CA2571165C

CA2571165C - Novel muntin bar assemblies

Info

Publication number: CA2571165C
Application number: CA002571165A
Authority: CA
Inventors: Benjamin Zurn; Curt Queck; Daniel Stava
Original assignee: Cardinal IG Co
Current assignee: Cardinal IG Co
Priority date: 2005-12-15
Filing date: 2006-12-14
Publication date: 2009-10-06
Anticipated expiration: 2026-12-14
Also published as: CA2571165A1; US20070157544A1

Abstract

A muntin bar assembly, for example, included in an insulating glass unit, includes at least one weld joint joining a muntin bar keeper to a spacer; the keeper holds a muntin bar in a fixed relation with the spacer. A method for preparing the assembly includes steps of welding the keeper to the spacer and attaching the muntin bar to the keeper. The keeper may include a base, which accommodates welding of the keeper to the spacer, and at least one engaging element extending out from the base to hold the muntin bar.

Description

_. a ,. .

NOVEL MUNTIN BAR ASSEMBLIES
TECHNICAL FIELD

[01] The present invention pertains to glazing assemblies and more particularly to glazing assemblies incorporating muntin bar assemblies.

BACKGROUND

[02] Muntin grids, or lattices, are often added to glazing assemblies, in order to increase the aesthetic appeal of the glazing assemblies. Muntin grids typically consist of lineal elements, or muntin bars, that subdivide a glazed opening created by a perimeter frame work assembly, particularly in the context of windows and doors.
Insulated glass type glazing assemblies, or insulating glass units, often incorporate the muntin bars between two glass panes which are spaced apart by a spacer frame to which the muntin bars are attached. The muntin bars may be attached to the spacer frame by components called muntin keepers, which are cross-connecting pieces having one portion designed for attachment to the end of a muntin bar and another portion for attachment to the spacer frame; alternately muntin bar ends may be embedded within a sealing material extending along the inside perimeter of the spacer frame between the glass panes.

[03] The secure attachment of muntin bars to spacer frames, before and after completing the assembly of insulating glass units, is important in preventing costly re-work along the assembly line, and to maintaining an aesthetically pleasing appearance of the final product assembled into a door or window that is subject to environmental loading.
Furthermore, it is desirable that muntin bar attachment not compromise the integrity of other elements of the insulating glass (IG) assembly/unit, for example, that of the spacer frame or of the seal between the glass panes and the spacer frame, nor interfere with, or reduce the efficiency of, other processes required for IG unit production.
Thus, there is a need for new methods and components providing for the secure attachment of muntin bars to spacer frames without compromising the integrity of IG unit components, or the efficiency of assembly processes.

SUMMARY

[04] Accordingly, in one aspect there is provided a muntin bar assembly, comprising:
a spacer including a surface;
a muntin bar;

at least one muntin bar keeper including a base and at least one engaging element, the at least one engaging element extending out from the base and holding the muntin bar in a fixed relation with the spacer, and the base and the at least one engaging element being integrally formed from sheet metal; and at least one weld joint formed between the base of the at least one keeper and the spacer surface.

[04a] According to another aspect there is provided a method for preparing a muntin bar assembly, the method comprising:
forming at least one muntin bar keeper from sheet metal such that at least one engaging element of each of the at least one keeper extends integrally with, and out from, a corresponding base of each of the at least one keeper;
welding the base of each of the at least one muntin bar keeper to a spacer;
and attaching a muntin bar to the engaging element of each of the at least one keeper.
[04b] According to yet another aspect there is provided a component for holding a muntin bar in a fixed relation with a spacer within an insulating glass assembly, the component comprising:
at least one engaging element to hold the muntin bar; and a base supporting the engaging element and including an area being offset from the engaging element to accommodate welding of the base to a surface of the spacer, wherein the base is free of any spacer-engaging protrusions.

[04c] According to yet another aspect there is provided a component for holding a muntin bar in a fixed relation with a spacer within an insulating glass assembly, the component comprising:
at least one engaging element to hold the muntin bar; and a base supporting the engaging element and including a weld projection.
[04d] According to still yet another aspect there is provided an insulating glass assembly, comprising:
a pair of glass panes;
a spacer separating the glass panes from one another and including a surface disposed therebetween;
a muntin bar disposed between the glass panes;
at least one muntin bar keeper including a base and at least one engaging element, the at least one engaging element extending out from the base and holding the muntin bar . i . . ... . . .L. .. . . . . . .... _ .. ... . . .

i in a fixed relation with the spacer, and the base and the at least one engaging element being integrally formed from sheet metal; and at least one weld joint formed between the base of the at least one keeper and the spacer surface.

BRIEF DESCRIPTION OF THE DRAWINGS

[05] The following drawings are illustrative of particular embodiments of the present invention and therefore do not limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.

[06] Figure 1 is a perspective view, including a cut-away section, of an exemplary IG assembly.

[07] Figure 2A is an exploded view of a portion of the assembly shown in Figure 1, according to some embodiments of the present invention.

[08] Figure 2B is a perspective view of the keeper shown in Figure 2A.

[09] Figure 2C is an end view of a portion of the portion of the assembly shown in Figure 2A, according to some embodiments of the present invention.

[010] Figure 2D is an end view of the keeper shown in Figure 2B.

[011] Figure 3 is a cross-section view through section A-A of Figure 1, according to some embodiments of the present invention.

[012] Figure 4 is a flow chart outlining some assembly methods of the present invention.

[013] Figures 5A-B are schematics showing alternative welding process set ups, according to some embodiments of the present invention.

[014] Figure 5C is a plot of an exemplary resistance welding schedule, according to some embodiments of the present invention.

[015] Figure 6 is a schematic showing a cohesive group of keepers, according to some embodiments of the present invention.

[016] Figure 7A is a perspective view of an alternate embodiment of a muntin bar keeper.

[017] Figures 7B-C are a perspective view and an end view, respectively of another alternate embodiment of a muntin bar keeper.

2a Practitioner Docket # 44046.103.272.2 Utility Patent Application [18] Figure 7D is a cross-section view, for example, through section line A-A
of Figure 1, according to some alternate embodiments of the present invention.

[19] Figure 8A is a perspective view of yet another embodiment of a muntin bar keeper.

[20] Figure 8B is a cross-section view, for example, through section line A-A
of Figure 1, according to additional alternate embodiments of the present invention.

[21] Figure 9 is a cross-section view, for example, through section line A-A
of Figure 1, according to yet further embodiments of the present invention.

DETAILED DESCRIPTION

[22] The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides practical illustrations for implementing exemplary embodiments of the present invention.

[23] Figure 1 is a perspective view, including a cut-away section, of an exemplary IG
assembly 20. Figure 1 illustrates IG assembly 20 including a pair of glass panes 22 spaced apart by sides 35 (Figures 2A,C) of a spacer frame 24, to which panes 22 are fixed, for example, by an adhesive, which may double as a sealant; a muntin bar grid 40 is shown disposed in the space between panes 22, being held in a fixed relation with spacer frame 24. Figure 1 further illustrates spacer frame 24 being formed by a spacer 30 which includes a wall 32 defining a lumen or channel 34 in which a plurality of desiccant granules 36 are disposed; such granules 36 may be useful for preventing condensation between panes 22. According to the illustrated embodiment, grid 40 includes a relatively long muntin bar 41 extending from a first end 411 to a second end 412, and two shorter bars 43 each extending from a first end 431 to a second end 432; ends 411, 412 of longer muntin bar 41 and ends 431 of shorter muntin bars 43 are joined to corresponding sides of spacer frame, while ends 432 of shorter muntin bars 43 are joined to longer muntin bar 41. It should be noted that the scope of the present invention is not limited by any particular number and/or arrangement of muntin bars.

[24] Figure 2A is an exploded view of a portion of assembly 20, according to some embodiments of the present invention. Figure 2A illustrates a muntin bar keeper 220 joined to spacer 30 along a surface 104 thereof; keeper 220 includes a base 26, for joining Practitioner Docket # 44046.103.272.2 Utility Patent Application keeper 220 to spacer 30, and an engaging element 200 extending out from base 26, which, when inserted, at end 411, within a center rectangular portion 302 formed by a wall 401 of muntin bar 41, holds muntin bar 41 in fixed relation with spacer 30. (It should be noted that Figure 2A may also be illustrative of end 412 of muntin bar 41 as well as end 431 of muntin bar 43.) Muntin bars 41, 43, as well as others described herein, may be formed from aluminum, stainless steel, or any other suitable metal, or from plastics or composites, being either hollow, as described herein, or solid, according to alternate embodiments.

[25] Figure 2B is a perspective view of keeper 220, and Figure 2C is an end view of the portion shown in Figure 2A including keeper 220 and spacer 30. According to the illustrated embodiment, base 26 of keeper 220 extends alongside spacer surface 104 and is attached thereto by two weld joints 25, which are disposed on either side of engaging element 200 on tab portions 260 of base 26. With reference to the embodiment illustrated in Figure 2C, it may be appreciated that the attachment of keeper 220 to spacer 30, by joints 25, does not compromise the integrity of spacer wal132, which could be compromised, for example, by a piercing of a protruding portion of another type of keeper through wall 32 at surface 104 - such piercing could allow desiccant granules 36 (Figure 1) to leak out from lumen 34. Neither does the attachment of keeper 220, according to the illustrated embodiment, compromise the integrity of bonds between panes 22 and spacer frame 24 (Figure 1), that extend alongside sides 35 of spacer 30.
Furthermore, according to preferred embodiments, attachment of keepers via welding can save a processing step required to create features in a spacer for the engagement of mating keeper features, for example, a forming of one or more holes through the spacer wall to engage keeper protrusions. However, it should be noted that alternate embodiments of the present invention may employ mating keeper and spacer features.

[26] Figure 2B further illustrates an optional weld projection 224 as a recess in an upper surface of each of tab portions 260. Figure 2D is an end view of keeper 220 showing weld projection 224 projecting from a lower surface of tab portion. Weld projection 224 may facilitate resistance welding, according to some embodiments that will be described below. An alternate embodiment of a weld projection is formed by a plurality of relatively smaller recessed surfaces. One or more weld projections included in certain Practitioner Docket # 44046.103.272.2 Utility Patent Application embodiments of the present invention should not be construed as interlocking features;
keepers, according to certain preferred embodiments of the present invention, are free of any spacer-engaging protrusions that need to be interlocked with a feature of the spacer in order to complete a junction between the keeper and the spacer.

[27] Figures 2A-C further illustrate engaging element 200 of keeper 220 including a pair of opposing legs 226 in an A-frame structure to provide for a press fit, a friction fit, or an interference fit within an interior portion of a muntin bar, for example, within wall 401 of muntin bar 41. According to the illustrated embodiment, legs 226 act like a spring, bending toward one another, to allow for insertion into muntin bar 41, and pressing outward against muntin bar wall 401 once inserted. Each leg 226 is shown to include an extension 206, folding outward and over toward base 26, in order to facilitate the insertion into muntin bar 41 and to provide a contact surface between engaging element 200 and an inner surface of wall 401. According to exemplary embodiments of the present invention, keeper 220 is formed by a sheet metal stamping process, for example, from stainless steel sheet metal having a thickness from approximately 0.005 inch to approximately 0.020 inch. It should be noted that the present invention is not limited to exemplary configurations of engaging elements described herein, and that alternate embodiments include any type of friction fitting or interlocking member, either male, for example, as in the illustrated embodiments, or female, to alternately fit about an exterior surface of a muntin bar.

[28] Figure 3 is a cross-section view through section A-A of Figure 1 illustrating the fit of engaging member 200 of keeper 220 within wall 401 of muntin bar 41, according to some embodiments of the present invention. It may be appreciated, with reference to Figure 3, that the fit of engaging member 200 within center rectangular portion 302 of bar 41 provides a stable attachment to hold bar 41 in the fixed relation with spacer 30. With reference to Figure 3, in conjunction with Figure 1, it may further be appreciated that the contoured profile of bar 41, as well as that of bars 43, effectively hides keeper 220 from view when bars 41 and 43 are attached to spacer 30, as shown in Figure 1. It should be noted that, in some configurations of the present invention, more than one keeper, of any embodiment described herein, may be used to hold a single end of a muntin bar, for example, a muntin bar having a relatively large profile cross-section.

Practitioner Docket # 44046.103.272.2 Utility Patent Application [29] Figure 4 is a flow chart outlining some assembly methods of the present invention.
According to the flow chart of Figure 4, an initial assembly step 501, in which a spacer is prepared, is followed by a step 503, in which one or more weld keepers are welded to the spacer. Following step 503, one or more muntin bars are attached to the spacer, per step 509, for example by insertion of a keeper, which is welded to the spacer, into an end of the muntin bar, as previously described. Additional spacer prep, per step 507, may be necessary, according to some embodiments, prior to attaching muntin bar(s).

[30] Spacers for IG assemblies are typically formed from lineal sections of rolled aluminum or stainless steel that are cut to length, according to a specified dimension of the corresponding IG unit, and then bent into a frame for subsequent glazing.
According to some assembly methods of the present invention, spacer lineal sections are cut to length, per step 501, and then one or more keepers are welded, per step 503, to the spacer, in lineal form, for example, as illustrated in the schematic of Figure 5A.
According to Figure 5A, spacer 30 has been cut to length, for example, appropriate for assembly 20 shown in Figure 1, keepers 220 have been positioned for muntin bar attachment, and keepers 220 and spacer 30 have been directed, per arrow C, so that each keeper passes beneath a welding station 650 for welding to spacer 30. However, according to alternate embodiments, welding station 650 may move to weld each keeper 220 to spacer 30, while spacer 30 is held stationary. Welding station 650 is shown to include two weld heads 65 which may either simultaneously or sequentially weld tab portions 260 (Figure 2A-B) of keepers 220 to spacer 30; according to alternate embodiments, a welding station includes a single weld head. It should be noted that any number of weld joints may be employed to join a keeper to a spacer without departing from the spirit and scope of the present invention. Figure 5A further illustrates, with dashed lines, optional additional welding stations 650, employed in order to increase productivity by welding more than one keeper at a time. Once keepers 220 have been welded to spacer 30, spacer can be bent into shape to form a frame, for example frame 24 of Figure 1, per step 507 of Figure 4, and then muntin bars are attached thereto, per step 509.

[31] According to some alternate assembly methods of the present invention, the spacer prep of step 501 fiuther includes bending the spacer into a frame so that the one or more keepers are welded to the spacer when it is in frame form, for example, as is illustrated in Practitioner Docket # 44046.103.272.2 Utility Patent Application the schematic of Figure 5B. According to Figure 5B, welding station 650 is held in a fixed position and spacer frame 24 is rotated, per arrow B, to bring each interior side of spacer frame 24 into position with respect to welding station 650 for the welding of each keeper 220 to a respective side. However, according to alternate embodiments, weld station 650 moves to each interior side of spacer frame 24, which is held stationary, in order to weld each keeper 220 to the respective side; and, according to additional alternate embodiments, multiple welding stations may be provided, so that more that one keeper 220 at a time may be welded to spacer frame 24. Figure 5B further illustrates ends 231, 232 of spacer uncoupled, leaving a gap 240, which facilitates flexing of frame 24 for subsequent attachment of muntin bars, per step 509 of Figure 4, and which is closed, by coupling of ends 231, 232 together, following muntin bar attachment.
However, frame 24 may flex enough without gap 240, so that, according to an alternate method, muntin bar attachment follows the coupling of spacer ends 231, 232.

[32] According to some preferred embodiments of the present invention, resistance-type welding is used to join keepers to spacers. Those skilled in the art of resistance welding understand that resistance welding uses the application of electric current and mechanical pressure to create a weld between two pieces of metal, thus, according to the preferred embodiments, weld heads 65 are electrodes which conduct an electric current to keeper base 26 and spacer wal132, while applying pressure to force base 26 and wa1132 together into intimate contact. A welding cycle first develops sufficient heat to raise a small volume of metal to the molten state, while pressure is applied; the metal then cools, while still under pressure, until it has adequate strength to hold the parts together. The current density and pressure must be sufficient to produce a weld nugget, but not so high as to expel molten metal from the weld zone. Figure SC is a plot of an exemplary schedule for a resistance welding cycle to weld a stainless steel muntin bar keeper, for example, along base 26 of keeper 220, to a stainless steel spacer, for example spacer 30. The illustrated exemplary weld schedule is suitable for a holding force of approximately 6 pounds and a keeper wall thickness in the range of approximately 0.005 inch to approximately 0.010 inch. Welding per the illustrated schedule may be facilitated by weld projection 224 (Figure 2B), which creates a receptacle for weld electrode 65, thereby providing a reduced and controlled surface area between keeper base 26 and spacer surface 104, for a Practitioner Docket # 44046.103.272.2 Utility Patent Application greater current density, so that less current is required for welding.
According to the exemplary welding schedule illustrated in Figure 5, weld head 65 applies pressure for 250 milliseconds, prior to ramping up a current to approximately 950 Amps, over approximately 1 milliseconds. The 950 Amp current is applied for approximately milliseconds before dropping back to zero, and the force is held for another milliseconds after the drop. It should be noted that the scope of the present invention is not limited by a particular welding schedule, since alternative resistance welding schedules may be tailored according to alternate materials and geometries of spacers and keepers within the scope of the present invention. Furthermore, although resistance welding is preferred, any other type of welding known to those skilled in the art may be employed, without departing from the spirit and scope of the present invention, examples of which include, without limitation, MIG (Gas Metal Arc Welding) welding, TIG
welding (Gas Tungsten Arc Welding), and mini-plasma welding.

[33] Some assembly methods of the present invention further include a step to separate each keeper 220 from a cohesive group, for example, group 600 shown in Figure 6, prior to placing each keeper 220 for welding to spacer 30. According to the illustrated embodiment, keepers 220 are held together in group 600 by a continuity of base 26, which includes severing points 62 disposed between each engagement element 200 and group 600 is formed in a coil so that engagement elements 200 face inward; the coil may be unrolled in order to dispense keepers 220, for example, via a hitch feed.
Alternately, keepers are held together in a group 600' which is formed as a stick.
According to some assembly methods, keepers 220 are fed into a hitch feed where they are separated from one another via shearing, or cutting, of base 26 at severing points 62. Once one of keepers 220 is separated from group 600, the keeper may be picked and placed, for example, on surface 104 of spacer 30 (Figures 2A, C), for welding. Group 600 may greatly facilitate automation of the assembly process. According to alternate embodiments, individual keepers 220, not joined along a common base, are joined together by adhesive attachment to a release liner from which the keepers may be pulled either one-by-one or in groups.

[34] Figure 7A is a perspective view of an alternate embodiment of a muntin bar keeper, and Figures 7B-C are a perspective view and an end view, respectively, of another alternate Practitioner Docket # 44046.103.272.2 Utility Patent Application embodiment of a muntin bar keeper. Figure 7A illustrates a muntin bar keeper including a base 76, a first engagement element 701 and second engagement element 702; each engaging element 701, 702 extends out from base 76, and first engaging element 701 is spaced apart from second engaging element 702 so that base 76 extends therebetween to provide an area, which is shown including an optional weld projection 724, for welding keeper 720 to a spacer, for example spacer 30. Figure 7A
fiuther illustrates each engagement element 701, 702 including a pair of opposing legs 776 in an A-frame structure, to provide for a press fit, a friction fit, or an interference fit within an interior portion of a muntin bar, wherein each leg 776 includes an extension 706, folding outward and over toward base 76. Figures 7B-C illustrate a muntin bar keeper 720' including a base 76' and first and second engaging elements 701', 702', which extend out from base 76' and are spaced apart from one another so that base 76' provides an area therebetween for welding, for example, to form weld joint 25 between keeper 702' and surface 104 of spacer 30 (Figure 7D). Figures 7B-C further illustrate each engaging member 701', 702', like members 701, 702 of Figure 7A, including opposing legs 776, which each include extension 706 folding outward and over toward base 76'.
According to the illustrated embodiments, each pair of legs 776 acts like a spring, wherein the opposing legs bend toward one another, to allow for insertion into a muntin bar, and press outward against an inner surface of a wall of the muntin bar, once inserted.
Extensions 706 can facilitate insertion and provide a contact surface between engaging elements 701, 702 and 701', 702'. With reference to Figures 7B-C, it should be noted that engaging members 701 ', 702' each further include tabs 726 extending inward from corresponding legs 776; tabs 726 provide a force opposing an inward bending of opposing legs toward one another, thereby increasing an outward pressing force of legs 776 against an inside surface of the muntin bar wall.
[35J Keepers 720, 720' may be more appropriate to support muntin bars having rectangular profiles, for example as illustrated in Figure 7D. Figure 7D is a cross-section view, for example, through section line A-A of Figure 1, according to an embodiment that includes a muntin bar 81 having a rectangular profile. Figure 7D illustrates the fit of engaging members 701', 702'of keeper 720' within a wall 801 of muntin bar 81. It may be appreciated, with reference to Figure 7D, that the fit of engaging members 701', 702' n 1 Practitioner Docket # 44046.103.272.2 Utility Patent Application within bar 81 provides a stable attachment to hold bar 81 in a fixed relation with spacer 30. With further reference to Figure 7D, it may also be appreciated that the rectangular profile of bar 81 effectively hides keeper 720' from view when bar 81 is attached to spacer 30.
[36] Figure 8A is a perspective view of yet another alternate embodiment of a muntin bar keeper. Figure 8A illustrates a muntin bar keeper 820 including a base 86 and an engaging element 800 extending out from base 86, such that base 86 includes areas, disposed on either side of element 800, for welding, for example, to form weld joints 25 between keeper 820 and surface 104 of spacer 30, for example as illustrated in Figure 8B.
Figure 8B is a cross-section view, for example, through section line A-A of Figure 1, according to an embodiment wherein engagement element 800 of keeper 820 holds a muntin bar 91, which has a substantially round profile, in a fixed relation with spacer 30.
Figure 8A further illustrates engaging element 800 including opposing legs 886 extending toward one another in an A-frame structure to provide for a press fit, or an interference fit, within an interior portion of a muntin bar, for example, muntin bar 91, as shown in Figure 8B. According to the illustrated embodiment, legs 886 act like a spring, bending toward one another, to allow for insertion into muntin bar 91, and pressing outward against a wal1901 of muntin bar 91, once inserted. Each leg 886 is shown to include an extension 806, folding outward and over toward base 86, in order to facilitate the insertion into muntin bar 91 and to provide points of contact between engaging element 800 and an inner surface of muntin bar wal1901. Figure 9 is a cross-section view illustrating yet another alternate embodiment of a keeper, which may be particularly suited for the round profile of muntin bar 91. The keeper shown in Figure 9 includes three engaging elements 301, 302, 303, each formed by a single leg, for example, similar to one of legs 886, which are disposed about a perimeter of a base 96 and extend outward therefrom; weld joint 25 is shown being formed in a central portion of the base.
[37] With reference back to Figure 2A it may be appreciated that spacer 30, having a width FW of surface 104, may accommodate attachment of muntin bars of various cross-sections, as long as corresponding keepers have widths MW less than width FW, since no special interlocking or mating features between the keeper and the spacer are employed by embodiments of the present invention. Furthermore, keepers of the present invention .

Practitioner Docket # 44046.103.272.2 Utility Patent Application may be positioned anywhere along a surface of a spacer, for example surface 104 of spacer 30, thereby providing flexibility for the manufacturing line to produce a variety of arrangements of muntin bars with a single type of spacer.
[38] In the foregoing detailed description, the invention has been described with reference to specific embodiments. However, it may be appreciated that various modifications and changes can be made without departing from the scope of the invention as set forth in the appended claims. For example, although various muntin bars are shown herein to extend orthogonally along two orthogonal planes which are approximately orthogonal to a surface of a spacer, to which a muntin bar keeper is attached, it is contemplated that engagement features of muntin bar keepers may be structured to allow muntin bars to extend in a plane skewed from one or both of the orthogonal planes.

Claims

1. A muntin bar assembly, comprising:
a spacer including a surface;
a muntin bar;
at least one muntin bar keeper including a base and at least one engaging element, the at least one engaging element extending out from the base and holding the muntin bar in a fixed relation with the spacer, and the base and the at least one engaging element being integrally formed from sheet metal; and at least one weld joint formed between the base of the at least one keeper and the spacer surface.

2. The assembly of claim 1, wherein the base of the at least one keeper is free of any spacer-engaging protrusions.

3. The assembly of claim 1, wherein the at least one weld joint is offset from the at least one engaging element.

4. The assembly of claim 1, wherein the muntin bar includes a perimeter wall forming a lumen and the at least one engaging element of the at least one keeper is press fitted within the lumen.

5. The assembly of claim 1, wherein the at least one engaging element includes opposing legs.

6. The assembly of claim 5, wherein the base includes a tab extending laterally from the legs and the at least one weld joint is formed between the tab and the spacer surface

7. The assembly of claim 1, wherein the at least one engaging element includes two engaging elements spaced apart from one another, and the base extends therebetween.

8. The assembly of claim 7, wherein the at least one weld joint is disposed between the two engaging elements.

9. The assembly of claim 1, wherein the muntin bar includes a perimeter wall extending around a substantial portion of the at least one keeper to effectively hide the keeper.

10. The assembly of claim 1, wherein the at least one keeper holds the muntin bar in the fixed relation without penetrating through the surface of the spacer.

11. A method for preparing a muntin bar assembly, the method comprising:
forming at least one muntin bar keeper from sheet metal such that at least one engaging element of each of the at least one keeper extends integrally with, and out from, a corresponding base of each of the at least one keeper;
welding the base of each of the at least one muntin bar keeper to a spacer;
and attaching a muntin bar to the engaging element of each of the at least one keeper.

12. The method of claim 11, further comprising cutting the spacer to length prior to welding.

13. The method of claim 11, further comprising cutting the spacer to length subsequent to welding.

14. The method of claim 11, further comprising bending the spacer into a spacer frame prior to welding.

15. The method of claim, 1, further comprising bending the spacer into a spacer frame subsequent to welding.

16. The method of claim 11, wherein the at least one keeper comprises a cohesive group of keepers, said method further comprising separating each of the at least one keeper from the cohesive group of keepers to place each of the at least one keeper for welding.

17. The method of claim 16, wherein the cohesive group is formed in a coil and separating each of the at least one keeper comprises unrolling a length of the cohesive group.

18. The method of claim 16, wherein separating each of the at least one keeper comprises shearing along a common base of the cohesive group of keepers.

19. The method of claim 11, wherein the at least one keeper comprises a first keeper and a second keeper, and welding comprises welding the first keeper to the spacer at a first location and welding the second keeper to the spacer at a second location, the second location being spaced apart from the first location along a length of the spacer.

20. The method of claim 19, wherein welding of the first and second keepers is simultaneous.

21. The method of claim 19, wherein welding of the first and second keepers is sequential.

22. The method of claim 11, wherein welding comprises resistance welding.

23. The method of claim 11, wherein welding the base of each of the at least one keeper comprises welding a first part of the base to a first location on the spacer and welding a second part of the base to a second location on the spacer.

24. The method of claim 23, wherein welding the first and second parts is simultaneous.

25. The method of claim 23, where welding the first and second parts is sequential.

26. The method of claim 11, wherein attaching the muntin bar to the engaging element of each of the at least one keeper comprises press fitting the muntin bar over the engaging element.

27. A component for holding a muntin bar in a fixed relation with a spacer within an insulating glass assembly, the component comprising:
at least one engaging element to hold the muntin bar; and a base supporting the engaging element and including an area being offset from the engaging element to accommodate welding of the base to a surface of the spacer, wherein the base is free of any spacer-engaging protrusions.

28. The component of claim 27, wherein the at least one engaging element comprises opposing legs.

29. The component of claim 27, wherein the at least one engaging element comprises two engaging elements spaced apart from one another, and the area of the base is disposed between the two engaging elements.

30. The component of claim 27, wherein the base has dimensions less than or equal to dimensions defining a profile of the muntin bar, so that the base is effectively hidden by the muntin bar when the muntin bar is held by the at least one engaging element.

31. The component of claim 27, wherein the area of the base includes a weld projection.

32. A component for holding a muntin bar in a fixed relation with a spacer within an insulating glass assembly, the component comprising:
at least one engaging element to hold the muntin bar; and a base supporting the engaging element and including a weld projection.

33. The component of claim 32, wherein the weld projection is offset from the at least one engaging element.

34. The component of claim 32, wherein the at least one engaging element comprises opposing legs.

35. The component of claim 32, wherein the at least one engaging element comprises two engaging elements spaced apart from one another, and the weld projection is disposed between the two engaging elements.

36. The component of claim 32, wherein the base has dimensions less than or equal to dimensions defining a profile of the muntin bar so that the base is effectively hidden by the muntin bar when the muntin bar is held by the at least one engaging element.

37. An insulating glass assembly, comprising:
a pair of glass panes;
a spacer separating the glass panes from one another and including a surface disposed therebetween;
a muntin bar disposed between the glass panes;
at least one muntin bar keeper including a base and at least one engaging element, the at least one engaging element extending out from the base and holding the muntin bar in a fixed relation with the spacer, and the base and the at least one engaging element being integrally formed from sheet metal; and at least one weld joint formed between the base of the at least one keeper and the spacer surface.

38. The assembly of claim 37, wherein the base of the at least one keeper is free of any spacer-engaging protrusions.

39. The assembly of claim 37, wherein the at least one weld joint is offset from the at least one engaging element.

40. The assembly of claim 37, wherein the muntin bar includes a perimeter wall forming a lumen and the at least one engaging element of the at least one keeper is press fitted within the lumen.

41. The assembly of claim 37, wherein the at least one engaging element includes opposing legs.

42. The assembly of claim 41, wherein the base includes a tab extending laterally from the legs and the at least one weld joint is formed between the tab and the spacer surface

43. The assembly of claim 37, wherein the at least one engaging element includes two engaging elements spaced apart from one another, and the base extends therebetween.

44. The assembly of claim 43, wherein the at least one weld joint is disposed between the two engaging elements.

45. The assembly of claim 37, wherein the muntin bar includes a perimeter wall extending around a substantial portion of the at least one keeper to effectively hide the keeper.

46. The assembly of claim 37, wherein the at least one keeper holds the muntin bar in the fixed relation without penetrating through the surface of the spacer.