CA1169299A - Spacer frame for an insulating glass panel - Google Patents
Spacer frame for an insulating glass panelInfo
- Publication number
- CA1169299A CA1169299A CA000397953A CA397953A CA1169299A CA 1169299 A CA1169299 A CA 1169299A CA 000397953 A CA000397953 A CA 000397953A CA 397953 A CA397953 A CA 397953A CA 1169299 A CA1169299 A CA 1169299A
- Authority
- CA
- Canada
- Prior art keywords
- frame
- body portions
- connector
- body portion
- latching
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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Abstract
Spacer Frame Connector for an Insulating Glass Panel Abstract A spacer frame assembly for an insulating glass panel is disclosed which is constructed by arranging a plurality of spacer frame segments end to end in substantial alignment, with adjacent frame ends being connected together, and supplying sealant to the aligned spacer frame segments substantially continuously along opposite sides. The adjacent frame segments are then pivoted about axes extending transversely to the opposite sides to form a generally planar polygonal frame configuration and the free ends of the frame are joined. A
connector for adjacent ends of the spacer frame segments is disclosed which includes first and second body portions secured to first and second frame segments, respectively, and hinge structure connecting the body portions for enabling movement of one frame segment relative to the other. The connector body portions are secured relative to each other by connect-ing structure with the first frame segment in a predetermined angular position with respect to the second frame segment.
connector for adjacent ends of the spacer frame segments is disclosed which includes first and second body portions secured to first and second frame segments, respectively, and hinge structure connecting the body portions for enabling movement of one frame segment relative to the other. The connector body portions are secured relative to each other by connect-ing structure with the first frame segment in a predetermined angular position with respect to the second frame segment.
Description
2~9 _escription ~__er r me Connector for an Insulating Glass Panel Technical Field The present invention relates to insulating glass panels or the like and more particularly to connectors that are useful in construction of the spacer frames of such panels~
Insulating glass panels of the sort commonly used as glazing in windows and doors are normally constructed by sandwiching a spacer frame assembly between sheets of glass, or equivalent material, and hermetically bonding the sheets to the spacer frame assembly. A finished panel is typically square or rectangular with the spacer frame assembly extending completely about and immediately adjacent the outer periphery. The panel can then be installed in a suitable supporting structure (such as a window frame) which masks the spacer frame assembly from view and enables the panel to be installed in a larger structure, such as an exterior building wallO
As its name implies the spacer frame assembly functions to space the glass sheets apart and thus provide an insula-tive "dead air" space hetween them. It is essential in such panels that the spacer frame assembly be and remain hermetically attached to the glass sheets throughout the expected life of the panel. If the air space between the glass sheets is not hermetic, atmospheric water vapor will eventually infiltrate the dead air space and inevitably, under appropriate atmospheric conditions, condense on the glass surfaces bounding the dead air space. While the presence of water vapor in the dead air space does not materially reduce the insulative effectiveness of the panel, condensation on the glass in the space "fogs" the glass, cannot be rernoved and the utility of the panel as a window is adversely affected. ~oreover, repeated condensation and evaporation of such moisture within the panels results ~.
~9~g9 in the windows becoming permanently stained and unsightly even when there is no condensation in the panel.
Back~round Art In order to assure a hermetic bond between the spacer 5 frame and the glass sheets a mastic-like sealant material has been applied to opposite sides of the spacer frame continuously about the panel. A typical sealant material, known in the industry as a Butyl "hot melt" adhesive, is applied to the spacer frame, the spacer frame assembly 10 is sandwiched between the glass sheets, and the panel is subjected to high energy radiant heating while the glass sheets are pressed against the spacer frame assembly.
The sealant is heated sufficiently to ~melt" and flow into sealing and bonding contact between the glass and the 15 spacer frame. Upon cooling, and in use, the sealant materi-al is relatively rigid although it does tend to exhibit plastic flow characteristics under stress.
In use the insulating glass panels are subjected to appreciable temperature differentials and to frequent 20 temperature "cycling." The spacer frames therefore have been subjected to stresses and strain resulting from tem-perature induced differential expansion and contraction.
In panels where the spacer frame segments were not firmly secured together, the applied stresses sometimes resulted 25 in the frame segments shifting apart and causing the sealant material to deform sufficienily to break the seal between the frame and the glass. While the structural integrity of the pane]s was not usually adversely affected, the broken seals permitted migration of atmospheric moisture into 30 the dead air spaceO
Accordingly the use of corner connectors between spacer frame seg~ents for securing the segments together and rigidifying the corners was proposed. The corner con-nectors were usually formed of relatively rigid plastic 35 or zinc alloy materials and when attached to the frame segments provided sufficient strength to maintain the inte-grity of the spacer frame assembly.
9 2 ~ 1~
Even though insulating glass panel components were hermetically bonded together and the seal remained intact, atmospheric moisture was trapped in the air space when the panels were bein~ assembled. The trapped air-borne 5 moisture often condensed within the panels. In order to avoid this problem the prior art proposed the use of tubular spacer frame segments containing particulate desiccant material. The spacer frame segments were constructed from aluminum or galvanized sheet steel and formed with slightly 10 open interiorly facing seams which permitted the segments to "breathe,~ i.e., the seams enabled communication between the desiccant'material and the panel air space while pre-venting loss of desiccant into the air space. The desiccant material was e'ffective to dehumidify the air trapped in 15 the panel air space.
The construction of the spacer frames and panels was complicated by the use of desiccant materials in the frame segments. In order to prevent dumping the desiccant material out of the frame segments the frame segments were 20 filled with desiccant material and assembled together using corner connectors which both plugged the ends of the frame segments and formed the spacer frame corners.
The application of sealant to an assembled spacer frame was usually a multi-step process involving multiple 25 ,operators. Typically, the spacer frame was moved past a sealant applying device at a controlled rate of travel, one side at a time. A four-sided frame would therefore require four individual sealant application steps in order to surround the entire perimeter with a sealant layer.
The spacer frame assembly process was relatively slow because of the multiple step sealant applying procedure.
The sealant applying machine had to be started and stopped repeatedly during the application of sealant to a single assembled spacer frame and the sealant was usually applied 35 at a relatively low application rate. Furthermore, applica-tion of ~he coatings was often difficult and cumbersome for the extrusion machine operator, particularly when large 2~
size frames had to be coated. For example, when spacer frames for sliding glass door panels were coated, the frames themselves were sometimes six feet long, or longer, per side and although the frame segments were securely con-nected together, the frames were still ~ui-te flexible and thus extremely difficult for the operator to manipulate.
The process of fabricating spacer frame assemblies was labor intensive and costly since five persons or more were required to produce the assemblies. It shouId be noted that spacer frames cannot effectively be produced and stockplled for eventual use without risking loss of effectiveness of the desiccant material in the frame segments before final assembly of the panels.
Disclosure of the Invention .
The present invention provides a new and improved spacer frame assembly for an insulating glass panel or the like including frame segments and segment connectors which enable the segments comprising a frame to be arranged in an aligned, end-to-end relationship during a sealant application, so that a layer of sealant can be applied continuously to all the segments in a single step. After the sealant is applied, the adjacent frame segments are pivoted relative to each other about a hinge structure defined by the segment connectors, to form the spacer frame configuration. The free ends of the spacer frame are attached together to complete the assembly by a suitable connecting device.
In accordance with a feature of the invention a new and improved frame segment connector is provided which has first and second body portions connectable with adjacent frame segment ends and hinge structure between the body portions to permit pivoting the frame segments to their desired positions. The connector body portions are latched after pivoting with respect to each other by a connecting arrangement when the frame assembly is complete.
The preferred frame segment connector employs first and second connecting elements that extend into latching 2~9 engagement with respective first and second keeper surfaces ~n the second and first body portions.
Other features and advantages of the invention will become apparent from the following detailed description 5 of a preferred embodiment made with reference to the accom-panying drawings which form part of the speciEication.
Brief Description of Drawings FIG~RE 1 is a perspective view of an insulating glass panel constructed according to the invention;
FIGURE 2 is a fragmentary cross sectional view of part of the panel seen approximately from the plane indica-ted by the line 2-2 of Figure l;
FIGURE 3 is a perspective view of a corner connector for a panel spacer frame constructed according to the 15 present invention;
FIGURE 4 is a cross sectional view of the connector of FIGURE 3 assembled to frame segments;
FIGURE 5 is a view like FIGURE 4 with the connector illustrated in a position for locking the frame segments 20 together to form a frame corner; and, FIGURE 6 is a view similar to FIGURES 4 and 5 illus-trating the connector in an intermediate position.
Best Mode for Carrying Out the Invention An insulating glass panel 10 constructed in accord-25 ance with the present invention is illustrated by FIGURES1 and 2 of the drawing. The insulating glass panel 10 includes a spacer frame assembly 12 sandwiched between sheets of glass 14, 16, or equivalent material, and bonded in place to the glass sheets 14, 16 to provide a hermetic 30 air space 18 bounded by the sheets and the spacer frame assembly.
The spacer frame assembly 12 extends completely about the outer periphery of the panel 10 adjacent the peripheral edges of the sheets 14, 16 and is formed by 35 frame segments 20a, 20b, 20c, 20d each forming one side of a rectangular generally planar spacer frame. The frame segments are joined at their ends to define frame corners 22~ The illustxated frame assembly 12 also includes a sealant body 24 which extends about the outer periphery of the panel 10 as well as between the frame segments and sheets 14, 16. The sealant body 24 assures that the sheets 5 are hermetically bonded to the spacer frame assembly.
In the illustrated embodiment of the invention each frame segment is formed by a thin walled open ended tube.
As is best illustrated by FIGURE 2 each frame segment has a generally square cross sectional shape and defines a 10 side wall 26 extending along one side of the air space 18 and having a perforate longitudinally extending seam 27~ opposite lateral side walls 28 facing the sheets 14, 16, respectively, which are formed with longitudinally extending ribs, or ridges, 29; and, an exteriorly facing 15 wall 30 extending along the outer periphery of the panel 10.
The frame segments are preferably formed from aluminum or a light gauge galvani~ed sheet steel since these materi-als are sufficiently strong and rigid to function as frame segments, exhibit good corrosion resistance and their struc-tural integrity is not adversely affected by long termexposure to sunlight.
The sealant body 24 includes opposite lateral seal sections 32 extending, respectively, between the frame segment side walls 28 and the adjacent glass panel sheet and an outer peripheral section 34 which is merged with the seal sections 32 and extends laterally between the glass sheets 14, 16 along the exteriorly facing frame segment walls 30. The sealant body 24 is preferably formed of material known in the industry as a Butyl hot melt mat-erial which is relatively rigid at room and atmospherictemperatures but can flow under moderate pressure when its temperature is elevated sufficiently above atmospheric temperature levels. The sealant body 24 can be formed from other conventional or suitable materials, if desired.
It should be noted that in some panels the outer peripheral sealant body section 34 may be omitted since the lateral sealing sections 32 are sufficient to hermetically join 2~
the panel components in placeO
In the preferred embodiment of the invention, and as illustrated by FIGURE 2, each spacer frame segment is filled with a particulate desiccant material 36 which is 5 in communication with the air space 18 via the perforate seam 27 in the respective frame segment side wall 26.
The desiccant material 36 is effective to dehumidify air which is trapped in the space 18 during assembly of the panel 10 so that the possibility of condensation of mois-10 ture from air entrapped in the air space 18 is avoided.
It should be appreciated that the perforate seam 27 in the frame segments is sufficiently narrow that the desic-cant material 36 cannot pass through the seam and into the air space 18.
An important feature of the new spacer frame assembly resides in connecting adjacent spacer frame segments to-gether for pivoting motion relative to each other and attaching the free ends of aligned spacer frame segments to complete the spacer frame assembly.
FIGURES 3-6 illustrate a frame segment connector 80, constructed in accordance with the invention, for hinge-ing adjacent ends of the spacer frame segments to enable alignment of the segments for sealant application and yet provide for relatively strong, durable frame assembly 25 corners. The connector 80 comprises first and second body portions 82, 84 secured to adjacent ends of respective first and second frame segments 20a, 20b, hinge structure 86 connecting the body portions together to enable pivoting motion of the segments 20a, 20b about their juncture and 30 a connecting arrangement 88 for securing the body portions in place with respect to each other when the frame segments are in their desired assembled orientation ~FIGURE 5).
The body portion 84 includes a frame segment engaging end region 90 projecting into the frame segment 20a and 35 a connecting end region 92 projecting from the end of the frame segment. The end region 90 includes a hook-like 2 ~ ~
construction 94 locked into place in the frame segment and a plug section 96 conforming to the cross sectional shape of the frame segment for sealing the frame segment end against loss of desiccant material. The hook construc-5 tion 94 engages a crimped wall portion of the frame segment,indicated by the reference character 95, so that the body portion 82 is securely fixed in the frame segment end.
The hinge 86 is disposed between the body portions 82, 84 to enable pivoting the Erame segments with respect 10 to each other to form a frame corner during the spacer frame assembly. The preferred hinge structure is formed by a thin strip of flexible material formed continuously with the respective body portions and extending between them throughout their lateral extents.
The connector 80 is preferably formed from a single piece of plastic material, such as nylon, polypropylene, or polyethylene, molded so that the hinge strip is continu-ous with the body portions. The hinge strip is suffici-ently thin and supple to provide flexibility for pivoting 20 the frame segments; but is strong and stiff enough to aid in resisting skewing of the frame segments with respect to each other when the corner has been formed. In the illustrated embodiment of the invention the hinge strip is provided with undercut areas 86a adjacent its ends to 25 enable the body portions to be moved into a frame corner-forming orientation with respect to each other without unduly stressing the hinge strip material.
The body portion end region 92 forms abutment sur-faces which confront correlative abutment surfaces of the 30 body portion 82 when the frame corner is formed to assist in rigidifying the frame corner. In the preferred and illus-trated connector three abutment surfaces, 100, 102, 104 are formed on the end region 92 and disposed in orthogonal planes. The surfaces 100, 102 are formed on a wall 106 35 extending along one lateral side of the connector 80 with the surface 102 disposed along the mid-line 107 of the connector (as viewed in FIGURE 3). The abutment surface 2 ~
g !
104 is formed by a wall 108 extending transversely across the connector mid-line from the wall 106.
The body portion 82 is configured similarly to the body portion 84, having a frame segment engaging end region 5 110 projecting into the frame segment 20b and a connecting end region 112 projecting from the end of the frame segment.
A hook-like construction 114 locks the end region 112 in the frame segment and a plug section 116 seals the frame segment end against loss of desiccant.
Orthogonal abutment surfaces 120, 122, 124 corres-pon2ing, respectively, to the surfaces 100, 102, 104 are formed on the end region 112, but on the opposite side of the connector mid-line 107. The surfaces 120, 122 are formed on an end region wall 126 while the surface 124 15 is formed on an end region wall 128.
When the connector 80 is flexed to form the frame corner, as illustrated by FIGURE 5, the correlative abut-ment surface pairs 100, 124, 102, 122; and 104, 120 are moved into confronting relationship and serve to stiffen the frame corner by preventing excessive flexure of the frame corner (i.e. preventing the illustrated frame corner from flexing to an acute angle materially less than 90~, and resisting skewing of the frame segments (by virtue of engagement of the surfaces 102, 122).
It should be appreciated that the angular relation-ships between the abutment surfaces on each connector body portion can be altered if desired and still permit forma-tion of a 90 frame corner. Likewise the abutment surfaces may be altered to produce frame corner angles different from 90 if that should be desirable. Furthermore the abutment surfaces need not necessarily be planar, although the correlative abutment surface pairs should, most desira-bly, conform to each other.
The connecting arrangement 88 is constructed and arranged to firmly latch the body portions 82, 84 in position with respect to each other when the frame corner is formed.
As illustrated by FIGURES 3-6, first and second latching , ~ ~
projections 13~, 132 are formed, respectively, on the first and second body portions 82, 84. When the frame corner is forrned (FIGURE 5), the projections are moved into latch-ing relationship with first and second keepers 134, 136 5 formed, respectively, on the second and first.body portions 84, 82. The reciprocal latching engagement between the body portions provides an extremely strong locking relation-ship between the body portions so that "opening" of the frame corner is strongly resisted.
The first locking projection 130 is formed continuously with the wall 126, extends substantially across the width of the wall and has a generally "L" shaped configuration~
A short, the stiff leg 140 extends from the end of the wall i26 adjacent the abutment surface 120 in the direction of the "inside" of the spacer frame periphery. A relatively longer, resiliently deflectable leg 142 extends from the leg 140 parallel to and spaced from the body portion 84 toward the frame segmen'c 20b.
The first keeper 134, associatecl with the latching projection 130, is formed by a wall-like lip extending from the surface 102, contiguous with the wall 108 and aligned with the latching projection 130. The iip 134 is preferably slightly wider than the projection 130 and -quite short so that it is stiffly resistant to flexure.
When the body portions 82, 84 are pi.voted to form the frame corner the keeper lip 134 engages the leg 142 and resiliently deflects the 1eg toward the wall 126 (see FIGURE 6). The extent of the leg 140 is sufficient to insure that the leg 142 flexes without interference with the wall 126. The lip 134 slides ?long and resiliently deflects the leg 142 as the body p~rtions are pivoted until the leg is free to resiliently snap back to its unflexed condition at which tirne the tip 144 of the leg 142 is in confronting relationship with a catch surface 146 formed by the lip 134. This condition is illustrated by FIGURE
5.
If the frame corner is stressed in a manner tending to straighten out the corner the leg tip 144 engages the catch surface 146, placing the leg 142 in compression and resisting the motion. The leg 140 is sufficiently short and stiff that it strongly resists being flexed when the corner tends to be straightened.
The second latching projection 132 is constructed the same as the pro3ection 130 but is ormed on the wall 1060 The leg 150 extends from the wall 106 whîle the resi-liently deflectable leg 152 extends parallel to and space~
from the wall~ The keeper lip 136 extending from the wall 126 is constructed like the lip 134~ Thus the lip 136 resiliently deflects the leg 152 as the body portions are pivoted and when the tip 154 of the leg 152 passes the lip 136 the leg 152 springs back to its unflexed condition so that the leg tip 154 confronts the catch surface 156 of the lip 136 and latches the body portions in their corner forming positions.
The latching projections and their associated keepers ~re preferably constructed identically and positioned the same relative to each other so that both latching project ions are latched in place with their respective keepers at the same time and just when the body portions are prop-erly positioned to form the frame corner.
The free ends of the spacer frame segments can be secured together by a variety of devices and rnethods.
For example, the disclosed segment connector 80 can be used to complete the assembly. To join the free ends of the segments, the connector 80 would be pivoted to its corner forming orientation and latched in position. The body portions 82, 84 would then be inserted into the free ends of the frame segments and then locked by crimping the wall of the segments to engage the respective hook constructions 94, 114, thereby joining and sealing the frame segments. The resulting juncture would appear identical to the juncture shown in Figure 5.
~ ~92~9 The spacer frame assembly 12 is constructed by arrang-ing the frame segments 20a-d end to end in alignment, with adjacent ends of the spacer frame segments connected by the connectors 80. The aligned spacer frame segments are then passed by suitable extrusion heads where the sealant body 24 is flowed onto the segments in a s;ngle operational step from one free end to the otherO The frame segments ~are then pivoted with respect to each other about their adjacent ends and the free spacer frame segment ends are connected to complete the spacer frame assembly.
The sealant material on the side walls 23 tends to bow slightly at the frame corners when the pivoting opera-tion takes place and the frame assembler therefore smooths out the sealant at the frame corners as well as manually molding the sealant into a continuous mass at the now joined frame segment free ends. The frame assembler also inspects the finished frame assembly to be certain the sealant is properly adhered and correctly placed on the frame seg-ments. Because of the sealant strip continuity along the 20~ frame segments, further inspection of the finished frame assemblies by a separate operator is not a necessity.
After the spacer frame assembly is completed, the frame assemblies are delivered to a panel assembly location where the frame assemblies are sandwiched between glass sheets and fed into a heating oven. The panel assembly moves through the oven while the sheets are compressed against the spacer frame assembly. The sealant is heated and flows into intimate contact with the glass sheets and the frame segments. The seaiant also flows sufficiently that the individual strips of sealant ~n the frame segment side walls flow into and merge with the strip on the frame segment outer wall 30.
The panel construction apparatus and procedures are conventional and therefore are not illustrated or described further here~
While a single embodiment of the invention has been illustrated and described in detail, the present invention should not be considered limited to the precise construct-i.on disclosed. Various adaptations, modifications and uses of the invent~on may occur to those skilled in the art to which the invention relates and the intention is to cover all such adaptations, modifications and uses falling within the spirit or scope of the appended claims~
Insulating glass panels of the sort commonly used as glazing in windows and doors are normally constructed by sandwiching a spacer frame assembly between sheets of glass, or equivalent material, and hermetically bonding the sheets to the spacer frame assembly. A finished panel is typically square or rectangular with the spacer frame assembly extending completely about and immediately adjacent the outer periphery. The panel can then be installed in a suitable supporting structure (such as a window frame) which masks the spacer frame assembly from view and enables the panel to be installed in a larger structure, such as an exterior building wallO
As its name implies the spacer frame assembly functions to space the glass sheets apart and thus provide an insula-tive "dead air" space hetween them. It is essential in such panels that the spacer frame assembly be and remain hermetically attached to the glass sheets throughout the expected life of the panel. If the air space between the glass sheets is not hermetic, atmospheric water vapor will eventually infiltrate the dead air space and inevitably, under appropriate atmospheric conditions, condense on the glass surfaces bounding the dead air space. While the presence of water vapor in the dead air space does not materially reduce the insulative effectiveness of the panel, condensation on the glass in the space "fogs" the glass, cannot be rernoved and the utility of the panel as a window is adversely affected. ~oreover, repeated condensation and evaporation of such moisture within the panels results ~.
~9~g9 in the windows becoming permanently stained and unsightly even when there is no condensation in the panel.
Back~round Art In order to assure a hermetic bond between the spacer 5 frame and the glass sheets a mastic-like sealant material has been applied to opposite sides of the spacer frame continuously about the panel. A typical sealant material, known in the industry as a Butyl "hot melt" adhesive, is applied to the spacer frame, the spacer frame assembly 10 is sandwiched between the glass sheets, and the panel is subjected to high energy radiant heating while the glass sheets are pressed against the spacer frame assembly.
The sealant is heated sufficiently to ~melt" and flow into sealing and bonding contact between the glass and the 15 spacer frame. Upon cooling, and in use, the sealant materi-al is relatively rigid although it does tend to exhibit plastic flow characteristics under stress.
In use the insulating glass panels are subjected to appreciable temperature differentials and to frequent 20 temperature "cycling." The spacer frames therefore have been subjected to stresses and strain resulting from tem-perature induced differential expansion and contraction.
In panels where the spacer frame segments were not firmly secured together, the applied stresses sometimes resulted 25 in the frame segments shifting apart and causing the sealant material to deform sufficienily to break the seal between the frame and the glass. While the structural integrity of the pane]s was not usually adversely affected, the broken seals permitted migration of atmospheric moisture into 30 the dead air spaceO
Accordingly the use of corner connectors between spacer frame seg~ents for securing the segments together and rigidifying the corners was proposed. The corner con-nectors were usually formed of relatively rigid plastic 35 or zinc alloy materials and when attached to the frame segments provided sufficient strength to maintain the inte-grity of the spacer frame assembly.
9 2 ~ 1~
Even though insulating glass panel components were hermetically bonded together and the seal remained intact, atmospheric moisture was trapped in the air space when the panels were bein~ assembled. The trapped air-borne 5 moisture often condensed within the panels. In order to avoid this problem the prior art proposed the use of tubular spacer frame segments containing particulate desiccant material. The spacer frame segments were constructed from aluminum or galvanized sheet steel and formed with slightly 10 open interiorly facing seams which permitted the segments to "breathe,~ i.e., the seams enabled communication between the desiccant'material and the panel air space while pre-venting loss of desiccant into the air space. The desiccant material was e'ffective to dehumidify the air trapped in 15 the panel air space.
The construction of the spacer frames and panels was complicated by the use of desiccant materials in the frame segments. In order to prevent dumping the desiccant material out of the frame segments the frame segments were 20 filled with desiccant material and assembled together using corner connectors which both plugged the ends of the frame segments and formed the spacer frame corners.
The application of sealant to an assembled spacer frame was usually a multi-step process involving multiple 25 ,operators. Typically, the spacer frame was moved past a sealant applying device at a controlled rate of travel, one side at a time. A four-sided frame would therefore require four individual sealant application steps in order to surround the entire perimeter with a sealant layer.
The spacer frame assembly process was relatively slow because of the multiple step sealant applying procedure.
The sealant applying machine had to be started and stopped repeatedly during the application of sealant to a single assembled spacer frame and the sealant was usually applied 35 at a relatively low application rate. Furthermore, applica-tion of ~he coatings was often difficult and cumbersome for the extrusion machine operator, particularly when large 2~
size frames had to be coated. For example, when spacer frames for sliding glass door panels were coated, the frames themselves were sometimes six feet long, or longer, per side and although the frame segments were securely con-nected together, the frames were still ~ui-te flexible and thus extremely difficult for the operator to manipulate.
The process of fabricating spacer frame assemblies was labor intensive and costly since five persons or more were required to produce the assemblies. It shouId be noted that spacer frames cannot effectively be produced and stockplled for eventual use without risking loss of effectiveness of the desiccant material in the frame segments before final assembly of the panels.
Disclosure of the Invention .
The present invention provides a new and improved spacer frame assembly for an insulating glass panel or the like including frame segments and segment connectors which enable the segments comprising a frame to be arranged in an aligned, end-to-end relationship during a sealant application, so that a layer of sealant can be applied continuously to all the segments in a single step. After the sealant is applied, the adjacent frame segments are pivoted relative to each other about a hinge structure defined by the segment connectors, to form the spacer frame configuration. The free ends of the spacer frame are attached together to complete the assembly by a suitable connecting device.
In accordance with a feature of the invention a new and improved frame segment connector is provided which has first and second body portions connectable with adjacent frame segment ends and hinge structure between the body portions to permit pivoting the frame segments to their desired positions. The connector body portions are latched after pivoting with respect to each other by a connecting arrangement when the frame assembly is complete.
The preferred frame segment connector employs first and second connecting elements that extend into latching 2~9 engagement with respective first and second keeper surfaces ~n the second and first body portions.
Other features and advantages of the invention will become apparent from the following detailed description 5 of a preferred embodiment made with reference to the accom-panying drawings which form part of the speciEication.
Brief Description of Drawings FIG~RE 1 is a perspective view of an insulating glass panel constructed according to the invention;
FIGURE 2 is a fragmentary cross sectional view of part of the panel seen approximately from the plane indica-ted by the line 2-2 of Figure l;
FIGURE 3 is a perspective view of a corner connector for a panel spacer frame constructed according to the 15 present invention;
FIGURE 4 is a cross sectional view of the connector of FIGURE 3 assembled to frame segments;
FIGURE 5 is a view like FIGURE 4 with the connector illustrated in a position for locking the frame segments 20 together to form a frame corner; and, FIGURE 6 is a view similar to FIGURES 4 and 5 illus-trating the connector in an intermediate position.
Best Mode for Carrying Out the Invention An insulating glass panel 10 constructed in accord-25 ance with the present invention is illustrated by FIGURES1 and 2 of the drawing. The insulating glass panel 10 includes a spacer frame assembly 12 sandwiched between sheets of glass 14, 16, or equivalent material, and bonded in place to the glass sheets 14, 16 to provide a hermetic 30 air space 18 bounded by the sheets and the spacer frame assembly.
The spacer frame assembly 12 extends completely about the outer periphery of the panel 10 adjacent the peripheral edges of the sheets 14, 16 and is formed by 35 frame segments 20a, 20b, 20c, 20d each forming one side of a rectangular generally planar spacer frame. The frame segments are joined at their ends to define frame corners 22~ The illustxated frame assembly 12 also includes a sealant body 24 which extends about the outer periphery of the panel 10 as well as between the frame segments and sheets 14, 16. The sealant body 24 assures that the sheets 5 are hermetically bonded to the spacer frame assembly.
In the illustrated embodiment of the invention each frame segment is formed by a thin walled open ended tube.
As is best illustrated by FIGURE 2 each frame segment has a generally square cross sectional shape and defines a 10 side wall 26 extending along one side of the air space 18 and having a perforate longitudinally extending seam 27~ opposite lateral side walls 28 facing the sheets 14, 16, respectively, which are formed with longitudinally extending ribs, or ridges, 29; and, an exteriorly facing 15 wall 30 extending along the outer periphery of the panel 10.
The frame segments are preferably formed from aluminum or a light gauge galvani~ed sheet steel since these materi-als are sufficiently strong and rigid to function as frame segments, exhibit good corrosion resistance and their struc-tural integrity is not adversely affected by long termexposure to sunlight.
The sealant body 24 includes opposite lateral seal sections 32 extending, respectively, between the frame segment side walls 28 and the adjacent glass panel sheet and an outer peripheral section 34 which is merged with the seal sections 32 and extends laterally between the glass sheets 14, 16 along the exteriorly facing frame segment walls 30. The sealant body 24 is preferably formed of material known in the industry as a Butyl hot melt mat-erial which is relatively rigid at room and atmospherictemperatures but can flow under moderate pressure when its temperature is elevated sufficiently above atmospheric temperature levels. The sealant body 24 can be formed from other conventional or suitable materials, if desired.
It should be noted that in some panels the outer peripheral sealant body section 34 may be omitted since the lateral sealing sections 32 are sufficient to hermetically join 2~
the panel components in placeO
In the preferred embodiment of the invention, and as illustrated by FIGURE 2, each spacer frame segment is filled with a particulate desiccant material 36 which is 5 in communication with the air space 18 via the perforate seam 27 in the respective frame segment side wall 26.
The desiccant material 36 is effective to dehumidify air which is trapped in the space 18 during assembly of the panel 10 so that the possibility of condensation of mois-10 ture from air entrapped in the air space 18 is avoided.
It should be appreciated that the perforate seam 27 in the frame segments is sufficiently narrow that the desic-cant material 36 cannot pass through the seam and into the air space 18.
An important feature of the new spacer frame assembly resides in connecting adjacent spacer frame segments to-gether for pivoting motion relative to each other and attaching the free ends of aligned spacer frame segments to complete the spacer frame assembly.
FIGURES 3-6 illustrate a frame segment connector 80, constructed in accordance with the invention, for hinge-ing adjacent ends of the spacer frame segments to enable alignment of the segments for sealant application and yet provide for relatively strong, durable frame assembly 25 corners. The connector 80 comprises first and second body portions 82, 84 secured to adjacent ends of respective first and second frame segments 20a, 20b, hinge structure 86 connecting the body portions together to enable pivoting motion of the segments 20a, 20b about their juncture and 30 a connecting arrangement 88 for securing the body portions in place with respect to each other when the frame segments are in their desired assembled orientation ~FIGURE 5).
The body portion 84 includes a frame segment engaging end region 90 projecting into the frame segment 20a and 35 a connecting end region 92 projecting from the end of the frame segment. The end region 90 includes a hook-like 2 ~ ~
construction 94 locked into place in the frame segment and a plug section 96 conforming to the cross sectional shape of the frame segment for sealing the frame segment end against loss of desiccant material. The hook construc-5 tion 94 engages a crimped wall portion of the frame segment,indicated by the reference character 95, so that the body portion 82 is securely fixed in the frame segment end.
The hinge 86 is disposed between the body portions 82, 84 to enable pivoting the Erame segments with respect 10 to each other to form a frame corner during the spacer frame assembly. The preferred hinge structure is formed by a thin strip of flexible material formed continuously with the respective body portions and extending between them throughout their lateral extents.
The connector 80 is preferably formed from a single piece of plastic material, such as nylon, polypropylene, or polyethylene, molded so that the hinge strip is continu-ous with the body portions. The hinge strip is suffici-ently thin and supple to provide flexibility for pivoting 20 the frame segments; but is strong and stiff enough to aid in resisting skewing of the frame segments with respect to each other when the corner has been formed. In the illustrated embodiment of the invention the hinge strip is provided with undercut areas 86a adjacent its ends to 25 enable the body portions to be moved into a frame corner-forming orientation with respect to each other without unduly stressing the hinge strip material.
The body portion end region 92 forms abutment sur-faces which confront correlative abutment surfaces of the 30 body portion 82 when the frame corner is formed to assist in rigidifying the frame corner. In the preferred and illus-trated connector three abutment surfaces, 100, 102, 104 are formed on the end region 92 and disposed in orthogonal planes. The surfaces 100, 102 are formed on a wall 106 35 extending along one lateral side of the connector 80 with the surface 102 disposed along the mid-line 107 of the connector (as viewed in FIGURE 3). The abutment surface 2 ~
g !
104 is formed by a wall 108 extending transversely across the connector mid-line from the wall 106.
The body portion 82 is configured similarly to the body portion 84, having a frame segment engaging end region 5 110 projecting into the frame segment 20b and a connecting end region 112 projecting from the end of the frame segment.
A hook-like construction 114 locks the end region 112 in the frame segment and a plug section 116 seals the frame segment end against loss of desiccant.
Orthogonal abutment surfaces 120, 122, 124 corres-pon2ing, respectively, to the surfaces 100, 102, 104 are formed on the end region 112, but on the opposite side of the connector mid-line 107. The surfaces 120, 122 are formed on an end region wall 126 while the surface 124 15 is formed on an end region wall 128.
When the connector 80 is flexed to form the frame corner, as illustrated by FIGURE 5, the correlative abut-ment surface pairs 100, 124, 102, 122; and 104, 120 are moved into confronting relationship and serve to stiffen the frame corner by preventing excessive flexure of the frame corner (i.e. preventing the illustrated frame corner from flexing to an acute angle materially less than 90~, and resisting skewing of the frame segments (by virtue of engagement of the surfaces 102, 122).
It should be appreciated that the angular relation-ships between the abutment surfaces on each connector body portion can be altered if desired and still permit forma-tion of a 90 frame corner. Likewise the abutment surfaces may be altered to produce frame corner angles different from 90 if that should be desirable. Furthermore the abutment surfaces need not necessarily be planar, although the correlative abutment surface pairs should, most desira-bly, conform to each other.
The connecting arrangement 88 is constructed and arranged to firmly latch the body portions 82, 84 in position with respect to each other when the frame corner is formed.
As illustrated by FIGURES 3-6, first and second latching , ~ ~
projections 13~, 132 are formed, respectively, on the first and second body portions 82, 84. When the frame corner is forrned (FIGURE 5), the projections are moved into latch-ing relationship with first and second keepers 134, 136 5 formed, respectively, on the second and first.body portions 84, 82. The reciprocal latching engagement between the body portions provides an extremely strong locking relation-ship between the body portions so that "opening" of the frame corner is strongly resisted.
The first locking projection 130 is formed continuously with the wall 126, extends substantially across the width of the wall and has a generally "L" shaped configuration~
A short, the stiff leg 140 extends from the end of the wall i26 adjacent the abutment surface 120 in the direction of the "inside" of the spacer frame periphery. A relatively longer, resiliently deflectable leg 142 extends from the leg 140 parallel to and spaced from the body portion 84 toward the frame segmen'c 20b.
The first keeper 134, associatecl with the latching projection 130, is formed by a wall-like lip extending from the surface 102, contiguous with the wall 108 and aligned with the latching projection 130. The iip 134 is preferably slightly wider than the projection 130 and -quite short so that it is stiffly resistant to flexure.
When the body portions 82, 84 are pi.voted to form the frame corner the keeper lip 134 engages the leg 142 and resiliently deflects the 1eg toward the wall 126 (see FIGURE 6). The extent of the leg 140 is sufficient to insure that the leg 142 flexes without interference with the wall 126. The lip 134 slides ?long and resiliently deflects the leg 142 as the body p~rtions are pivoted until the leg is free to resiliently snap back to its unflexed condition at which tirne the tip 144 of the leg 142 is in confronting relationship with a catch surface 146 formed by the lip 134. This condition is illustrated by FIGURE
5.
If the frame corner is stressed in a manner tending to straighten out the corner the leg tip 144 engages the catch surface 146, placing the leg 142 in compression and resisting the motion. The leg 140 is sufficiently short and stiff that it strongly resists being flexed when the corner tends to be straightened.
The second latching projection 132 is constructed the same as the pro3ection 130 but is ormed on the wall 1060 The leg 150 extends from the wall 106 whîle the resi-liently deflectable leg 152 extends parallel to and space~
from the wall~ The keeper lip 136 extending from the wall 126 is constructed like the lip 134~ Thus the lip 136 resiliently deflects the leg 152 as the body portions are pivoted and when the tip 154 of the leg 152 passes the lip 136 the leg 152 springs back to its unflexed condition so that the leg tip 154 confronts the catch surface 156 of the lip 136 and latches the body portions in their corner forming positions.
The latching projections and their associated keepers ~re preferably constructed identically and positioned the same relative to each other so that both latching project ions are latched in place with their respective keepers at the same time and just when the body portions are prop-erly positioned to form the frame corner.
The free ends of the spacer frame segments can be secured together by a variety of devices and rnethods.
For example, the disclosed segment connector 80 can be used to complete the assembly. To join the free ends of the segments, the connector 80 would be pivoted to its corner forming orientation and latched in position. The body portions 82, 84 would then be inserted into the free ends of the frame segments and then locked by crimping the wall of the segments to engage the respective hook constructions 94, 114, thereby joining and sealing the frame segments. The resulting juncture would appear identical to the juncture shown in Figure 5.
~ ~92~9 The spacer frame assembly 12 is constructed by arrang-ing the frame segments 20a-d end to end in alignment, with adjacent ends of the spacer frame segments connected by the connectors 80. The aligned spacer frame segments are then passed by suitable extrusion heads where the sealant body 24 is flowed onto the segments in a s;ngle operational step from one free end to the otherO The frame segments ~are then pivoted with respect to each other about their adjacent ends and the free spacer frame segment ends are connected to complete the spacer frame assembly.
The sealant material on the side walls 23 tends to bow slightly at the frame corners when the pivoting opera-tion takes place and the frame assembler therefore smooths out the sealant at the frame corners as well as manually molding the sealant into a continuous mass at the now joined frame segment free ends. The frame assembler also inspects the finished frame assembly to be certain the sealant is properly adhered and correctly placed on the frame seg-ments. Because of the sealant strip continuity along the 20~ frame segments, further inspection of the finished frame assemblies by a separate operator is not a necessity.
After the spacer frame assembly is completed, the frame assemblies are delivered to a panel assembly location where the frame assemblies are sandwiched between glass sheets and fed into a heating oven. The panel assembly moves through the oven while the sheets are compressed against the spacer frame assembly. The sealant is heated and flows into intimate contact with the glass sheets and the frame segments. The seaiant also flows sufficiently that the individual strips of sealant ~n the frame segment side walls flow into and merge with the strip on the frame segment outer wall 30.
The panel construction apparatus and procedures are conventional and therefore are not illustrated or described further here~
While a single embodiment of the invention has been illustrated and described in detail, the present invention should not be considered limited to the precise construct-i.on disclosed. Various adaptations, modifications and uses of the invent~on may occur to those skilled in the art to which the invention relates and the intention is to cover all such adaptations, modifications and uses falling within the spirit or scope of the appended claims~
Claims (21)
OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A connector for adjacent ends of first and second spacer frame segments in an insulating glass panel or the like comprising:
a) a first body portion connectable to the first frame segment;
b) a second body portion connectable to the second frame segment;
c) hinge means connecting said first and second body portions together for enabling movement of one frame segment relative to the other frame segment, said hinge means comprising a thin flexible strip of material exten-ding between said body portions; and, d) connecting means for securing said body portions in position when said body portions are hingedly moved to predetermined relative positions, said connecting means comprising an element projecting from one body portion and engageable with said other body portion to secure the body portions in said predetermined relative positions.
a) a first body portion connectable to the first frame segment;
b) a second body portion connectable to the second frame segment;
c) hinge means connecting said first and second body portions together for enabling movement of one frame segment relative to the other frame segment, said hinge means comprising a thin flexible strip of material exten-ding between said body portions; and, d) connecting means for securing said body portions in position when said body portions are hingedly moved to predetermined relative positions, said connecting means comprising an element projecting from one body portion and engageable with said other body portion to secure the body portions in said predetermined relative positions.
2. The connector claimed in claim 1 wherein each said body portion is projectable into a tubular frame segment.
3. The connector claimed in claim 1 wherein said first and second body portions each define an abutment surface, said surfaces being moved into confronting re-lationship when said body portions are in said predeter-mined relative positions.
4. The connector claimed in claim 1 or 3 wherein said connecting means further includes a second element projecting from the other body portion and engageable with said one body portion to secure the body portions in said predetermined relative positions.
5. The connector claimed in claim 1 wherein said strip of material is continuous with said body portions.
6. The connector claimed in claim 1 wherein said projecting element extends into latching engagement with said other body portion when said body portions are in said predetermined relative positions.
7. The connector claimed in claim 6 wherein said body portions each define an abutment surface, said abutment surfaces being in confronting relationship when said body portions are in said predetermined relative positions.
8. The connector claimed in claim 6 wherein said projecting element defines a catch surface engageable with a keeper formed by said other body portion, said projecting element being resiliently deflectable to enable engagement of said catch surface and keeper.
9. The connector claimed in claim 8 further including a second element extending between said body portions, said second element defining a catch surface engaged with a keeper formed by a body portion.
10. The connector claimed in claim 1 wherein said first and second body portions each defines a wall surface, said wall surfaces being moved to confront each other when said body portions are in said predetermined positions r said wall surfaces abutting to resist skewing of said body portions from said predetermined positions.
11. The connector claimed in claim 1 wherein said connecting means further comprises a second element pro-jecting from one body portion and engageable with the other body portion to secure the body portions in said predetermined relative positions.
12. A connector for spacer frame segments in an insulating glass panel comprising:
a) first and second body portions respectively connectable to adjacent frame segments;
b) a hinge connecting said body portions together for enabling said body portions to be pivoted about the hinge to form, with the associated spacer frame segments, a frame corner;
c) connecting means for securing said body portions against relative movement when the frame corner is formed, said connecting means comprising:
i) a first latching projection extending from said first body portion into latching relationship with a first keeper surface on said second body portion;
ii) a second latching projecting extending from said second body portion into latching relationship with a second keeper surface on said first body portion.
a) first and second body portions respectively connectable to adjacent frame segments;
b) a hinge connecting said body portions together for enabling said body portions to be pivoted about the hinge to form, with the associated spacer frame segments, a frame corner;
c) connecting means for securing said body portions against relative movement when the frame corner is formed, said connecting means comprising:
i) a first latching projection extending from said first body portion into latching relationship with a first keeper surface on said second body portion;
ii) a second latching projecting extending from said second body portion into latching relationship with a second keeper surface on said first body portion.
13. The connector claimed in claim 12 wherein said first and second body poxtions respectively define abutment surfaces in confronting relationship when the frame corner is formed.
14. The connector claimed in claim 12 wherein each of said first and second body portions defines first and second abutment surfaces, said abutment surfaces on each body portion respectively disposed generally along intersecting planes which come together when the body portions are pivoted to form the frame corner.
15. A corner connector for spacer frame segments in an insulating glass panel comprising:
a) first and second body portions respectively connectable to adjacent frame segments;
b) a hinge connecting said body portions together for enabling said body portions to be pivoted about the hinge to form, with the associated spacer frame segments, a frame corner;
c) connecting means for securing said body portions against relative movement when the frame corner is formed, the connecting means comprising first and second latching projections formed on said first and second body portions, respectively, and first and second keeper structures formed on said second and first body portions, respectively, said first latching projection in latching relationship with said first keeper structure and said second latching projection in latching relationship with said second keeper structure to prevent relative movement between said body portions when the frame corner is formed.
a) first and second body portions respectively connectable to adjacent frame segments;
b) a hinge connecting said body portions together for enabling said body portions to be pivoted about the hinge to form, with the associated spacer frame segments, a frame corner;
c) connecting means for securing said body portions against relative movement when the frame corner is formed, the connecting means comprising first and second latching projections formed on said first and second body portions, respectively, and first and second keeper structures formed on said second and first body portions, respectively, said first latching projection in latching relationship with said first keeper structure and said second latching projection in latching relationship with said second keeper structure to prevent relative movement between said body portions when the frame corner is formed.
16. The corner connector claimed in claim 15 wherein said first and second latching projections each comprises a resiliently flexible latch element projecting from the associated body portion, each latch element being resiliently deformed by part of the associated keeper structure as the body portions approach their frame corner forming orientations, said latch element springing into the latching relationship.
17. The corner connector claimed in claim 16 wherein each said latch element comprises an elongated flexible section extending in a direction transverse to the direction of extent of the hinge pivot axis and having keeper struc-ture engaging surface extending in a plane generally parallel to the direction of extent of the hinge axis.
18. The connector claimed in claim 17 wherein said keeper structure comprises a latch element deflecting surface and an adjacent keeper surface disposed for engage-ment with said keeper structure engaging surface.
19. A spacer frame assembly for an insulating glass panel or the like comprising:
a) a plurality of tubular spacer frame segments forming sides of a polygonal generally planar spacer frame;
b) a connector for securing adjacent frame segments together at a corner of the frame comprising:
i) a first connector body portion extending into one of the frame segments having an abutment face disposed exteriorly of said frame segment, said first body portion attached to said frame segment;
ii) a second body portion extending into the adjacent frame segment having a second abutment face disposed exteriorly of said second frame segment, said second body portion attached to said adjacent frame segment;
iii) a thin strip of readily flexible material connecting said first and second body portions together for hinging movement relative to each other to move said abutment faces into confronting relationship; and, iv) connecting means for securing said body portions in a position in which said first and second abutment faces confront each other for rigidifying the frame corner, said connecting means comprising a resiliently deflectable part of one body portion engageable with a part of the other body portion to prevent separation of said abutment faces.
a) a plurality of tubular spacer frame segments forming sides of a polygonal generally planar spacer frame;
b) a connector for securing adjacent frame segments together at a corner of the frame comprising:
i) a first connector body portion extending into one of the frame segments having an abutment face disposed exteriorly of said frame segment, said first body portion attached to said frame segment;
ii) a second body portion extending into the adjacent frame segment having a second abutment face disposed exteriorly of said second frame segment, said second body portion attached to said adjacent frame segment;
iii) a thin strip of readily flexible material connecting said first and second body portions together for hinging movement relative to each other to move said abutment faces into confronting relationship; and, iv) connecting means for securing said body portions in a position in which said first and second abutment faces confront each other for rigidifying the frame corner, said connecting means comprising a resiliently deflectable part of one body portion engageable with a part of the other body portion to prevent separation of said abutment faces.
20. The spacer frame assembly claimed in claim 19 wherein said resiliently deflectable part of one body portion forms a latching projection extending from said one of said body portions and latching projection engaging structure on the other body portion.
21. The spacer frame assembly claimed in claim 20 further including a second resiliently deflectable latching projection on said other body portion and a second latching projection engaging structure on said one body portion, said second latching projection being in latching relationship with said second projection engaging structure when said first latching projection is engaged with said first projection engaging structure.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000397953A CA1169299A (en) | 1982-03-09 | 1982-03-09 | Spacer frame for an insulating glass panel |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000397953A CA1169299A (en) | 1982-03-09 | 1982-03-09 | Spacer frame for an insulating glass panel |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1169299A true CA1169299A (en) | 1984-06-19 |
Family
ID=4122252
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000397953A Expired CA1169299A (en) | 1982-03-09 | 1982-03-09 | Spacer frame for an insulating glass panel |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1169299A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4822205A (en) * | 1987-01-21 | 1989-04-18 | Indal Limited | Fold-up corner piece for spacer tube assembly |
-
1982
- 1982-03-09 CA CA000397953A patent/CA1169299A/en not_active Expired
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4822205A (en) * | 1987-01-21 | 1989-04-18 | Indal Limited | Fold-up corner piece for spacer tube assembly |
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