SEALED UNIT AND SPACER WITH STABILIZED ELONGATE STRIP

BACKGROUND

Windows often include two facing sheets of glass separated by an air space. The air space reduces heat transfer through the window to insulate the interior of a building to which it is attached from external temperature variations. As a result, the energy efficiency of the building is improved, and a more even temperature distribution is achieved within the building. A rigid pre-formed spacer is typically used to maintain the space between the two facing sheets of glass.

SUMMARY

In general terms, this disclosure is directed to a sealed unit and a spacer. In one possible configuration and by non-limiting example, a sealed unit includes a first sheet, a second sheet, and a spacer arranged between the first sheet and the second sheet. The spacer includes an elongate strip and two sets of stabilizers. The first set of stabilizers is arranged along a first edge of the elongate strip and the second set of stabilizers is arranged along a second edge of the elongate strip.

One aspect is a spacer comprising: an elongate strip having a first longitudinal edge and a second longitudinal edge and defining a plane extending between at least portions of the first and second longitudinal edges; and a first stabilizer connected to the elongate strip adjacent the first longitudinal edge, the first stabilizer having a first surface arranged substantially perpendicular to the plane, the first surface adapted to support the elongate strip against a first sheet of material.

Another aspect is a method of making a spacer, the method comprising: forming an undulating shape in a first elongate strip, the undulating shape having a regular and repeating pattern, wherein the first elongate strip has a first longitudinal edge and a second longitudinal edge; and forming a first stabilizer on the elongate strip adjacent the first longitudinal edge.

Yet another aspect is a sealed unit comprising: a first sheet having a first surface; a second sheet having a second surface; a spacer arranged between the first and second sheets to maintain a gap between the first and second sheets, the spacer comprising: an elongate strip having a first edge and a second edge; a first stabilizer connected to the elongate strip adjacent the first edge of the elongate strip, the first stabilizer including a first sealant trough; and a second stabilizer connected to the elongate strip adjacent the second edge of the elongate strip, the first stabilizer including a second sealant trough; a first sealant bead arranged in the first sealant trough and connecting the spacer to the first sheet; and a second sealant bead arranged in the second sealant trough and connecting the spacer to the second sheet.

There is no requirement that an arrangement include all of the features characterized herein to obtain some advantage according to the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic front view of an example window assembly including a windows spacer according to the present disclosure.

FIG. 2 is a perspective view of a portion of the window assembly shown in FIG.

FIG. 3 is a top view of a portion of the window assembly shown in FIG. 1.

FIG. 4 is a cross-sectional view of a portion of the window assembly shown in FIGS. 1-3.

FIG. 5 is a schematic front view of an example embodiment of an elongate strip according to the present disclosure.

FIG. 6 is a perspective view of a portion of the spacer shown in FIG. 1.

FIG. 7 is a top view of the portion of the spacer shown in FIG. 6.

FIG. 8 is a front view of the portion of the spacer shown in FIG. 6.

FIG. 9 is a cross-sectional view of the portion of the spacer shown in FIG. 6.

FIG. 10 is a cross-sectional view of another embodiment of a window spacer according to the present disclosure including sealant and desiccant.

FIG. 11 is a perspective view of a portion of the spacer shown in FIG. 10.

FIG. 12 is a front view of another example embodiment of a spacer according to the present disclosure arranged in a corner configuration and including a standard stabilizer configuration.

FIG. 13 is perspective view of the portion of the spacer shown in FIG. 12 including a modified stabilizer configuration.

FIG. 14 is a front view of the portion of the spacer shown in FIG. 13.

FIG. 15 is a perspective view of a portion of another example embodiment of a spacer according to the present disclosure.

FIG. 16 is a top view of the portion of the spacer shown in FIG. 15.

FIG. 17 is a cross-sectional view of the spacer shown in FIG. 15.

FIG. 18 is a perspective view of a portion of another example embodiment of a spacer according to the present disclosure in an unbent configuration and including notches.

FIG. 19 is a bottom view of the portion of the spacer shown in FIG. 18.

FIG. 20 is a top view of the portion of the spacer shown in FIG. 18.

FIG. 21 is a front view of the portion of the spacer shown in FIG. 18.

FIG. 22 is a front perspective view of the portion of the spacer shown in FIG. 18 and arranged in a corner configuration.

FIG. 23 is a front view of the portion the spacer shown in FIG. 22.

FIG. 24 is a cross-sectional view of another example embodiment of a window assembly according to the present disclosure.

FIG. 25 is a perspective view of a portion of another example spacer according to the present disclosure and further including an example muntin bar.

DETAILED DESCRIPTION

Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.

Although some of the examples discussed herein are directed to a window assembly and a window spacer, such embodiments can alternatively be used in any of various types of sealed units to form yet other embodiments according to the present disclosure. A sealed unit typically includes at least two sheets of material separated by a spacer, where the spacer provides a gap between the two sheets of material.

FIG. 1 is a schematic front view of example window assembly 100 according to the present disclosure. In some embodiments, window assembly 100 includes sheet 102, sheet 104, and spacer 106. Sheets 102 and 104 are made of a material that allows at least some light to pass through. Typically, sheets 102 and 104 are made of a transparent material, such as glass, plastic, or other suitable materials. Alternatively, a translucent or semi-transparent material is used, such as etched, stained, or tinted glass or plastic.

Ends of spacer 106 can be connected together with one or more fasteners to form a closed loop in some embodiments. Spacer 106 and sheets 102 and 104 together define an interior space 120 of window assembly 100. Interior space 120 reduces heat transfer through window assembly 100.

A gas is typically sealed within interior space 120. In some embodiments, the gas is air. Other embodiments include oxygen, carbon dioxide, nitrogen, or other gases. Yet other embodiments include an inert gas, such as helium, neon or a noble gas such as krypton, argon, and the like. Combinations of these or other gases are used in other embodiments.

In some embodiments, spacer 106 is flexible and can be bent to form corner configurations such as described herein. An example embodiment of a corner is corner 122. Example embodiments of corner 122 will be discussed in further detail below in FIGS. 12-14 and 22-23. In other embodiments, spacer 106 is not flexible and another fastener, such as a corner key, is used with rigid spacers to form corner 122.

FIGS. 2-4 illustrate a portion of another example window assembly 100. FIG. 2 is a perspective view. FIG. 3 is a top view. FIG. 4 is a cross-sectional view. In this example, spacer 106 includes elongate strip 210 and a plurality of stabilizers 212. Spacer 106 is disposed between sheets 102 and 104 to keep sheets 102 and 104 spaced from each other. Typically, spacer 106 is arranged to form a closed loop near to the perimeter of sheets 102 and 104. Spacer 106 is able to withstand compressive forces applied to sheets 102 and/or 104 to maintain a desired space between sheets 102 and 104. An interior space 120 is defined within window assembly 100 by spacer 106 and sheets 102 and 104.

Elongate strip 210 is typically a long and thin strip of a solid material, such as metal or plastic. An example of a suitable metal is stainless steel. An example of a suitable plastic is a thermoplastic polymer, such as polyethylene terephthalate. A material with low or no permeability is preferred in some embodiments. Other embodiments include a material having a low thermal conductivity.

Elongate strip 210 is typically flexible, including both bending and torsional flexibility. Bending flexibility allows spacer 106 to be bent to form corners. Bending and torsional flexibility also allow for ease of manufacturing. Such flexibility includes either elastic or plastic deformation such that elongate strip 210 does not fracture during installation into window assembly 100.

A benefit of some embodiments having a single elongate strip 210 is increased flexibility of spacer 106. Another benefit of some embodiments having a single elongate strip 210 is reduced thickness of spacer 106. In some embodiments, spacer 106 has more than one elongate strip 210 (e.g. two, three, four, or more).

Another benefit of some embodiments having a single elongate strip 210 is reduced thermal transfer through spacer 106. In another example embodiment, the thermal properties of spacer 106 are further enhanced by dividing elongate strip 210 into two strips that are separated by thermal break. The separation of elongate strip 210 by thermal breaks further reduces heat transfer through elongate strip 210 to improve the insulating properties of spacer 106. For example, if sheet 102 is adjacent a relatively cold space and sheet 104 is adjacent a relatively warm space, less heat transfer will occur through elongate strip 210 due to the presence of the thermal break.

The thermal break is preferably made of a material with low thermal conductivity. In one embodiment, thermal break is a fibrous material, such as paper or fabric. In other embodiments, thermal break is an adhesive, sealant, paint, or other coating. In yet other embodiments, the thermal break is a polymer, such as plastic. Further embodiments include other materials, such as metal, vinyl, or any other suitable material. In some embodiments, the thermal break is made of multiple materials, such as paper coated with an adhesive or sealant material on both sides to adhere the paper to elongate strip 210. Another alternative embodiment divides elongate strip 210 into at least three strips, and includes more than one thermal break.

Plurality of stabilizers 212 help stabilize elongate strip 210 between sheet 102 and sheet 104. Due to the flexibility of elongate strip 210, the added support of stabilizers 212 aids in the installation and improves the stability of spacer 106. The plurality of stabilizers 212, reduce the change that the thin elongate strip 210 will bend, buckle, or displace such a compressive force is applied to one or both of sheets 102 and 104. Plurality of stabilizers 212 help keep elongate strip 210 in a generally perpendicular orientation to sheets 102 and 104, promoting strength and stability of elongate strip 210. Plurality of stabilizers 212 further allow spacer 106 to maintain appropriate spacing between sheets 102 and 104 and help reduce the change of buckling, bending, or breaking of elongate strip 210. An advantage of some embodiments using plurality of stabilizers 212 is that the material thickness (e.g., T1 shown in FIG. 4) of elongate strip 210 can be reduced. In doing so, material costs are reduced. Furthermore, thermal transfer through elongate strip 210 is also reduced.

FIG. 4 is a cross sectional view of a portion of window assembly 100. In this embodiment, window assembly 100 includes sheet 102, sheet 104, and spacer 106.

Sheet 102 includes outer surface 410, inner surface 412, and perimeter 414. Sheet 104 includes outer surface 420, inner surface 422, and perimeter 424. In one example, WI is the thickness of sheets 102 and 104. WI is typically in a range from about 0.05 inches (about 0.15 centimeter) to about 1 inch (about 2.5 centimeters), and preferably from about 0.1 inches (about 0.25 centimeter) to about 0.5 inches (about 1.5 centimeters). Other embodiments include other dimensions. In some embodiments, the thickness of sheet 102 is the same as the thickness of sheet 104. In other embodiments, the thickness of sheet 102 is different from the thickness of sheet 104. Sheets 102 and 104 are not required in all embodiments.

In some embodiments, spacer 106 is arranged between inner surface 412 and inner surface 422. Spacer 106 is typically arranged near perimeters 414 and 424. In one example, D1 is the distance between and connected to perimeters 414 and 424 and elongate strip 210 of spacer 106. D1 is typically in a range from about 0 inches (about 0 centimeter) to about 2 inches (about 5 centimeters), and preferably from about 0.1 inches (about 0.25 centimeter) to about 0.5 inches (about 1.5 centimeters). However, in other embodiments spacer 106 is arranged in other locations between sheets 102 and 104.

Spacer 106 maintains a space between sheets 102 and 104. In one example, W3 is the overall width of spacer 106 and the distance between sheets 102 and 104. W3 is typically in a range from about 0.1 inches (about 0.25 centimeter) to about 2 inches (about 5 centimeters) and preferably from about 0.3 inches (about 0.75 centimeter) to about 1 inch (about 2.5 centimeters). Other embodiments include other spaces.

Spacer 106 is connected to sheets 102 and 104. In some embodiments, stabilizers 212 connect spacer 106 to sheets 102 and 104. In other embodiments, stabilizers 212 are connected to sheets 102 and 104 by any suitable fastener. An example of a fastener is a sealant or adhesive, as described in more detail below. In yet other embodiments, a frame, sash, or the like is constructed around window assembly 100 to support spacer 106 between sheets 102 and 104. In some embodiments, spacer 106 is connected to the frame or sash by a fastener, such as adhesive. In example embodiments, spacer 106 is fastened to the frame or sash prior to installation of sheets 102 and 104.

FIG. 5 is a schematic front view of an example embodiment of elongate strip 210 according to the present disclosure. In this embodiment, elongate strip 210 has an undulating shape. In some embodiments, elongate strip 210 is formed of a metal ribbon, such as stainless steel, which is then bent into the undulating shape. Some possible embodiments of the undulating shape include sinusoidal, arcuate, square, rectangular, triangular, and other desired shapes.

One benefit of stainless steel is that it is resistant to ultraviolet radiation. Other metals are used in other embodiments, such as titanium. Titanium has a lower thermal conductivity, a lower density, and better corrosion resistance than stainless steel. Other embodiments include other materials, such as aluminum. Some embodiments are formed by other processes, such as molding.

In some embodiments, elongate strip 210 has bending flexibility and torsional flexibility. Bending flexibility allows spacer 106 to be formed around a corner of a window, for example. In addition, bending flexibility allows elongate strip 210 to be made from rolled stock. Rolled stock saves space during transportation and is therefore easier and less expensive to transport. Portions of elongate strip 210 are then unrolled during assembly. In some embodiments a tool is used to guide elongate strip 210 into the desired arrangement and to attach plurality of stabilizers 212 to form spacer 106. In other embodiments, a machine or robot is used to automatically manufacture spacer 106 and window assembly 100.

One of the benefits of the undulating shape is that the flexibility of elongate strip 210 is increased, including bending and torsional flexibility. The undulating shape resists permanent deformation, such as kinks and fractures. This allows elongate strip 210 to be more easily handled during manufacturing without damaging elongate strip 210. The undulating shape also increases the structural stability of elongate strip 210 to improve the ability of spacer 106 to withstand compressive and torsional loads. Some embodiments of elongate strip 210 are also able to extend and contract, which is beneficial, for example, when spacer 106 is formed around a corner. In some embodiments, the undulating shape reduces the need for notching or other stress relief.

In one example, elongate strip 210 has material thicknesses T1. T1 is typically in a range from about 0.0001 inches (about 0.00025 centimeter) to about 0.010 inches (about 0.025 centimeter), and preferably from about 0.0003 inches (about 0.00075 centimeter) to about 0.004 inches (about 0.01 centimeter). Such thin material thickness reduces material costs and reduces thermal conductivity through elongate strip 210. The undulating shape of elongate strip 210 defines a waveform having a peak-to-peak amplitude and a peak-to-peak period. The peak-to-peak amplitude is also the overall thickness T3 of elongate strip 210. T3 is typically in a range from about 0.005 inches (about 0.015 centimeter) to about 0.1 inches (about 0.25 centimeter), and preferably from about 0.02 inches (about 0.05 centimeter) to about 0.04 inches (about 0.1 centimeter). P1 is the peak-to-peak period of undulating elongate strip 210. P1 is typically in a range from about 0.005 inches (about 0.015 centimeter) to about 0.1 inches (about 0.25 centimeter), and preferably from about 0.02 inches (about 0.05 centimeter) to about 0.04 inches (about 0.1 centimeter).

Other embodiments include other dimensions. For example, some embodiments have an elongate strip 210 with a larger waveform. Elongate strips with larger waveforms have increased stability because the overall thickness is increased. This thickness resists torsional forces and in some embodiments provides increased resistance to compressive loads. Elongate strip 210 can be expanded and compressed, such as to form a corner. In one embodiment, an elongate strip 210 with a larger waveform is expandable between a first length (having the large undulating shape) and a second length (in which elongate strip 210 is substantially straight and substantially lacking an undulating shape) or any length there between. In some embodiments, the second length is in a range from 25 percent to about 60 percent greater than the first length, and preferably from about 30 percent to about 50 percent greater.

When elongate strip 210 has a larger waveform it also includes greater surface area. The greater surface area provides a stronger bond with a sealant or adhesive and one or more sheets. The greater surface area also provides increased strength and stability. In other embodiments, elongate strip 210 is generally flat and smooth (e.g. having an amplitude of about 0 inches (about 0 centimeter) and a period of about 0 inches (about 0 centimeter)) without an undulating shape.

FIGS. 6-9 illustrate another example spacer 106 according to the present disclosure. FIG. 6 is a perspective view of a portion of spacer 106. FIG. 7 is a top view of the portion of spacer 106. FIG. 8 is a front view of the portion of spacer 106. FIG. 9 is a cross-sectional view of spacer 106.

Spacer 106 includes elongate strip 210. Elongate strip 210 includes edge 632 and an edge 634. When installed in example window assembly 100, edge 632 of spacer 106 typically contacts and extends generally perpendicular to a surface of sheet 102. When installed in example window assembly 100, edge 634 typically contacts and extends generally perpendicular to a surface of sheet 104. Elongate strip 210 also includes an external surface 636 and an internal surface 638. Internal surface 638 is adjacent to interior space 120 when assembled into a window assembly. In some embodiments internal surface 638 of elongate strip 210 is visible by a person when looking through window assembly 100. Internal surface 638 of elongate strip 210 provides a clean and finished appearance to spacer 106.

In example embodiments, stabilizers 212 include a first set of stabilizers 642 and a second set of stabilizers 644. First set of stabilizers 642 is attached to elongate strip 210 near edge 632. When installed in example window assembly 100, first set of stabilizers 642 is adjacent to sheet 102. First set of stabilizers 642 is attached to the external surface 636 and internal surface 638 near edge 632 of elongate strip 210. Second set of stabilizers 644 is attached to elongate strip 210 near edge 604. When installed in example window assembly 100, second set of stabilizers 642 is adjacent to sheet 104. Second set of stabilizers 644 is attached to the external surface 636 and internal surface 638 near edge 634 of elongate strip 210.

First set of stabilizers 642 and second set of stabilizers 644 are typically made of a strong, rigid material such as metal or plastic. In example embodiments, plastic stabilizers are preferable to metal because they are cheaper to manufacture and easier to install, while still providing the necessary strength to stabilize the elongate strip 210.

FIGS. 7-8 illustrate dimensions for one example of spacer 106. In this example, each of stabilizers 212 of example spacer 106 has a length L1. L1 is typically in a range from about 0.01 inches (about 0.025 centimeter) to about 1 inch (about 2.5 centimeters), and preferably from about 0.05 inches (about 0.15 centimeter) to about 0.5 inches (about 1.5 centimeters). Additionally, each of stabilizers 212 of example spacer 106 is separated from its closest adjacent stabilizer by a length L3. L3 is typically in a range from about 0.01 inches (about 0.025 centimeter) to about 1 inch (about 2.5 centimeters), and preferably from about 0.05 inches (about 0.15 centimeter) to about 0.5 inches (about 1.5 centimeters). Other embodiments include other dimensions.

Looking to FIG. 9, spacer 106 is shown in further detail in a cross-sectional view. Spacer 106 includes elongate strip 210, stabilizer 920 (of first set of stabilizers 642), and stabilizer 940 (of second set of stabilizers 644).

In some embodiments, stabilizer 920 includes an external stabilizer portion 922 and an internal stabilizer portion 924. External stabilizer portion 922 is attached to external surface 636 near edge 632 of elongate strip 210. Internal stabilizer portion 924 is attached to internal surface 638 near edge 632 of elongate strip 210. External stabilizer portion 922 and internal stabilizer portion 924 are shaped so that when both are connected to elongate strip 210, external stabilizer portion 922 and internal stabilizer portion 924 create a trough 926. In specific embodiments, trough 926 has an arcuate shape with a radius RI. In this embodiment, RI is the distance between edge 632 and the surface of stabilizer 920 that forms trough 926. In example embodiments, trough 926 is divided into two areas by edge 632 of elongate strip 210. The area of trough 926 created between external surface 636 and external stabilizer portion 922 is external trough area 928. The area of trough 926 created between internal surface 638 and internal stabilizer portion 924 is internal trough area 930. External trough area 928 and internal trough area 930 are cavities into which material, such as sealants and desiccants, can be placed during installation of spacer 106, as discussed in more detail below.

As with stabilizer 920, stabilizer 940 includes an external stabilizer portion 942 and an internal stabilizer portion 944. External stabilizer portion 942 is attached to external surface 636 near edge 634 of elongate strip 210. Internal stabilizer portion 944 is attached to internal surface 638 near edge 634 of elongate strip 210. External stabilizer portion 942 and internal stabilizer portion 944 are shaped so that when both are connected to elongate strip 210, external stabilizer portion 942 and internal stabilizer portion 944 create a trough 946. In specific embodiments, trough 946 has an arcuate shape with a radius RI. In this embodiment, RI is the distance between edge 634 and the surface of stabilizer 940 that forms trough 946. In example embodiments, trough 946 is divided into two areas by edge 634 of elongate strip 210. The area created between external surface 636 and external stabilizer portion 942 is external trough area 948. The area created between internal surface 638 and internal stabilizer portion 944 is internal trough area 950. External trough area 948 and internal trough area 950 are cavities into which material, such as sealant, can be placed during installation of spacer 106, as discussed in more detail below.

In some embodiments, each of external stabilizer portion 922, internal stabilizer portion 924, external stabilizer portion 942, and internal stabilizer portion 944 have a width w5. Looking to external stabilizer portion 922 as an example, W5 is the width of external stabilizer portion 922 from a surface 932 nearer edge 632 of elongate strip 210 to a surface 934 at an opposite side of stabilizer portion 922. W5 is typically in a range from about 0.01 inches (about 0.025 centimeter) to about 1 inch (about 2.5 centimeters), and preferably from about 0.05 inches (about 0.15 centimeter) to about 0.5 inches (about 1.5 centimeters). Internal stabilizer portion 924, external stabilizer portion 942, and internal stabilizer portion 944 have W5 values equal to or similar to external stabilizer portion 922 in some embodiments. In example embodiments, W5 values are approximately the same for each individual stabilizer of plurality of stabilizers 212. In other embodiments, W5 varies.

In some embodiments, each of external stabilizer portion 922, internal stabilizer portion 924, external stabilizer portion 942, and internal stabilizer portion 944 have a height H1. Looking again to external stabilizer portion 922 as an example, H1 is the height of external stabilizer portion 922 from a surface 936 of external stabilizer portion 922, where external stabilizer portion 922 is attached to external surface 636 of elongate strip 210, to a distal surface 938 of external stabilizer portion 922, farthest from surface 636 of elongate strip 210. H1 is typically in a range from about 0.01 inches (about 0.025 centimeter) to about 1 inch (about 2.5 centimeters), and preferably from about 0.05 inches (about 0.15 centimeter) to about 0.5 inches (about 1.5 centimeters). Internal stabilizer portion 924, external stabilizer portion 942, and internal stabilizer portion 944 have H1 values equal to or similar to external stabilizer portion 922 in some embodiments. In example embodiments, H1 values are approximately the same for each individual stabilizer of plurality of stabilizers 212. In other embodiments, H1 varies.

First set of stabilizers 642, including external stabilizer portion 922 and internal stabilizer portion 924, and second set of stabilizers 644, including external stabilizer portion 942 and internal stabilizer portion 944, are attached to elongate strip 210. In one example, first set of stabilizers 642 and second set of stabilizers 644 are made of plastic and extruded directly onto elongate strip 210. As the plastic contacts elongate strip 210 and cools, the plastic bonds to elongate strip 210. In other embodiments, first set of stabilizers 642 and second set of stabilizers 644 are preformed and subsequently attached to elongate strip 210 with an adhesive.

In other embodiments, external stabilizer portion 922 of first set of stabilizers 642 and internal stabilizer portion 924 of first set of stabilizers 642 are attached together with a fastener, thus sandwiching elongate strip 210 in between. Specifically, a metal fastener such as a screw, nail, or pin can connect external stabilizer portion 922 to internal stabilizer portion 924 by puncturing through elongate strip 210. This same method is used to connect external stabilizer portion 942 of second set of stabilizers 644 and internal stabilizer portion 944 of second set of stabilizers 644 to each other and to elongate strip 210 in some embodiments.

FIGS. 10-11 illustrate another example spacer 106 further including sealant and desiccant. FIG. 10 is a cross-sectional view of spacer 106 including sealant and desiccant. FIG. 11 is a perspective view of spacer 106 including sealant and desiccant.

In example embodiments, sealants 1002 and 1004 are used to connect spacer 106 to sheets 102 and 104 of window assembly 100. Examples of sealants 1002 and 1004 include polyisobutylene (PIB), butyl, curable PIB, reactive hot melt beutal (such as D-2000 manufactured by Delchem, Inc. located in Wilmington, Del.), curative hot melt (such as HL-5153 manufactured by H.B. Fuller Company), hot melt silicon, copolymers of silicon and polyisobutylene, acrylic adhesive, acrylic sealant, and other Dual Seal Equivalent (DSE) type materials.

In one embodiment, sealant 1002 is filled into external trough area 928 and internal trough area 930 of trough 926 until it covers edge 632 of elongate strip 210. The sealant covered edge 632 and sealant filed trough 926 are then pressed against inner surface 412 of sheet 102. Sealant 1004 is also filled into external trough area 948 and internal trough area 950 of trough 946 until it covers edge 634 of elongate strip 210. The sealant covered edge 634 and sealant filed trough 926 are then pressed against inner surface 422 of sheet 104. In other embodiments, beads of sealant 1002 and 1004 are applied to sheets 102 and 104, and spacer 106 is then pressed into the beads. Edges 632 and 634 are covered with sealants 1002 and 1004 and troughs 926 and 946 are filled with sealants 1002 and 1004.

In some embodiments, once spacer 106 is installed into a window assembly (e.g. 100 shown in FIG. 1), first set of stabilizers 642, edge 632 of elongate strip 210, and sealant 1002 sit flush against sheet 102 and second set of stabilizers 644, edge 634 of elongate strip 210, and sealant 1004 sit flush against sheet 104.

In some embodiments, sealants 1002 and 1004 are a material having adhesive properties, such that sealants 1002 and 1004 act to fasten spacer 106 to sheets 102 and 104. Typically, sealant 1002 and 1004 is arranged to support spacer 106 is an orientation generally normal to inner surfaces 412 and 422 of sheets 102 and 104. Sealants 1002 and 1004 also act to seal the joint formed between spacer 106 and sheets 102 and 104 to inhibit gas or liquid intrusion into interior space 120.

In some embodiments, a desiccant 1006 is applied to internal surface 638 of elongate strip 210. Desiccant 1006 acts to remove moisture from interior space 120. Desiccants include molecular sieve and silica gel type desiccants. One example of a desiccant is a beaded desiccant, such as PHONOSORB® molecular sieve beads manufactured by W. R. Grace & Co. of Columbia, Md. If desired, an adhesive is used to attach beaded desiccant to internal surface 638 of elongate strip 210. A matrix desiccant is used in some embodiments, such as those manufactured by W.R. Grace & Co. and H.B. Fuller Corporation. In some embodiments, desiccant 1006 also provides thermal insulation. Thermal insulation reduces heat transfer through spacer 106 both between sheets 102 and 104, and between the interior space 120 and an exterior side of spacer 106.

FIG. 12 is a front view of a portion of an example spacer 106 arranged in a corner configuration with a standard stabilizer configuration. In some embodiments, the spacer shown in FIG. 12 is the same as the spacer shown in FIG. 6 after a bending operation. Spacer 106 includes elongate strip 210 and plurality of stabilizers 212. In this embodiment, elongate strip 210 has an undulating shape. The portion of spacer 106 is shown arranged as a corner, such that a first region 1202 of the spacer 106 is oriented at approximately a 90 degree angle from a second region 1204 of spacer 106. Some embodiments of spacer 106 are able to be arranged to form a corner without kinking or breaking.

Elongate strip 210 includes an undulating shape. As a result, elongate strip 210 is arranged to expand and compress as necessary. The undulating shape is able to expand by stretching. In some embodiments, the undulating shape of elongate strip 210 is expandable from a first length (having an undulating shape) to a second length (at which point the elongate strip is substantially flat and without an undulating shape). The second length is typically in a range from about 5 percent to about 25 percent longer than the first length, and is preferably from about 10 percent to about 20 percent longer than the first length. In some embodiments, the undulating shape of elongate strip 210 is also compressible. The illustrated embodiment shows elongate strip 210 slightly compressed. In some embodiments, however, elongate strip 210 bends without significant compression or expansion of the undulating shape.

Spacer 106 has bending flexibility. For example, a radius of curvature (as measured from a centerline of spacer 106, is typically in a range from about 0.05 inches (about 0.15 centimeter) to about 0.5 inches (about 1.5 centimeters), and preferably from about 0.05 inches (about 0.15 centimeter) to about 0.25 inches (about 0.65 centimeter) without undesired kinking, fracture, or damage to spacer 106.

In the example embodiment illustrated in FIG. 12, all of plurality of stabilizers 212 have approximately the same size and shape. Thus, the corner configuration of FIG. 12 has a standard stabilizer configuration. Lengths L1 and L3 are such that spacer 106 can be arranged in corner configuration without any of the plurality of stabilizers 212 prohibiting the bending of spacer 106, even in the standard configuration. Because the stabilizer configuration has not been modified, the L3 value between the stabilizers in the corner is changed from the standard L3 value found between the others of the plurality of stabilizers 212. In other embodiments, such as the embodiment illustrated in FIGS. 13-14, the stabilizer configuration can be modified.

FIGS. 13-14 illustrate an example spacer 106 arranged in a corner configuration with a modified stabilizer configuration. FIG. 13 is perspective view of a portion of spacer 106 arranged in a corner configuration with a modified stabilizer configuration. FIG. 14 is a front view of a portion of spacer 106 arranged in a corner configuration with a modified stabilizer configuration.

In the example embodiment illustrated by FIGS. 13-14, spacer 106 includes elongate strip 210 and plurality of stabilizers 212. Elongate strip 210 has an undulating shape. The portion of spacer 106 is shown arranged as a corner, such that a first region 1202 of the spacer 106 is oriented at approximately a 90 degree angle from a second region 1204 of the spacer 106. Spacer 106 is able to be arranged to form a corner without kinking or breaking.

As described above, the undulating shape of elongate strip 210 allows elongate strip 210 to expand and compress as necessary to form a corner 122. The example embodiment of spacer 106 illustrated in FIGS. 13-14 differs from that illustrated in FIG. 12 in its stabilizer shape and size. In this embodiment, the stabilizer configuration of spacer 106 has been modified. Modified corner stabilizers 1310 have been modified from the standard stabilizer size and shape to better suit usage in corner 122.

Looking to FIG. 14, modified corner stabilizers 1310 include internal stabilizer portions 1402 on the inside of the window assembly 100 in the interior space 120 and external stabilizer portion 1404 on the exterior of window assembly 100. Internal stabilizer portions 1402 of modified corner stabilizers 1310 have been reduced slightly in size, while external stabilizer portions 1404 of modified corner stabilizers 1310 have been enlarged slightly in size. In specific embodiments, the modified corner stabilizers 1310 taper from being slightly smaller than the others of plurality of stabilizers 212 at internal stabilizer portions 1402 to being slightly larger than the others of plurality of stabilizers 212 at the external stabilizer portions 1404. In example embodiments, the distance between each individual stabilizer and the next individual stabilizer is kept constant by the modifications to the size of internal stabilizer portions 1402 and external stabilizer portions 1404 on modified corner stabilizers 1310.

Although FIGS. 12-14 illustrate bending in only one direction, spacer 106 is capable of bending in multiple directions at once. Furthermore, spacer 106 is also capable of stretching and twisting without causing permanent damage to spacer 106, such as buckling, cracking, or breaking.

FIGS. 15-17 illustrate another example spacer 1502 according to the present disclosure. FIG. 15 is a perspective view of spacer 1502. FIG. 16 is a top view of spacer 1502. FIG. 17 is a cross-sectional view of spacer 1502.

Example spacer 1502 can be designed to further enhance the aesthetics of window assembly 100 compared to other spacers. Spacer 1502 includes elongate strip 210 and a plurality of stabilizers 1504.

Elongate strip 210 includes edge 632 and an edge 634. When installed in example window assembly 100, edge 632 of spacer 1502 is adjacent and perpendicular to sheet 102. When installed in example window assembly 100, edge 634 is adjacent and perpendicular to sheet 104. Elongate strip 210 also includes an external surface 636 and an internal surface 638. Internal surface 638 is adjacent to interior space 120. In some embodiments internal surface 638 of elongate strip 210 is visible by a person when looking through window assembly 100. Internal surface 638 of elongate strip 210 provides a clean and finished appearance to spacer 1502.

Plurality of stabilizers 1504 includes a first stabilizer 1510 and a second stabilizer 1520. First stabilizer 1510 is a single piece of material attached to elongate strip 210 near edge 632. First stabilizer 1510 is approximately the same length as elongate strip 210. When installed in example window assembly 100, first stabilizer 1510 is adjacent to sheet 102. First stabilizer 1510 is attached to the external surface 636 and internal surface 638 near edge 632 of elongate strip 210. Second stabilizer 1520 is a single piece of material attached to elongate strip 210 near edge 604. Second stabilizer 1520 is approximately the same length as elongate strip 210. When installed in example window assembly 100, second stabilizer 1520 is adjacent to sheet 104. Second stabilizer 1520 is attached to the external surface 636 and internal surface 638 near edge 634 of elongate strip 210.

In example embodiments, first stabilizer 1510 and second stabilizer 1520 are arcuate in shape, each forming a semicircle. First stabilizer 1510 and second stabilizer 1520 are made of a strong, rigid material such as metal or plastic. In example embodiments, plastic is preferable to metal because it is cheaper to manufacture and easier to install, while still providing the necessary strength to stabilize the elongate strip 210.

In example embodiments, stabilizer 1510 includes a plurality of apertures 1512 and stabilizer 1520 includes a plurality of apertures 1522. Apertures 1512 and 1522 will be detailed further below.

Looking to the cross-sectional view of spacer 1502 in FIG. 17, stabilizer 1510 has two parts, an external stabilizer portion 1702 and an internal stabilizer portion 1704. External stabilizer portion 1702 is attached to external surface 636 near edge 632 of elongate strip 210. Internal stabilizer portion 1704 is attached to internal surface 638 near edge 632 of elongate strip 210. External stabilizer portion 1702 and internal stabilizer portion 1704 are shaped so that when both are connected to elongate strip 210, external stabilizer portion 1702 and internal stabilizer portion 1704 create a trough 1706. In specific embodiments, trough 1706 has an arcuate shape with a radius R3. In this embodiment, R3 is the distance between edge 632 and the surface of stabilizer 1510 that forms trough 1706. In example embodiments, trough 1706 is divided into two areas by edge 632 of elongate strip 210. The area of trough 1706 created between external surface 636 and external stabilizer portion 1702 is external trough area 1708. The area of trough 1706 created between internal surface 638 and internal stabilizer portion 1704 is internal trough area 1710. External trough area 1708 and internal trough area 1710 are cavities into which material, such as sealants and desiccants, can be placed during installation of spacer 106. Sealants and desiccants can be applied to spacer 1502 in a manner similar to that shown in FIGS. 10-11 and described above.

In example embodiments, plurality of apertures 1512 are included in internal stabilizer portion 1704 of stabilizer 1510. Apertures 1512 allow gas and moisture to pass through internal stabilizer portion 1704 of stabilizer 1510. As a result, moisture located within interior space 120 is allowed to pass through internal stabilizer portion 1704 of stabilizer 1510 and into internal trough area 1710, where it is removed by a desiccant placed within inner trough area 1710. In another embodiment, apertures 1512 are used for registration. In yet another embodiment, apertures provide reduced thermal transfer. In one example, apertures 1512 have a diameter in a range from about 0.002 inches (about 0.005 centimeter) to about 0.050 inches (about 0.15 centimeter). Apertures 1512 are made by any suitable method, such as cutting, punching, drilling, laser forming, or the like.

As with stabilizer 1510, stabilizer 1520 has two parts, an external stabilizer portion 1722 and an internal stabilizer portion 1724. External stabilizer portion 1722 is attached to external surface 636 near edge 634 of elongate strip 210. Internal stabilizer portion 1724 is attached to internal surface 638 near edge 634 of elongate strip 210. External stabilizer portion 1722 and internal stabilizer portion 1724 are shaped so that when both are connected to elongate strip 210, external stabilizer portion 1722 and internal stabilizer portion 1724 create a trough 1726. In specific embodiments, trough 1726 has an arcuate shape with a radius R3. In this embodiment, R3 is the distance between edge 634 and the surface of stabilizer 1520 that forms trough 1726. In example embodiments, trough 1726 is divided into two areas by edge 634 of elongate strip 210. The area of trough 1726 created between external surface 636 and external stabilizer portion 1722 is external trough area 1728. The area of trough 1726 created between internal surface 638 and internal stabilizer portion 1724 is internal trough area 1730. External trough area 1728 and internal trough area 1730 are cavities into which material, such as sealants and desiccants, can be placed during installation of spacer 106. Sealants and desiccants can be applied to spacer 1502 in a manner similar to that shown in FIGS. 10-11 and described above.

In example embodiments, plurality of apertures 1522 are included in internal stabilizer portion 1724 of stabilizer 1520. Apertures 1522 allow gas and moisture to pass through internal stabilizer portion 1724 of stabilizer 1520. As a result, moisture located within interior space 120 is allowed to pass through internal stabilizer portion 1724 of stabilizer 1520 and into internal trough area 1730, where it is removed by a desiccant placed within inner trough area 1730. In another embodiment, apertures 1522 are used for registration. In yet another embodiment, apertures provide reduced thermal transfer. In one example, apertures 1522 have a diameter in a range from about 0.002 inches (about 0.005 centimeter) to about 0.050 inches (about 0.15 centimeter). Apertures 1522 are made by any suitable method, such as cutting, punching, drilling, laser forming, or the like.

First stabilizer 1510, including external stabilizer portion 1702 and internal stabilizer portion 1704, and second stabilizer 1520, including external stabilizer portion 1722 and internal stabilizer portion 1724, can be attached to elongate strip 210 by various means and methods. In example embodiments, first stabilizer 1510 and second stabilizer 1520 are made of plastic extruded directly onto elongate strip 210. In other embodiments, first stabilizer 1510 and second stabilizer 1520 are attached to elongate strip 210 with an adhesive.

As with the example embodiment previously described, external stabilizer portion 1702 of first stabilizer 1510 and internal stabilizer portion 1704 of first stabilizer 1510 may also be attached together with a fastener, thus sandwiching elongate strip 210 in between. Specifically, a metal fastener such as a screw or nail can connect external stabilizer portion 1702 to internal stabilizer portion 1704 by puncturing through elongate strip 210. This same method can be used to connect external stabilizer portion 1722 of second stabilizer 1520 and internal stabilizer portion 1724 of second stabilizer 1520 to each other and to elongate strip 210.

In some embodiments, each of external stabilizer portion 1702, internal stabilizer portion 1704, external stabilizer portion 1722, and internal stabilizer portion 1724 have a width W7. Looking to internal stabilizer portion 1704 as an example, W7 is the width of internal stabilizer portion 1704 from a surface 1712 nearer edge 632 of elongate strip 210 to an outer edge 1714 farther from edge 632 of elongate strip 210. W7 is typically in a range from about 0.01 inches (about 0.025 centimeter) to about 1 inch (about 2.5 centimeters), and preferably from about 0.05 inches (about 0.15 centimeter) to about 0.5 inches (about 1.5 centimeters). External stabilizer portion 1702, external stabilizer portion 1722, and internal stabilizer portion 1724 have W7 values equal to or similar to external stabilizer portion 1702 in some embodiments. In example embodiments, W7 values are approximately the same for both first stabilizer 1510 and second stabilizer 1520. In other embodiments, W7 varies.

In some embodiments, each of external stabilizer portion 1702, internal stabilizer portion 1704, external stabilizer portion 1722, and internal stabilizer portion 1724 also have a height H3. Looking again to internal stabilizer portion 1704 as an example, H3 is the height of internal stabilizer portion 1704 from a surface 1716 of internal stabilizer portion 1704, where internal stabilizer portion 1704 is attached to internal surface 638 of elongate strip 210, to a surface 1718 of internal stabilizer portion 1704, farthest from surface 638 of elongate strip 210. H3 is typically in a range from about 0.01 inches (about 0.025 centimeter) to about 1 inch (about 2.5 centimeters), and preferably from about 0.05 inches (about 0.15 centimeter) to about 0.5 inches (about 1.5 centimeters). External stabilizer portion 1702, external stabilizer portion 1722, and internal stabilizer portion 1724 have H3 values equal to or similar to internal stabilizer portion 1704. In example embodiments, H3 values are approximately the same for each individual stabilizer of plurality of stabilizers 212. In other embodiments, H3 varies.

FIGS. 18-21 illustrate another example spacer 1802 according to the present disclosure. FIG. 18 is a perspective view of spacer 1802. FIG. 19 is a bottom view of spacer 1802. FIG. 20 is a top view of spacer 1802. FIG. 21 is a front view of spacer 1802. Spacer 1802 includes elongate strip 210 and a plurality of stabilizers 1504.

Unlike spacer 106, spacer 1502 of FIGS. 15-17 cannot be easily bent into corner 122 because first stabilizer 1510 and second stabilizer 1520 are rigid and span the entire length of elongate strip 210. Example spacer 1802 solves this problem by including several notches in first stabilizer 1510 and second stabilizer 1520. Notch 1810 is included in external stabilizer portion 1702 of first stabilizer 1510 and notch 1812 is included in internal stabilizer portion 1704 of first stabilizer 1510. Notch 1814 (not visible in FIG. 18) is included in external stabilizer portion 1722 of second stabilizer 1520 and notch 1816 is included in internal stabilizer portion 1724 of second stabilizer 1520.

Notches 1810, 1812, 1814, and 1816 allow spacer 1802 to be bent to form the 90 degree angles necessary for corner 122. Notches 1810, 1812, 1814, and 1816 can be created in a number of ways. In example embodiments, notches 1810, 1812, 1814, and 1816 are cut out of first stabilizer 1510 and second stabilizer 1520.

Looking to the bottom view of spacer 1802 in FIG. 19, notch 1810 is cut out of external stabilizer portion 1702 creating two surfaces 1910 and 1912. Surfaces 1910 and 1912 converge at a point 1914 on elongate strip 210 and extend in opposite directions to points 1916 and 1918 on the edge of external stabilizer portion 1702. Notch 1814 is cut out of external stabilizer portion 1722 creating two surfaces 1920 and 1922. Surfaces 1920 and 1922 converge at a point 1924 on elongate strip 210 and extend in opposite directions to points 1926 and 1928 on the edge of external stabilizer portion 1722.

Looking to the top view of spacer 1802 in FIG. 20, notch 1812 is cut out of internal stabilizer portion 1704 creating two surfaces 2010 and 2012. Surfaces 2010 and 2012 converge at a point 2014 on elongate strip 210 and extend in opposite directions to points 2016 and 2018 on the edge of internal stabilizer portion 1704. Notch 1816 is cut out of internal stabilizer portion 1724 creating two surfaces 2020 and 2022. Surfaces 2020 and 2022 converge at a point 2024 on elongate strip 210 and extend in opposite directions to points 2026 and 2028 on the edge of internal stabilizer portion 1724.

With notches 1810, 1812, 1814, and 1816 created, spacer 1802 can now be bent along the line between points 1914 and 1924 and 2014 and 2024. In example embodiments, spacer 1802 can be bent approximately 90 degrees so that surfaces 2010 and 2012 come into contact with one another and so that surface 2020 and 2022 come into contact with one another. This corner configuration of spacer 1802 is shown in further detail in FIG. 21-22.

FIG. 22-23 illustrate example spacer 1802 in corner configuration. FIG. 22 is a perspective view of spacer 1802 in corner configuration. FIG. 23 is a front view of spacer 1802 in a corner configuration. As noted above, example spacer 1802 includes elongate strip 210 and a plurality of stabilizers 1504.

With notches 1810, 1812, 1814, and 1816 created as described above, spacer 1802 is now bent along the line between points 1914 and 1924 and 2014 and 2024. Spacer 1802 is bent approximately 90 degrees so that surface 2010 comes into contact with surface 2012 and so that surface 2020 comes into contact with surface 2022. When spacer 1802 is installed in window assembly 100, surface 2010 is flush against surface 2012 and surface 2020 is flush against surface 2022. Thus, the aesthetics of installed spacer 1802 and window assembly 100 as a whole are enhanced due to the clean finished look of stabilizers 1510 and 1520 in combination with elongate strip 210.

Apertures 1512 of stabilizers 1510 and apertures 1522 of stabilizer 1520 allow desiccant to be hidden in internal trough area 1710 and internal trough area 1730 behind the clean finished look of stabilizers 1510 and 1520. The sealant is also hidden in trough 1706 of first stabilizer 1510 and trough 1726 of second stabilizer 1520 so that installed spacer 1802 in window assembly 100 is aesthetically appealing while maintaining the functional benefits of the stabilizers and hidden desiccant.

FIG. 24 is a cross-sectional view of another embodiment of window assembly 100 according to the present disclosure. Window assembly 100 includes sheet 102, sheet 104, and spacer 106. Spacer 106 is similar to the spacer shown in FIG. 6-9 in that it includes elongate strip 210 and plurality of stabilizers 212. In this embodiment, spacer further includes sheet attachment means 2402 for attachment of a sheet 2404. This third sheet of window material forms a triple paned window. In example embodiments, sheet attachment means 2402 is a continuation of interior stabilizer portion 944. Interior stabilizer portion 944 extends in front of elongate strip 210 on interior surface 638. This embodiment is advantageous, because it allows for an additional sheet 2404 to be attached in between sheets 102 and 104. The addition of sheet 2404 potentially increases the insulating properties of window assembly 100. The inclusion of sheet attachment means 2402 is advantageous because elongate strip 210 by itself might not be rigid enough to support sheet 2404.

In certain embodiments, sheet 2404 is a film or plate. For example, sheet 2404 is a film or plate of material that absorbs or reflects ultraviolet radiation, thereby warming interior space 120. In some embodiments, sheet 2404 divides interior space 120 into two or more regions. Sheet 2404 can incorporate a Mylar film in some embodiments. A benefit of some embodiments is that the addition of sheet 2404 does not require additional spacers or sealants.

FIG. 25 is a perspective view of another example spacer 1502 according to the present disclosure. Example spacer 1502 is similar to that shown in FIGS. 15-17 in that it includes elongate strip 210 and plurality of stabilizers 1504. In this embodiment, spacer 1502 includes a plurality of muntin bar clips 2502 and a plurality of muntin bars 2504 (only one is visible in FIG. 25). Plurality of muntin bar clips 2502 are connected to spacer 1502 by a series of muntin bar connector supports 2506. In example embodiments, muntin bar connector supports 2506 are permanently attached to muntin bar clips 2502. Next, muntin bar connector supports 2506 are connected to spacer 1502 through apertures 1512 and apertures 1522. In specific embodiments, muntin bar connector supports can be added and removed from spacer 106 after plurality of stabilizers 1504 are attached to elongate strip 210. In other embodiments, muntin bar connector supports 2506 must be added before spacer 106 is assembled. Plurality of muntin bars 2504 are connected to plurality of muntin bar clips 2502 as shown in FIG. 24. The use of muntin bars 2504 in addition to the clean look of plurality of stabilizers 1504 in spacer 1502 make spacer 1502 of FIG. 25 particularly advantageous for use in applications where aesthetics are paramount.

The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the intended scope of the following claims.

Number	Date	Country
60987681	Nov 2007	US
61049593	May 2008	US
61049599	May 2008	US
61038803	Mar 2008	US

SEALED UNIT AND SPACER WITH STABILIZED ELONGATE STRIP

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