This invention relates to multi-pane windows and doors, and particularly to mounting clips used to support internally contained decorative members to achieve a multi-pane window effect.
Technological advances in the 11th century AD permitted some of the first glass sheets to be produced, with constant improvement made ever since, including an early 1900s sheet glass drawing machine, which made the mass production of windows possible. Perhaps one of the most notable of recent advances was the development of double pane windows. Single-pane window construction suffered significant thermal losses derived by cold air blowing across the window exterior to create an unhindered heat sink, resulting in windows fogging or frosting, as well as being uncomfortably cold upon contact. Double-pane window construction significantly reduced thermal loss by incorporating a thin layer of trapped air, which is an extraordinarily good insulator when not allowed to convect or otherwise conduct heat away from an object.
A by-product of the double-pane construction method is the ability to utilize the unexposed glass faces, which will never experience ordinary wear from physical contact, for coatings or filters. In addition, the gap itself can serve other uses, most common of which is to accommodate decorative inserts.
Modern styled homes and commercial buildings commonly utilize long uninterrupted sheets of glass, however, many if not most residences and apartment buildings incorporate a multi-pane window or multi-pane door look to achieve a French or colonial style appearance. With single panel construction, this necessitated that either multiple glass panes were in fact utilized, or a faux multi-pane look could be accomplished by attaching a decorative lattice to the interior side of the window or door. This latter approach is still commonly used by window manufacturers, some of whom offer interchangeable grilles that allow purchasers to alternate between various window appearances.
However, double-pane window construction permitted the introduction of the decorative lattice to the air gap between the panes. The vertical and horizontal elements that formed such a lattice on true multi-paned windows were termed muntin bars, and this terminology has similarly been carried over in referring to the vertical and horizontal members trapped within the air gap of double-pane windows and doors.
In constructing multi-paned windows, the window panes are typically separated by insulating material that is wrapped about a hallowed, metallic, frame having a rectangular cross-section. To simplify the manufacturing process and incorporate the decorative inserts, various mounting schemes have been utilized, and often do not use mechanical fasters, but rather involve a clip that is inserted into the metallic frame and serve as a mounting post over which each end of the hallow muntin bar is inserted. This mounting clip is aptly termed a muntin clip. Although existing versions of these clips serve to expedite and simplify construction of multi-paned glass windows, the most functional of these clips exhibits some deficiencies which are addressed by the current invention.
On illustrative example of the prior art can be found in U.S. Pat. No. 5,678,377. The design of the muntin clip is a plastic part composed of a flat base or “body,” and an orthogonal support member called a base flange. Protruding from that same side of the body is a longer slender “central spine” from which extends, at an angle, “bar retaining fingers.” The bar retaining fingers are intended to initially capture and thereafter positionally support the muntin bar. The combination of the finger's length and angular orientation permit the muntin bar to contact the first pair of fingers and depress them to further increase its angular position with respect to the spine, and in so doing, provide pre-load which maintains contact between the bar retaining fingers with the muntin bar. Although functional as to maintaining contact with the muntin bar, the configuration of the clip assembly requires concerted effort to align the end of the muntin bar with the oversized bar retaining finger which has a width before installation slightly greater that the internal dimension of the muntin bar. This is one drawback which is addressed in the current disclosure.
Protruding from the side of the body opposite the base flange, spine, and bar retaining fingers, are a pair of slender hooks referred to as “latching fingers” which are intended to positively retain the clip in contact with the frame, and, therefore, also maintain the position of the muntin bar. However, these fingers are designed with sufficient length to provide flexibility to deflect on installation and then spring back to be captured by a flange of the frame. However, that same flexibility is disadvantageous for retention of the clip in the frame, while trying to install the opposing end of the muntin bar into its respective clip. This drawback of the prior art, along with several other improvements are addressed by the current invention.
The present invention is intended to be used in conjunction with double-pane windows to provide support for muntin bars located between the panes in order to create a multi-pane look. A metallic frame with generally a C-shaped cross-section, in conjunction with insulating material, is used to provide separation between the window panes. The opening of the C-shaped frame is oriented to face the interior of the window. i.e., the area between the panes. At predetermined intervals along the frame, are pairs of notches in the edges of both sides of the “C”. The respective pair of notches at a frame location additionally appear in the frame directly on the opposite side of the window. The notch locations correspond to the desired placement of a muntin bar. To provide the appearance, for example, that a window is composed of 6 individual panes of glass, would necessitate that one muntin bar run in either the vertical or horizontal direction, and two muntin bars run in the direction perpendicular to the first muntin bar. This 6-pane appearance results in the need for 6 sets of notches, with each set of notches corresponding to one end of each of the muntin bars. Muntin bar attachment is accomplished through use of a muntin clip. The muntin clip of the disclosed invention is configured to attach, without mechanical fasteners, to the C-section frame. Unlike the prior art, this disclosure does not utilize the slender “latching” fingers, but instead uses a rigid overhanging hook to positively attach the clip to the frame. To accommodate installation of the clip, the disclosed invention utilizes a split body and double spine arrangement that permits in-plane deflection of the base which draws the hook back from the lip of the C-section. Once released, both base sections spring back to their natural positions. Orienting the hooks to face in opposite directions prevents inadvertent dislodging of the clip due to pressure upon one side, as that naturally causes increased pressure and contact of the opposite hook with the frame, and consequently retention.
The smaller restrict tab provides for restricting motion of the clip, and therefore naturally the bar itself, along the length of the frame. It is a small preferably rigid plastic piece extending downwardly from the underside of each base section. It is typically situated near or adjacent to the hook pieces, but may be anywhere in relation to the hook on the underside of the base section. Although in a preferred embodiment, the smaller tab will be an entirely separate piece, in an alternative embodiment, the tab and the hook may be connected by a small plastic perpendicular piece, further strengthening the grip that the clip has on the window frame.
As illustrated by
The clip 1 may have at least one intermediate plate 3, preferably two, a set of fasteners 11, also preferably two, that are projected from the bottom surface 32 of each intermediate plate 3, a bar plug 9 that extends outwardly from the top surface 33 of each intermediate plate 3, at least one tab, preferably two, 5 and 6 projecting from the bottom surface 32 of each intermediate plate (giving at least two tabs overall on the clip), and one or more sets of lateral ribs 34 projecting from the side surface 27 of the bar plug 9 and inclined toward the nearest intermediate plate 3. In the preferred embodiment of the present invention, though, as illustrated by Figures 1-10, the clip 1 has two intermediate plates 3, each with a fastener 11 projecting from its bottom surface 32, a bar plug 9, one larger outer tab 5 projecting from the bottom surface 32 of each intermediate plate, one smaller inner tab 6 projecting from another point on each intermediate plate, and two pairs of lateral ribs 34 projecting from the side surface 27 of the bar plug 9, each pair inclined toward the nearest intermediate plate 3. The outer tab 5 is optionally present.
As seen in
In the preferred embodiment, the clip 1 of the present invention utilizes two separate intermediate plates 3, which are connected to the bar plug 9 by a pair of leg-like members 4, as shown in
It should be noted that the tabs 5 and 6 of the clip 1 may be generally any shape or size and may even be identical in size and shape. Moreover, tabs 5 and 6 may be situated anywhere along the bottom surface of the intermediate plate 3. In light of this, the following paragraph details the preferred embodiment of the present invention as illustrated by
For aesthetic purposes, the distance between the edges 8 of each intermediate plate 3 preferably would not exceed the width of the spacer 10, because in such embodiment, when the clip 1 is positioned on the spacer 10, the edges 8 of each intermediate plate 3 would not extend over the spacer 10. Thus, if the muntin bar has the same width as spacer 10 which is very common for insulating glass units, once the muntin bar is positioned on the clip 1, the edges 8 of each intermediate plate 3 would be coincident with the width of the spacer and thus, the clip would be completely hidden from view.
Lateral restrict inner tabs 6 of the clip may be embedded into the notches 14 made in the spacer 10, thus preventing movement of the clip 1 along spacer 10. Outer tabs 5, on the other hand, would provide the alignment along the spacer 10. The extending fasteners 11 may provide fixed positioning of the clip 1 on the spacer 10. It will be shown that the tips 17 of the fasteners 11 may extend beyond edges 19 of the flanges 35 spacer 10 underneath of such edges, securing flanges 35 between tips 17 and bottom surface 32 of each intermediate plate 3 thus providing outward fixed positioning of the clip 1 relative to the spacer 10.
The fasteners 11 may be embodied as relatively narrow strips of preferably rigid plastic material that extend outwardly from the bottom surface 32 of each intermediate plate 3. At some point, initially generally perpendicular to the bottom surface 32 of the plate 3, the direction of the fastener 11 may be changed approximately at the middle of its entire length and at approximately 90 degrees forming the tip 17 that secures the intermediate plate 3 of the clip 1 of the flanges 35 of the spacer 10. It will be shown that such shape of the fastener may provide better support of such fastener when it is positioned upon the spacer 10.
As illustrated in
While the body 16 of each fastener 11 is firmly attached to the bottom surface 32 of each intermediate plate 3, the tip 17 of the fastener should be preferably suspended. The tip 17 of the suspended arm 18 of the fasteners 11, may be configured in any shape, but, in the preferred embodiment, it is generally in the shape of a right triangle and preferably tapered outwardly from the intermediate plate 3 in such manner that the tip's 17 thickness gradually increases from the lower edge 25 of the tip 17 toward the upper edge 26 of the tip 17. The fasteners 11 may be configured in such way that the distance between the lower edges 26 of both tips of fasteners 11 is approximately equal to or less than the width of the gap between the edges 19 of the flanges 35 of the spacer 10 and the distance between upper edges 25 of the tips 17 of the fasteners 11 is slightly larger than the width of the gap between the edges 19 of the spacer 10. In such configuration, when the clip 1 is pushed toward the spacer 10, the fasteners 11 would enter the gap between edges 19 of flanges 35 of the spacer 10. Also, it is preferred that there be a space provided between the upper edge 26 of the tip 17 of the fastener 11 and the bottom surface 32 of the intermediate plates 3 of the clip 1 and the width of such space is preferably equal or slightly larger then the thickness of the flanges 35 of the spacer 10. It would allow the tips 17 of the fasteners 11, as they passed through the opening between edges 19 of the flanges 35 of the spacer, to catch the top surface 13 of the flanges 35 of the spacer 10. At this point, the upper edges 25 of the tips 17 would bear against the top surface 13 of the flanges 35 of the space frame provider 11 trapping the flanges 35 between the upper edges 25 of the tips 17 and the bottom surface 32 of the intermediate plates 3 of the clip 1 and as result, fixedly positioning the clip 1 on the spacer 10.
While one end 12 of the fastener 11 is firmly attached in generally perpendicular direction to the bottom surface 32 of the intermediate plate 3, the tip 17 of the fastener may be suspended in order to catch the edge 19 of the spacer 10. While the fasteners 11 may be flexible, in the preferred embodiment, they are constructed of a rigid plastic material that provides support when pressure is placed on the clip in an outward direction and is not bendable. This is because, in the preferred embodiment, the plates 3 have a flexible connection to legs 4 necessary to facilitate installation or removal of the clip of the present invention. Thus, by making the leg-plate connection a flexible one, the need for a flexible fastener is eliminated. The positioning of clip 1 upon the spacer 10 is generally conducted in the following way in the preferred embodiment: At the moment of insertion of the clip 1 into spacer 10, the tip 17 of fastener 11 is slightly depressed by the flange 35 of spacer 10 at one side of the intermediate plate 3; the plate 3 is then flexibly twisted around the axis of leg 4 in rotational direction C, as
The bar plug 9 is preferably a flat rectangular or square plate-like member that may have at least one upper cross-member 22, a central rib 23, with at least two sets of lateral ribs 34, and, preferably, at its bottom, a split spine 29, ending in at least one lower cross member 21. In the preferred embodiment, the central rib 23 extends between the upper cross member 22 and the split spine 29. Although, only one lower cross member 21 may be utilized in the present bar plug, in the preferred embodiment illustrated by
The lateral edges 24 of the upper cross member 22 are tapered away from the intermediate plates 3 for easier positioning of the muntin bar upon the clip 1. Because this embodiment facilitates insertion of the bar plug 9 into the end of the hollow muntin bar, the width of the cross members 21 and 22 be preferably approximately equal to the width of the cross-section of the muntin bar in order for the side edges of the cross members 21 and 22 to bear against the inside surfaces of the walls of the muntin bars to hold the bar plug 9 firmly inside the muntin bar. Moreover, when the bar plug 9 is inserted into the open end of the muntin bar, the lateral ribs frictionally engage the top surface of the walls of the muntin bar and secure it to the clip 1.
In an alternate embodiment, as illustrated by
The clip 1 of the embodiment illustrated by
Although only certain embodiments of this invention has been in details described above, those skilled in the art will readily appreciate that many modifications of the exemplary embodiment are possible without materially departing from the novel teachings and advantages of this invention. All such variations and modifications intended to be included within the scope if this invention as defined in the claims.
Other modifications, substitutions, omissions and changes may be made in the design, size, materials used or pro portions, operating conditions, arrangement or positioning of elements and members of the preferred embodiment without departing from the spirit of this invention as described in the claims.