS. 5A
and 6A) in the direction of arrows A, B, C, and D as illustrated in
FIG. 6C and particularly, inserting the frame structure end or nose
362 of the connecting structure 334 into an opposite channel 355
formed at the opposite end 354 of segment 330d with concomitant
rotation of the segments (arrows A-D). This concomitant rotation
continues until the connecting structure 334 slides into the
opposite channel 355 of segment 330d at the opposite end 354. In
the illustrated example embodiment of FIG. 6C, the opposite end 354
engages positive stops 364 in the connecting structure 334 forming
a telescopic union 358 and lateral connection 360 that is spaced
from the corners 332. It would be appreciated by one having
ordinary skill in the art that the lateral connection 360 and/or
the telescopic union 358 could be located anywhere between the
first and fourth corners 332a, 332d. Further discussion as to the
stop 364 and lateral connection 360 that is spaced from the corners
332 is discussed in U.S. Pat. No. 9,428,953, U.S Patent Publication
No. 2015/0361713, which are incorporated herein by reference in its
entirety and for all purposes.
The Production Line 100
[0053] An operation by which elongated window components are made
is schematically illustrated in FIG. 7 as a production line 100
through which thermal sheet stock 310 comprising the two thin,
relatively narrow ribbons of sheet metal stock 306, 308 linked by
the thermal interruption strip 302 and the film 304 is fed endwise
from a coil into one end of the assembly line and substantially
completed elongated window components 312 emerge from the other end
of the line 100.
[0054] The line 100 comprises a stock supply station 102, a first
forming station 104, a transfer mechanism 105, a second forming
station 110, a conveyor 113, a scrap removal apparatus 111, third
and fourth forming stations 114, 116, respectively. Wherein within
the line 100, partially formed spacer members are separated from
the leading end of the thermal sheet stock 310, the thermal sheet
stock is roll formed, and frame corner locations are deformed. At a
desiccant application station 119 desiccant is applied to an
interior region of the spacer frame member, and at an extrusion
station 120 sealant is applied to the yet to be folded frame
member. A scheduler/motion controller unit 122 interacts with the
stations and loop feed sensors to govern the spacer stock size,
spacer assembly size, the stock feeding speeds in the line, and
other parameters involved in production. A preferred controller
unit 122 is commercially available from Delta Tau, 21314 Lassen St,
Chatsworth, Calif. 91311 as part number UMAC. In one embodiment a
separate controller 122' controls the desiccant application and
adhesive or sealant application. Additional details of a
representative spacer frame fabrication system are contained in US
Pat. Pub. No. 2006/0075719 to James et al., which is incorporated
herein by reference.
Thermal Stock 310
[0055] In one example embodiment, the spacer assembly 312 enhances
the thermal properties of the resulting window by interrupting
thermal energy flow of energy through an installed window. The
thermal energy flow between an interior wall and an exterior wall
is interrupted by the presence of the thermal interruption strip
302. For example, the thermal interruption strip 302 better
maintains the temperature of the window's inwardly facing edge in
winter by impeding heat flow from inside a home or other building
and impeding the energy loss caused by lower temperature from the
outwardly facing edge of the window.
[0056] In the illustrated example embodiment of FIG. 13, heat flow
disruption is accomplished by the thermal conductivity interruption
created by the thermal interruption strip 302 of the peripheral
wall 340 of the frame 312. The thermal interruption strip 302 links
an inner edge 303b of the first metal strip 306 and an inner edge
307b of the second metal strip 308 (see FIG. 14). The links of the
inner edges 303b and 307b in the illustrated example embodiment is
in an alternating sinusoidal manner increasing the strength and
support between the thermal interruption strip 302 and the ribbons
306.
[0057] The thermal interruption strip 302 comprises a polymer
bridge 399. The polymer bridge 399 comprises a mechanically crimped
polymer bridge with the frame member before or after roll forming,
a co-extruded polymer bridge, a molded polymer bridge, or the like.
In this embodiment, the thermal stock 310 is formed by an automated
apparatus. In one example embodiment, such as illustrated in FIG.
8, when the thermal interruption strip 302 comprises the
mechanically crimped polymer bridge, the thermal interruption strip
302 comprises a central portion 302a, an upper portion 302b, and a
lower portion 302c, wherein the lower portion is positioned to
interact with bottom faces 306b, 308b of the frame stock 306, 308,
the central portion is positioned between the frame stock and on
top of the lower portion, and the upper portion 302a is positioned
on to interact with top faces 306a, 306b of the frame stock and the
central portion. The upper, central, and lower portions 302a-302c
are mechanically crimped together, manually or automatically, to
form the thermal interruption strip 302 and to bond the thermal
interruption strip to the frame stock 306, 308, to form the thermal
stock 310.
[0058] In another example embodiment, when the thermal interruption
strip 302 comprises the co-extruded polymer bridge, the thermal
interruption strip 302 is formed as a single unit while interacting
with the frame stock 306, 308. The frame stock 306, 308 is aligned
relative to an extrusion apparatus, and the polymer bridge material
is extruded, manually or automatically, onto the frame stock to
form the thermal interruption strip 302 linking the frame stock and
the thermal interruption strip 302.
[0059] In the illustrated example embodiment of FIGS. 8, 9, and 10,
the thermal interruption strip 302 is a polygon, and in particular,
a hexagonal polygon that provides strength and support between the
thermal interruption strip and ribbons 306, 308. This construction
assists in providing support for high stress conditions that occurs
on the strip, ribbon, and connection therebetween, especially at
the corners when the spacer frame is bent for assembly. In the
illustrated example embodiment, the hexagonal construction forms a
hexagonal prism cross-section as seen in FIG. 10. The hexagonal
prism cross-section extends longitudinally around the entire
profile of the spacer frame. Laterally, the hexagonal prism
cross-section includes mirrored first and second ends having upper
and lower transverse ends extending to a point forming a sandwich
connection with the ribbons 306, 308 starting at the first and
second stability extents and extending to and beyond ends 303b and
307b (see FIGS. 8 and 10). The hexagonal prism cross-section
further comprises a planar body that connects the spaced mirrored
first and second ends and covers the stability extents and gap
between the ends 303b and 307b as illustrated in FIGS. 8 and
10).
[0060] In yet another example embodiment, when the thermal
interruption strip 302 comprises the molded polymer bridge, the
thermal interruption strip 302 is formed by positioning the frame
stock 306, 308 relative to a thermal interruption strip mold, and
filling the mold with the thermal interruption strip material. The
frame stock 306, 308 is aligned relative to the mold to obtain
desired dimensions of the thermal interruption strip 302 relative
to the frame stock. The polymer bridge material is injected,
manually or automatically, onto the mold to form the thermal
interruption strip 302 and, thus, the thermal stock 310. In yet
another example embodiment, the frame stock 306, 308 is positioned
after the mold has been filled, but while the thermal interruption
strip material is still pliable (e.g., while a temperature of the
thermal interruption strip material is over a temperature at which
the material would become inflexible).
[0061] In the illustrated example embodiment of FIG. 8, the thermal
interruption strip 302 extends a first stability distance 313 over
a top face 306a and/or a bottom face 306b of the first frame stock
portion 306 and a second stability distance 315 over a top face
308a and/or a bottom face 308b of the second frame stock portion
308 to increase a strength of the linking of the first and second
frame stock portion. The thermal interruption strip 302 provides a
gap distance 311 between the inner edges 303b, 307b (see FIGS. 8
and 14) of the first and second frame stock portions 306, 308. The
first and second stability distances 313, 315, and the gap distance
311 are proportional to a final width 317 of the spacer frame 316
and/or a stock width 327 of the stock 310 (see FIGS. 8-9). For
example, a sum of the first and second stability distances 313,
315, and the gap distance 311 is between 1/8th to about 1/4th of
the total stock width 327. The first and second stability distances
313, 315 are proportional to the gap distance 311 (e.g., at a ratio
of between 1:2 to 1:4). In one example embodiment, the greater the
gap distance 311 the greater the first and second stability
distances 313, 315. In another example embodiment, the first and
second stability distances 313, 315 are substantially equal to the
gap distance 311. In yet another example embodiment, the sum of the
first and second stability distances 313, 315, and the gap distance
311 is less than final width 317 of the spacer frame 316.
[0062] In another embodiment, the thermal interruption strip 302 is
glued or adhered (e.g., with a pressure sensitive adhesive) to the
frame stock 306, 308 (see FIGS. 8, and 14). In this embodiment, the
thermal stock 310 is formed by an automated strip laminating
apparatus. When the thermal interruption strip 302 is linked to the
frame stock 306, 308 via adhesives or glue, the lower portion 302c
is positioned to interact with bottom faces 306b, 308b of the metal
strips 306, 308, the central portion 302a is positioned between the
frame stock portions and on top of the lower portion, and the upper
portion 302b is positioned on top faces 306a, 306b) of the frame
stock and the central portion, wherein an adhesive or glue is
disposed between the upper, central, and lower portions, and/or the
frame stock. The upper, central, and lower portions 302a-302c are
glued/adhered together, manually or automatically, (e.g., using
pressure, such as a uniform pressure of 20-30 psi) to form the
thermal interruption strip 302 and additionally, glued/adhered to
the frame stock 306, 308, to form the thermal strip 310.
[0063] In yet another example embodiment, the frame stock 306, 308
(see FIG. 14) comprise serrations or shapes that add surface area
to aid adherence of the thermal interruption strip 302 to along the
inner edges 303b, 307b of the frame stock 306, 308. In the
illustrated example embodiment of FIG. 14, the first frame stock
portion 306 comprises intruding 306a and protruding 306b
undulations. The second frame stock portion 308 comprises intruding
308a and protruding 308b undulations that are complementary
intruding 306a and protruding 306b undulations of the first frame
stock portion 306. In an additional example embodiments, the frame
stock portion 306, 308 comprise interruptions (e.g., holes 341,
mesh material 339, etc.) (see FIG. 14) along and adjacent to the
inner edges 303b, 307b of the metal strips 306, 308 to provide
added grip strength/bonding surface area to the thermal
interruption strip 302. The gap distance 311 between the inner
edges 303b, 307b is variable and is a factor in minimum spacer
width capability. For example, a larger gap distance 311 is more
thermally efficient. In one example embodiment, the thermal
interruption strip 302 provides the gap distance 311 having a range
between about 1/8'' (inches) to about 1/4'' (inches). In another
example embodiment, the thermal interruption strip 302 comprises a
thermal interruption strip thickness 323 (see FIG. 13). The thermal
interruption strip thickness 323 having a range between about 1/8''
(inches) to about 1/4''(inches). The thermal interruption strip 302
disrupts heat transfer across the wall from one side wall 342 to
the opposed side wall 344 while maintaining a structural integrity
of the wall 340.
[0064] The film 304 is applied as the thermal interruption strip
302 is being formed, before, or after the thermal interruption
strip has been formed. The film 304 is applied longitudinally along
the linear extent of the thermal stock 310. In one example
embodiment, the film 304 is placed within the mold prior to
injection of the thermal material. In this embodiment, a lower
layer 304b of the film 304 (see FIG. 13) is placed in the mold and
in partial contact with the first and second metal stock portions
306, 308 and an upper layer 304a of the film is placed over the
thermal interruption strip 302 and over at least a portion of the
first and second metal stock portions. The heat from the mold links
the film 304 to the thermal interruption strip 302 and the first
and second metal stock portions 306, 308. The film 304 is applied
via at least one of glue or adhesive, thermal pressure, etc, and/or
a combination thereof. In another example embodiment, the film 304
is applied prior to, during, or after the thermal stock 310 is roll
formed into its channel shape. The film 304 is airtight and
prevents fluid transfers from inside the IGU 333 to outside the
IGU. Additionally, the film 304 prevents the desiccant 319 from
escaping the IGU 333. In one example embodiment, the film 304
comprises a sputtered metal barrier, and is applied to the thermal
stock 310 before roll forming or around the perimeter of the unit
333 after roll forming but before folding the frame 316 into a
rectangle. The film 304 stretches around the corners 332 as the
frame 316 is bent, adding strength and support to the ribbons 306
and 308 with the thermal interruption strip 302. An example of a
suitable film 304 is 3M's `Very Low Outgassing High Shear Polyester
Tape` sold as model 8439, `Low Outgassing Polyester Tape` sold
under model number 8333, `Very Low Outgassing Linered Polyester
Tape` sold as model number 6690, and `Aluminum Foil Tape` sold as
model number 431 or 439L (Linered). The product specification
sheets of these film materials are incorporated herein by reference
in their entireties and for all purposes.
[0065] In another example embodiment, the thermal interruption
strip 302 forms first and second projections 371a, 372a,
illustrated in dashed lines in FIG. 14A. In this illustrated
example embodiment, the first gas fill aperture 371 comprises the
first projection 371a through the base wall 340a into the channel
and the second gas fill aperture 372 comprises a second projection
372a into the channel, wherein the first projection interweaves
with the second projection when assembled. The interweaving
provides a friction connection. The friction connection is a
responsive tactile connection, in that it provides to the assembler
feedback if there is over-travel or under-travel when advancing one
or both of the connecting structure 334 and the opposite channel
355 towards each other. That is, the friction during assembly
remains high during under-travel until the interweaving of the
projections 371a, 372 as achieved to form the friction or
responsive tactile connection. Once the interweaving is achieved,
the friction significantly diminishes between the base wall 340a
and the second projection 372a. Similarly, if over-travel from the
tactile connection occurs, the friction significantly increases.
This tactile response occurs because the second projection 372a
rubs the base wall 340a of the connecting structure 334, until the
tactile connection is reached between the first and second
projections 371a, 372a. Further discussion as to the first and
second projections, and the tactile connection is discussed in U.S.
Provisional Pat. App. No. 62/402,312 and U.S. nonprovsional patent
application Ser. No. 15/720,892 filed Sep. 29, 2017 which are
incorporated herein by reference.
Thermal Analysis
[0066] Although the patterns and/or composition of the inner edges
303b, 307b of the metal stock portions 306, 308 vary, an isotherm
that simulates the thermal energy transfer of this spacer system
can be generated by performing a thermal analysis. FIG. 15A
illustrates an isotherm of the typical IGU 10 and FIG. 15B
illustrates the thermal IGU 333, both IGUs being subjected to
boundary temperature of 0.degree. F. outside 15a, 315a and
70.degree. F. inside 15b, 315b, respectively. The lines on the
isotherms are joining points representing states of equal
temperature, wherein the temperature in Fahrenheit corresponds to
the line as shown in a box overlaying the line.
[0067] In the illustrated example embodiment of FIG. 15B, the model
illustrates where the frame stock portions 306, 308 are separated
by the thermal interruption strip 302, wherein the gap distance 311
is 1/8'' (inches). It would be understood by one of ordinary skill
in the art that a greater gap distance 311 would cause a greater
interruption in the thermal energy transfer. Comparing the
traditional IGU 10, which has an inside lite 15b temperature of
34.9 F, to the thermal IGU 333, which has an inside lite 315a
temperature of 48.3 F, illustrates that less thermal energy is lost
when the thermal IGU 333 is being utilized.
[0068] In the foregoing specification, specific embodiments have
been described. However, one of ordinary skill in the art
appreciates that various modifications and changes can be made
without departing from the scope of the disclosure as set forth in
the claims below. Accordingly, the specification and figures are to
be regarded in an illustrative rather than a restrictive sense, and
all such modifications are intended to be included within the scope
of present teachings.
[0069] The benefits, advantages, solutions to problems, and any
element(s) that may cause any benefit, advantage, or solution to
occur or become more pronounced are not to be construed as a
critical, required, or essential features or elements of any or all
the claims. The disclosure is defined solely by the appended claims
including any amendments made during the pendency of this
application and all equivalents of those claims as issued.
[0070] Moreover in this document, relational terms such as first
and second, top and bottom, and the like may be used solely to
distinguish one entity or action from another entity or action
without necessarily requiring or implying any actual such
relationship or order between such entities or actions. The terms
"comprises," "comprising," "has", "having," "includes",
"including," "contains", "containing" or any other variation
thereof, are intended to cover a non-exclusive inclusion, such that
a process, method, article, or apparatus that comprises, has,
includes, contains a list of elements does not include only those
elements but may include other elements not expressly listed or
inherent to such process, method, article, or apparatus. An element
proceeded by "comprises . . . a", "has . . . a", "includes . . .
a", "contains . . . a" does not, without more constraints, preclude
the existence of additional identical elements in the process,
method, article, or apparatus that comprises, has, includes,
contains the element. The terms "a" and "an" are defined as one or
more unless explicitly stated otherwise herein. The terms
"substantially", "essentially", "approximately", "about" or any
other version thereof, are defined as being close to as understood
by one of ordinary skill in the art, and in one non-limiting
embodiment the term is defined to be within 10%, in another
embodiment within 5%, in another embodiment within 1% and in
another embodiment within 0.5%. The term "coupled" as used herein
is defined as connected, although not necessarily directly and not
necessarily mechanically. A device or structure that is
"configured" in a certain way is configured in at least that way,
but may also be configured in ways that are not listed.
[0071] The Abstract of the Disclosure is provided to allow the
reader to quickly ascertain the nature of the technical disclosure.
It is submitted with the understanding that it will not be used to
interpret or limit the scope or meaning of the claims. In addition,
in the foregoing Detailed Description, it can be seen that various
features are grouped together in various embodiments for the
purpose of streamlining the disclosure. This method of disclosure
is not to be interpreted as reflecting an intention that the
claimed embodiments require more features than are expressly
recited in each claim. Rather, as the following claims reflect,
inventive subject matter lies in less than all features of a single
disclosed embodiment. Thus, the following claims are hereby
incorporated into the Detailed Description, with each claim
standing on its own as a separately claimed subject matter.
* * * * *