Patent Application
20060218875
The present invention relates generally to commercial, residential and architectural windows and doors and, more particularly, to vapor barriers, desiccants, spacer structures and simulated muntin bar structures for multipane window units and sash assemblies.
As is currently well known in the art, insulating glass units, or IG units, are widely used as elements of windows, skylights, doors and related products, including vehicles. Such units are used to reduce heat loss from building interiors in winter, and reduce heat gain into air-conditioned buildings in summer. The insulating glass units are typically formed separately from the sash, and then in a separate step the insulating glass unit is installed in a sash.
Alternative methods for manufacturing insulating glass structures, where the IG unit is formed integrally with the sash itself, are disclosed in J. France U.S. patent application Ser. No. 09/307,825 ('825) filed on May 7, 1999, entitled “Integrated Multipane Window Unit and Sash Assembly and Method for Manufacturing the Same”, now U.S. Pat. No. 6,286,288, corresponding to PCT published application WO 00/68539 dated Nov. 16, 2000; J. France U.S. patent application Ser. No. 09/907,528 filed on Jul. 17, 2001, entitled “Integrated Multipane Window Unit and Sash Assembly and Method for Manufacturing the Same”; R. Hornung et al. U.S. patent application Ser. No. 09/882,295 ('295) filed on Jun. 15, 2001, entitled “Insulating Glass Sash Assemblies with Adhesive Mounting and Spacing Structures”; R. Hornung et al. U.S. patent application Ser. No. 09/925,293 ('293) filed on Aug. 9, 2001, entitled “Method for Fabricating an Integrated Multipane Window Sash”; and R. Hornung U.S. patent application Ser. No. 10/004,112 ('112) filed on Nov. 15, 2001, entitled “Window Sash Assembly with Hinged Glazing Components”, all incorporated herein by reference. In addition to providing a comprehensive explanation of the prior art, the aforementioned '288 patent discloses an improved but less complex insulating glass structure that is integrated with the window sash.
More particularly, the aforementioned '288 patent discloses a multipane window unit in which a sash frame is formed having an integral spacing structure upon which glazing panes are directly affixed. The integral spacing structure provides vertical glazing surfaces extending from the sash. Adhesive can be affixed to the vertical glazing surfaces to attach the glazing panes. In this manner, a rigid, structural sash frame is formed prior to attachment of the glazing panes, thereby eliminating the need for using separately manufactured insulating glass units, while obtaining similar and improved thermal benefits.
Further improvements to insulating glass structures for use in windows, doors and the like, while incorporating the basic concept of the aforementioned '288 patent, i.e., the provision of a sash and IG unit in an integrated structure, can be found in the aforementioned '295, '293 and '112 patent applications. In addition to providing a comprehensive explanation of the prior art, these patent applications disclose improved but less complex insulating glass structures that are integrated with the window sash. In particular, the '295 application discloses, inter alia, an integrated insulating glass and sash structure where parallel glass panes are directly mounted to and supported on the sash by an adhesive mounting or an adhesive mounting and spacing structure.
Advantageously, such an adhesive can be applied to the sash directly in the form of a bead, such as a bead of sealant (or a combination of sealants or sealant and tape, sealant and foam, etc.) which can also function as the spacer element between the glass panes. Alternatively, the adhesive can be co-extruded (or post-extruded) with the sash profile. Still further, the adhesive can comprise an integrated, single component desiccated sealant-adhesive glazing material. In a particularly advantageous embodiment, this material can be pre-formed into a variety of shapes and sizes, thereby providing, when adhered to the sash profile, an integrated sash/glazing assembly. Methods for assembling multipane window units using the disclosed adhesive spacing and mounting structure are also disclosed.
The '293 application discloses, inter alia, methods for manufacturing integrated multipane window sashes. The '112 application discloses, inter alia, a window sash structure with hinged glazing components, such as hinged glazing beads.
It would be advantageous to further improve structures such as those described above by providing desiccant and vapor barrier components that are economical to fabricate and easy to install. It would be further advantageous to provide such components that facilitate the assembly of muntin bar structures between the panes of a multipane window or door. It would be still further advantageous to provide such components that are manufactured of adhesive, sealant, sealant strip, tape, extrusion with tape, foam, resin, metallic or plastic materials, or combinations of such materials (hereinafter referred to as “Component Materials”). Also advantageous would be the provision of such components that are pre-molded or molded in place, are robotically applied, applied via a snap, wedge or compression fit, are manually applied, comprise extrusions, or comprise any other suitable structure that may serve as a desiccant and/or vapor barrier.
The present invention provides the above and further advantages.
According to the invention, various components are provided for a multipane window unit sash assembly having an integral glazing pane mounting structure. In one embodiment, the mounting structure comprises an interior channel having two interior side walls and an interior bottom wall. The inventive component comprises at least one of a desiccant, vapor barrier or sealant material applied to the two interior side walls and bottom wall.
The component material can, for example, be extruded onto the side and bottom walls of the channel. The side walls terminate at top edges extending from the channel, and the component material can also be applied to the top edges, e.g., to complete a vapor barrier. The material can have both desiccating and vapor barrier properties and can comprise, for example, any of the previously mentioned Component Materials. Moreover, the material can extend from a top edge of a first one of the interior side walls to the bottom wall, across said bottom wall, and continue to a top edge of the second one of the interior side walls. The material can also continue past the top edges onto exterior surfaces of the mounting structure. Further, the component material can be preformed to fit into the interior channel.
The mounting structure can be designed to receive at least one glazing pane. The component can include a projection or “fin” extending therefrom for receiving at least one additional glazing pane. In an illustrated embodiment, the mounting structure is adapted to receive two glazing panes, and the projection is adapted to receive at least a third glazing pane.
In another embodiment of the invention, a glazing pane mount is provided for a multipane window unit sash assembly. The mount comprises a spacer for attachment (e.g., by adhesive or mechanical means) to the sash. The spacer has mounting surfaces for at least two glazing panes. The spacer also includes at least one muntin bar retainer between the mounting surfaces.
The muntin bar retainer can comprise at least one groove in the spacer. The groove can be adapted to accommodate a retaining element for a muntin bar. Alternatively, the groove can be adapted to directly receive an end of the muntin bar or to receive an additional glazing pane.
In an illustrated embodiment, two substantially parallel grooves are provided in the spacer to accommodate a muntin bar retaining element. The retaining element can comprise a clip adapted to snap into the at least one groove. The spacer can comprise, for example, any of the previously mentioned Component Materials, which can be adhesively mounted to the sash.
The mounting surfaces of the spacer can be provided on flanges extending from the spacer. In such an embodiment, each flange in combination with the sash defines a respective channel therebetween for accommodating at least one sealant. The sealant is adapted to adhesively mount the glazing panes in position with respect to the spacer. The sealant can either partially or substantially fill the channel.
A glazing pane mount for a multipane window unit sash assembly is disclosed which comprises a spacer for attachment to the sash. The spacer has mounting surfaces for at least two glazing panes. The mounting surfaces are provided on flanges extending from the spacer and the flanges in combination with the sash define a channel therebetween for accommodating at least one sealant. At least one sealant is adapted to adhesively mount the glazing panes in position with respect to the spacer. Edges of the flanges provide a first seal to the glazing pane, and the sealant provides a second seal to the glazing pane. The spacer can comprise, for example, any of the previously mentioned Component Materials. The spacer can be preformed and can be adapted, e.g., for mechanical attachment (e.g., friction or snap fit) or adhesive attachment to the sash.
Components are also disclosed for a multipane window unit sash assembly having an integral glazing pane mounting structure, wherein the mounting structure comprises at least two upright walls, each connected to a respective transverse top wall portion. The component comprises at least one of a desiccant, vapor barrier or sealant material applied to the two upright walls and top wall portions. The respective transverse top wall portions can be unconnected to each other. Alternatively, the respective transverse top wall portions can be connected together. The material can be extruded onto the upright and top wall portions, and can cover any part of or substantially all exterior surfaces of the upright and top wall portions. In an embodiment where the respective transverse top wall portions are connected to each other, the material may extend all of the way thereacross.
Sealant can be applied to an exterior surface of the component material on each of the upright walls, for use in mounting respective glazing panes to the upright walls via the material. The material can, for example, comprise any of the previously mentioned Component Materials, and can be preformed to fit over the mounting structure.
The mounting structure can be adapted to receive at least one glazing pane via the material adjacent at least one of the upright walls. In addition, the material can have a projection or “fin” extending therefrom for receiving at least one additional glazing pane. In an illustrated embodiment, the mounting structure is adapted to receive two glazing panes, and the projection is adapted to receive at least a third glazing pane.
In an embodiment where the respective transverse top wall portions of the mounting structure are unconnected to each other with a space therebetween, a portion of the component is advantageously adapted to fit into the space. In an illustrated embodiment, a portion of the component is adapted to snap or be pressure fit into the space provided by the unconnected transverse top wall portions of the mounting structure. Also illustrated are embodiments where the inventive components are provided in roll form for application to the mounting structure.
In another illustrated embodiment, components are provided for a multipane window unit sash assembly having an integral glazing pane mounting structure that comprises an upright wall extending from a base portion of the sash assembly. The upright wall has first and second opposed surfaces. The component comprises at least one of a desiccant, vapor barrier or sealant material applied to the base portion adjacent to the first surface of the upright wall. The second surface of the upright wall provides a mounting surface for a first glazing pane. The component provides a mounting surface for a second glazing pane. The material of the component can comprise, e.g., any of the previously mentioned Component Materials. Moreover, the material can be extruded onto the base portion. The component can serve as a spacer to maintain a fixed space between said first and second glazing panes.
Also disclosed is a component in combination with a multipane window sash frame. The sash frame has an integral glazing pane mounting structure, which mounting structure includes a spacer having a defined shape extending from and integral with the sash frame. The spacer has at least two opposing surfaces to which separate glazing panes can be adhesively mounted with the spacer therebetween. The component is preformed from a desiccated material in a shape that is adapted to mate with the defined shape of the spacer, for application to the spacer prior to the mounting of glazing panes thereto.
A component for a multipane window sash is also provided, where the component is a preformed desiccated element. The shape of the preformed element is adapted to mate with a shape of a spacer integral with the sash.
In another embodiment, a component for a multipane window unit sash assembly is provided, where the component is a preformed spacer for attachment to the sash. The spacer has mounting surfaces for at least two glazing panes. The mounting surfaces are provided on flanges extending from the spacer. The flanges in combination with the sash define a channel therebetween for accommodating at least one of a sealant or adhesive.
A method is disclosed for fabricating an integrated multipane sash, in which a length of sash profile has a glazing pane supporting portion with at least first and second glazing pane supporting surfaces. A preformed desiccated component is attached to the supporting surfaces. The length of sash profile is cut into pieces, and a frame is formed from the pieces. A pair of glazing panes is adhesively mounted to the first and second glass supporting surfaces.
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
Referring now to
The component 10 can comprise, for example, a desiccant, a vapor barrier, a sealant, or a combination of these materials. For example, desiccated sealants are known in the art, and can be used in accordance with the present invention to both secure glazing panes (mounted on either side of the component 10) to the sash profile 12 and to absorb moisture in the space between the glazing panes. Such a desiccated sealant may also have vapor barrier properties, so that volatiles and/or other vapors that may be emitted by the sash profile material are prevented from being introduced into the space between the glazing panes, thereby preventing fogging of the interior surfaces of the panes. The glazing panes are typically glass panes, although panes of other materials can be substituted. Such panes can comprise, for example, clear or frosted plastic, such as Plexiglas, tempered glass, safety glass, security glass, privacy glass, or any other known glazing material.
The component 10, which may be of any suitable shape, can be fabricated from, e.g., any of the previously mentioned Component Materials with tape on exterior surfaces thereof to provide adhesive mounting surfaces to mount the component to the sash profile and/or to mount glazing panes to the component. A separate sealant material can be provided instead of or in addition to a tape for adhesively mounting the component to the sash profile and/or to mount glazing panes to the component. Sealant and/or tape can also be provided between the component and the glazing panes in order to implement a dual seal embodiment. Such embodiments are discussed in greater detail below.
The inventive structure is intended to provide, inter alia, a desiccating structure that will adsorb and/or absorb vapor, gases, moisture, chemical volatiles or any other contaminates that may reside, appear, or form within the air space of a multipane window unit and sash assembly, such as, for example, window units and sash assemblies of the type disclosed in the aforementioned '288 patent. The term “window unit” as used herein is not meant to be limited to windows, but is to be interpreted as broadly as possible to include all window type structures such as, e.g., glass doors, skylights, refrigeration units with transparent doors and/or cases, vehicle windows, and the like.
The invention can also provide a barrier or lining that will prohibit vapor, gases, moisture, chemical volatiles or any other contaminates from passing from the structure and/or surface of a multipane window unit and sash assembly into the air space between adjacent glazing panes. The barrier/desiccant/spacer component of the present invention may have numerous shapes as depicted in the Figures and described in greater detail below. The dimensions of thickness, width, and height may also vary as related to the total assembly or its various parts. The barrier/desiccant/spacer component may be manufactured and fabricated (e.g., sized) as a separate member and applied to the sash assembly.
The barrier/desiccant/spacer component may be co-manufactured or processed such as by co-extrusion, co-application, or co-joining as the multipane window unit and sash assembly extrusion/profile/shape is formed, and prior to the assembly, joining, or molding of the sash corner. Moreover, the barrier/desiccant/spacer component may comprise any of the previously mentioned Component Materials. It can be fabricated from pliable or rigid material, or any single, dual, or multiple version thereof in any combination or layering of tape, adhesive, metal, extrusion, spray or other coating or combination required to meet industry test standards. The component of the present invention can comprise any material that effectively prohibits the passage of vapor, gases, moisture, chemical volatiles or any other contaminates that must be isolated from the internal air space between adjacent glazing panes.
The inventive barrier/desiccant/spacer component may be attached to the multipane window unit and sash assembly by adhesive, tape, spray coating, liquid application, co-extrusion, or by mechanical means such as a snap fit, wedge fit, or any other suitable type of joinery that precludes or utilizes chemical bonding, such as with glue. Any of the above application methods may be manual or automated. Additionally, the inventive component may provide one or more mounting surfaces for attaching glazing panes in any one or more of “single seal”, “dual seal” or “tape seal” configurations via, e.g., sealants and/or adhesives used to fasten the glazing panels to the mounting surfaces.
In one embodiment, as illustrated in
The legs (i.e., glass supporting portion, glazing pane supporting portion) 22a and 22b serve as mounting structures for glazing panes (glass lites) 30a, 30b. The glazing panes are mounted to the legs via a sealant or other adhesive 32. Although only one strip of sealant 32 is shown on each leg, it should be appreciated that multiple strips can be provided to provide a dual, triple, or greater seal. The sealant can 32 can be in the form of one or more narrow strips or beads as shown, or can cover the entire external side wall of each leg. The glazing panes can rest on the surface of the sealant, or be partially or substantially fully embedded therein.
In the embodiment of
Flanges 48 on the component 40 define the top of a channel 72 (see
The component 40 further includes parallel channels 46 which are designed to accept a muntin bar retaining clip 42. In this manner, muntin bars 44 can be attached, via clips 42, to the spacer and retained by the spacer in the space between adjacent glazing panes. Although a specific embodiment for the muntin bar retaining clips and corresponding channels in the spacer component 40 are illustrated, it should be appreciated that many other implementations can be substituted without departing from the intended scope of the invention. For example, the muntin bars may be directly wedged, press fit, snapped or adhesively mounted to the spacer component 40 with or without a retaining clip. The spacer component 40 would, of course, be provided with a corresponding receptacle and/or projection to accommodate such a wedge, press or snap fit. Other muntin bar arrangements are also contemplated through the use of a suitably designed spacer component and corresponding muntin bar structure.
It is noted that a similar channel, like channels 46, could instead be provided to hold a third glazing pane therein. Components are also envisioned where such channels are provided for all of the glazing panes, or at least some of the panes.
The components 50, 52 and 54 illustrated in
The component 85 of
Sealant 106 can comprise a single bead of sealant as shown, a wide strip of sealant that covers substantially the entire outer surface of the respective leg 22a or 22b, or a plurality of sealant strips (which can each comprise the same or a different sealant). It will be appreciated by those skilled in the art that when the glazing panes are pressed toward the respective mounting surfaces of legs 22a, 22b, the sealant 106 will flatten and spread (e.g., whet out). It is envisioned that the sealant may spread to the point that it fills part or all of the gap 108 between the edge of the glazing pane and the surface 110 of the sash profile 18. In such an instance, the perimeter edge of the glazing pane will be partially or fully embedded in the sealant 106.
Additional component embodiments 111, 113, 114, 115, 116, 117, 118, 119 are illustrated in
As with the other embodiments disclosed herein, the desiccant and/or vapor barrier components 111, 113, 114, 115, 116, 117, 118, and 119 of
Component 122 provides an alternative structure that can be adhesively mounted to spacing and mounting structure 124 by chemical adhesive, tape, sealant, or other suitable adhesive material. The remaining elements illustrated in
The second surface 143 of the upright wall 140 provides a mounting surface for a first glazing pane 30b, e.g., via sealant or other adhesive 144b. The component 142 provides a mounting surface for a second glazing pane 30a, e.g., via sealant or other adhesive 144a.
It is noted that sealant or other adhesive 144a is optional in the event that component 142 itself has adhesive properties for use in mounting glazing pane 30a. Moreover, a layer of adhesive may be used to mount component 142 to the sash assembly 146. Such a layer of adhesive could be placed between component 142 and surface 141 of upright wall 140, between component 142 and the base portion 147 of the sash profile, or both.
The embodiment of
Although snap-in blocks 150 are illustrated in
The component 160 of
It should now be appreciated that the present invention provides advantageous components for use in the manufacture of multipane window units, including such units manufactured from a sash assembly with an integral glazing pane mounting structure. The components of the present invention can provide desiccant, vapor barrier and/or sealant properties.
Although the invention has been described in connection with various particular embodiments, it should be appreciated that many adaptations and modifications may be made thereto without departing from the scope of the invention, as set forth in the claims. For example, various features of one disclosed embodiment can be used and/or substituted for features of the other embodiments.
This application is a continuation of U.S. patent application Ser. No. 10/285,343 filed on Oct. 30, 2002, which claims the benefit of U.S. provisional application No. 60/338,920, filed Nov. 5, 2001, the entire contents of which is hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60338920 | Nov 2001 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10285343 | Oct 2002 | US |
| Child | 11447390 | Jun 2006 | US |
