Patent Application
20090056265
1.) Field of the Invention
This invention relates to muntin grids for transparencies and to transparencies having muntin grids, and more particularly, to a grid simulating muntins having shaped ends to engage spacer frame between glass sheets of a multi-sheet unit to mount the grid within the spacer frame and between the glass sheets.
2.) Discussion of the Available Technology
Clips usually referred to as “muntin clips” are used to mount grids simulating muntins between adjacent sheets of a multi-sheet insulating unit, for example, as discussed in U.S. Pat. Nos. 5,313,761 and 6,115,989; United States Patent Publication Numbers US2004/0123557 and US2005/0028458A1 and in U.S. patent application Ser. No. ______ filed Aug. 30, 2007 in the names of Barent Rosskamp, Michael Buchanan, Stephen Crandell, William Davis and Cory Steffek and titled Retainer Clip for Grid Simulating Muntins (hereinafter also referred to as “U.S. Pat. No. ______”). In general, but not liming to the discussion, a multi-sheet insulating unit includes a glass sheet secured to each side of a spacer frame by a moisture and gas impervious adhesive-sealant to provide a sealed compartment between the sheets. The sealed compartment is usually filled with an insulating gas. The spacer frame in one embodiment of a multi-sheet insulating unit has a U-shaped cross section, e.g. as disclosed in U.S. Pat. No. 5,655,282. One of the features of the spacer frame having a U-shaped cross section is that the upright legs of the spacer frame are free to move toward and away from one another in unison with the glass sheets as the insulating gas in the compartment between the sheets expands and contracts due to pressure changes acting on the outer surfaces of the sheets.
The current practices of mounting a grid simulating muntins within the spacer frame, includes mounting the muntin clips on the ends of the grid, and mounting the clips on the interior surface of the spacer frame, or mounting the muntin clips on the interior surface of the spacer frame followed by mounting the ends of the grid on the muntin clips. United States Patent Application Publication Number US 2004/0123557 discloses a number of muntin clip designs. Although the present design of the muntin clips is acceptable for mounting grids simulating muntins between sheets of insulating units, there are drawbacks and/or limitations.
More particularly, many of the present muntin clips designs include a rigid base that bridges the two upright legs of the spacer frame maintaining the upright legs in a fixed relationship to one another. The drawback with this muntin clip design is that the muntin clip prevents portions of the upright legs and marginal edges of the sheets from moving toward one another as the pressure acting on the outside surface of the sheets increases. Another drawback with muntin clips having a rigid base is that during the pressing of the marginal edges of the sheets toward the outer surfaces of the space frame to flow the adhesive-sealant between the sheets and the spacer frame, the upright legs between adjacent muntin clips are flexible and move toward one another whereas the muntin clip is not flexible and prevents the upright legs at the position of the muntin clip from moving toward one another. The undesirable result is that the adhesive-sealant between adjacent muntin clips is thicker than the thickness of the adhesive-sealant at the position of the muntin clips. This drawback results in a “moisture sealant path” or “diffusion path” having a non-uniform thickness and can result in premature failure of the seal by allowing atmospheric air to diffuse into the sealed compartment. For a detailed discussion of the “diffusion path,” reference can be made to column 13, lines 7-43 of U.S. Pat. No. 5,655,282 which patent is hereby incorporated by reference.
Another limitation with having the base of the muntin clip supported on and spanning the upright legs of the spacer frame is that the muntin clip is in the sight line of the insulating unit. Therefore, care has to be taken to make certain that the ends of the grid simulating muntins is flush with the base to avoid any space, or minimize the space, between the ends of the grid and the base of the muntin clip. Noticeable separations between the base of the clip and the end of the grid are aesthetically unacceptable.
U.S. Pat. No. ______ discloses a muntin clip that eliminates the above drawbacks. More particularly, the muntin clip of U.S. Pat. No. ______ has a spacer-engaging member having bendable walls that are positioned between the upright legs of the spacer frame with the end of the grid simulating muntins below the sight line of the unit. Although the muntin clip of U.S. Pat. No. ______ eliminates the above discussed drawbacks, the muntin clips of U.S. Pat. No. ______ have limitations. More particularly, muntin clips are required to secure the grid within the spacer frame. As is appreciated by those skilled in the art, the open ends of the horizontal and vertical members of the grids simulating muntins have different dimensions requiring an inventory of different size muntin clips for the different size end openings of the horizontal and vertical members.
As is appreciated by those skilled in the art, it would be advantages to provide a grid simulating muntins that does not require the use muntin clips and provides the benefits of the muntin clips of U.S. Pat. No. ______.
This invention relates to a grid simulating muntins of the type having a first plurality of spaced elongated members connected to a second plurality of elongated members, wherein one of the elongated members of the first plurality of elongated members. In one non-limiting embodiment of the invention, the grid simulating muntins includes a first side having an outer surface; a second side opposite the first side, the second side having an outer surface facing away from the outer surface of the first side; a first end, and an opposite second end. The first and second sides at the first end each have an end part, wherein the end part of the first side is angled toward the outer surface of the first side and the end part of the second side is angled toward the outer surface of the second side, and ends of the end parts of the first and second sides at the first end of the one of the elongated members are each shaped to have a ledge.
The invention further relates to a multi-sheet unit having the grid of the invention simulating muntins. In one on-limiting embodiment of the invention, the multi-sheet unit includes a spacer frame having a base, a pair of legs extending from the base toward interior of the spacer frame, and an interior side facing interior of the spacer frame; a pair of sheets, wherein the spacer frame is between the sheets and the sheets are mounted on outer surface of the pair of legs. The grid simulating muntins is in the interior of the spacer frame between the sheets, the grid includes a first plurality of spaced elongated members, and a second plurality of spaced elongated members. Each of the first plurality of elongated members and each of second plurality of elongated members includes a first side having an outer surface; a second side opposite the first side, the second side having an outer surface; a first end, and an opposite second end, the first and second sides at the first end each have an end part, wherein the end part of the first side and the end part of the second side are each angled toward the second end, the outer surface of the first side on the end part of the first side in facing relationship to the outer surface of the second side on the end part of the second side, and the ends of the end parts of the first and second sides at the first end are each shaped to have a ledge, and the first side and the second side at the second end each have an end part, wherein the end part of the first side and the end part of the second side at the second end are each angled toward the first end, the outer surface of the first side on the end part of the first side at the second end in facing relationship to the outer surface of the second side on the end part of the second side at the second end, and the ends of the end parts of first and second sides at the second end are each shaped to have a ledge.
The ledge of the end part of the first side and the ledge of the end part of the second side at the first end of each of the first plurality of elongated members engages a first length of the interior side of the spacer frame, and the portion of the end part of the first side and of the second side at the first end of the first plurality of elongated members is between the interior side and inner surface of the base of the spacer frame; the ledge of the end part of the first side and the ledge of the end part of the second side at the second end of each of the first plurality of elongated members engages a second length of the interior side of the spacer frame, the second length opposite to the first length, and the portion of the end part of the first side and of the second side at the second end of the first plurality of elongated members is between the interior side and the inner surface of the base of the spacer frame; the ledge of the end part of the first side and the ledge of the end part of the second side at the first end of each of the second plurality of the elongated members engages a third length of the interior side of the spacer frame, and the portion of the end part of the first side and of the second side at the first end of the second plurality of elongated members is between the interior side and the inner surface of the base of the spacer frame, and the ledge of the end part of the first side and the ledge of the end part of the second side at the second end of each of the second plurality of elongated members engages a fourth length of the interior side of the spacer frame, the fourth length opposite the third length, and the portion of the end part of the first side and of the second side at the second end of the second plurality of elongated members is between the interior side and the inner surface of the base of the spacer frame.
The invention still further relates to a method of making a grid simulating muntins. In a non-limiting embodiment of the invention the method includes providing a first plurality of elongated members and a second plurality of elongated members, each of the elongated members having a first side, a second side, a third side and a fourth side with the first side and the second side opposite to one another, the third side opposite to the fourth side opposite to one another and between the first and second sides, a first end and an opposite second end; removing a portion of the third side and the fourth side at the first end of one of the plurality of elongated members defined as a first elongated member to provide the first side with an end part and the second side with an end part at the first end of the first elongated member; bending the end part of the first side at the first end toward the second end of the first elongated member, and bending the end part of the second side at the first end toward the second end of the first elongated member; shaping free end of the end part of the first side to form a ledge and free end part of the second side to form a ledge, and joining the first and second plurality of elongated members to form the grid simulating muntins.
As used herein, spatial or directional terms, such as “inner”, “outer”, “left”, “right”, “up”, “down”, “horizontal”, “vertical”, and the like, relate to the invention as it is shown in the drawing figures. However, it is to be understood that the invention can assume various alternative orientations and, accordingly, such terms are not to be considered as limiting. Further, all numbers expressing dimensions, physical characteristics, and so forth, used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical values set forth in the following specification and claims can vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a stated range of “1 to 10” should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more and ending with a maximum value of 10 or less, e.g., 1 to 6.7, or 3.2 to 8.1, or 5.5 to 10. Also, as used herein, the terms “mounted over”, “positioned over”, or “provided over” mean mounted, positioned, or provided on but not necessarily in surface contact with. For example, one article “provided over” another article does not preclude the presence of materials between the articles.
Before discussing non-limiting embodiments of the invention, it is understood that the invention is not limited in its application to the details of the particular non-limiting embodiments shown and discussed herein since the invention is capable of other embodiments. Further, the terminology used herein to discuss the invention is for the purpose of description and is not of limitation. Still further, unless indicated otherwise, in the following discussion like numbers refer to like elements.
In general, the non-limiting embodiments of the invention include, but are not limited to, securing grids simulating muntins between sheets, e.g. adjacent sheets, of multi-sheet units without the use of muntin clips by shaping the ends of the horizontal and vertical members of the grid in accordance to the teachings of the invention. The term “multi-sheet unit” is usually used to mean a unit having two or more sheets in spaced relationship to one another, and the term “multi-sheet insulating unit” is usually used to mean a unit having two or more sheets in spaced relationship to one another and a compartment or space between adjacent sheets in which there is an insulating gas and preferably no or limited ingress or egress of gas into and/or out of the compartment, usually referred to as a “sealed compartment.” In the following discussion, the term “multi-sheet unit”, unless indicated otherwise, is used to mean a “multi-sheet unit” and a “multi-sheet insulating unit.”
As can be appreciated, the practice of the invention is not limited to a multi-sheet unit and can be practiced on a transparency having only one sheet, with the one sheet secured to one side of a spacer frame; no sheet secured to the opposite side of the spacer frame, and the grid of the invention simulating muntins mounted within the spacer frame.
The invention is not limited to the material of the sheets 22 and 24 of the multi-sheet unit 20 of the invention, and the sheets can be made of any transparent material, e.g. glass, plastic and combinations thereof, and the selection of the material of the sheets is not limiting to the invention. Still further, the two or more sheets of the multi-sheet unit can be made of the same material or the sheets can be made of different materials. In addition, one sheet can be a monolithic sheet, and the other sheet can be a laminate, e.g. a transparency made of one or more monolithic sheets laminated together in any usual manner. One or both of the glass sheets of the unit can be uncoated and/or coated, and/or one or both of the sheets can be colored and/or clear sheets. For example and not limiting to the invention, the colored sheets can be of the type disclosed in U.S. Pat. Nos. 4,873,206; 4,792,536; 5,030,593 and 5,240,886, which disclosures are hereby incorporated by reference. Further, one or more of the surfaces of one or more of the sheets can have a coating to selectively pass predetermined wavelength ranges of light and energy, or one of the sheets can be opaque, e.g. made of an opaque material, e.g. metal, or can be transparent sheets having an opaque coating of the type used in making spandrels. Coatings of the type that can be used in the practice of the invention include but are not limited to the types disclosed in U.S. Pat. Nos. 4,170,460; 4,239,816; 4,462,884; 4,610,711; 4,692,389; 4,719,127; 4,806,220; 4,853,256 and 4,898,789, which disclosures are hereby incorporated by reference. Still further, in the practice of the non-limiting embodiments of the invention, one or more of the surfaces of the sheets can have a photocatalytic film or water reducing film, e.g. of the type disclosed in U.S. Pat. Nos. 5,873,203; 6,027,766, and 6,027,766, which disclosures are hereby incorporated by reference. It is contemplated that the photocatalytic film and/or the water reducing film can be applied or deposited on the outer surface of one or both of the sheets 22 and 24 of the multi-sheet unit 20.
The glass sheets 22 and 24 preferably have the same peripheral configuration and dimensions; however, as can be appreciated, one outer glass sheet can be larger than the other outer glass sheet. Further, the outer sheets 22 and 24 can have different peripheral configurations.
With continued reference to
A layer 48 of an adhesive, sealant or adhesive-sealant can be provided on outer surface 50 of the base 42 of the spacer frame 26. Preferably the outer surface 50 of the base 42 is recessed inwardly from the peripheral edges 52 of the outer sheets 22 and 24 as viewed in
The spacer frame 26 can be made of any material e.g., wood, plastic, metal coated plastic, metal (e.g., stainless steel, galvanized steel or tin coated steel), aluminum and combinations thereof. Types of spacer frames and spacer stock that can be used in the practice of the invention, but not limited thereto are disclosed in U.S. Pat. Nos. 5,177,916, and 5,655,282 and U.S. patent application Ser. No. 11/696,377 filed Apr. 4, 2007.
Although the invention is not limited to the design or construction of the spacer frame 26, in a preferred non-limiting embodiment of the invention, the spacer frame is an endless or close ended (“closed”) spacer frame having an interior opening as shown by dotted lines 55 in
As can be appreciated, the invention is not limited to a spacer frame made from a continuous strip or piece of spacer stock, and the spacer frame can be made from spacer sections joined together by corner keys or welding, e.g., as disclosed in U.S. patent application Ser. No. 11/696,377. Still further, the invention is not limited to the cross sectional shape of the spacer frame, and the spacer frame can have any cross sectional shape, e.g. and not limiting to the invention, the spacer frame can have a quadrilateral cross sectional shape as shown in
With continued reference to
With continued reference to
The vertical and the horizontal members 70 and 72, respectively, have shaped ends 74 (see FIGS. 3 and 6-9) that engage the extensions 43 and 44 of the spacer frame in a manner discussed below to position the grid 39 simulating muntins within the spacer frame 26, between the sheets 22 and 24, in the compartment 36. With reference to
The discussion of the invention is directed to the vertical elongated member 70 of the grid 39 with the understanding that the discussion is applicable to the horizontal elongated member 72 unless indicated otherwise. With reference to
In one non-limiting embodiment of the invention, each shaped end 74 of the vertical and horizontal elongated members 70 and 72, respectively, is shaped to engage the extensions 43 and 44 (see
With reference to
With reference to
The invention is not limited to the manner in which the end segments 190 and 196 of the major sides 186 and 188, respectively of the elongated vertical and horizontal members 70 and 72, respectively, are shaped and any shaping or forming technique can be used in the practice of the invention. With reference to
A length of an elongated member greater than the spaced distance between opposed sides of the spacer frame 26 is cut. The length is sufficient to provide the ends 74 with the V-shaped members 192 and 198 (see
The elongated vertical and horizontal members 70 and 72 of the grid 39 are joined together in any usual manner, and the shaped ends 74 of the elongated vertical and horizontal members 70 and 72, respectively of the grid 39 are mounted between the outer legs 40 and 41 of the spacer frame 26 as discussed above. The elongated vertical and horizontal members 70 and 72 of the grid 39 are hollow and flexible and are easily flexed to pass the shaped ends 74 of the members 70 and 72 between the extensions 43 and 44 of the spacer frame 26 to mount the grid 39 within the spacer frame 26. More particularly, and as is appreciated by those skilled in the art, the grid 39, the outer legs 40 and 41 of the spacer frame 28, and the sides of the spacer frame are flexible so that the grid 39 can be mounted within the closed ended spacer frame as discussed above; however, in those instances when the grid 39 and the spacer frame 26 do not provide sufficient flexibility, a corner of the spacer frame 26 can be left open, and after the grid is mounted within the spacer frame, the open end closed.
The above discussion presented several embodiments of the invention, however, the scope of the invention is not limited thereto, and the scope of the invention is only limited by the scope of the following claims.
