US20090123694A1 - Material with undulating shape - Google Patents

Material with undulating shape Download PDF

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Publication number
US20090123694A1
US20090123694A1 US12/270,393 US27039308A US2009123694A1 US 20090123694 A1 US20090123694 A1 US 20090123694A1 US 27039308 A US27039308 A US 27039308A US 2009123694 A1 US2009123694 A1 US 2009123694A1
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United States
Prior art keywords
sheet
material sheet
inches
undulating shape
shingle
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.)
Abandoned
Application number
US12/270,393
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English (en)
Inventor
Paul Trpkovski
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Guardian Glass LLC
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Infinite Edge Technologies LLC
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Filing date
Publication date
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Priority to US12/270,393 priority Critical patent/US20090123694A1/en
Assigned to INFINITE EDGE TECHNOLOGIES, LLC reassignment INFINITE EDGE TECHNOLOGIES, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TRPKOVSKI, PAUL
Publication of US20090123694A1 publication Critical patent/US20090123694A1/en
Assigned to GUARDIAN IGU, LLC reassignment GUARDIAN IGU, LLC CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: INFINITE EDGE TECHNOLOGIES, LLC
Assigned to GUARDIAN IGU, LLC reassignment GUARDIAN IGU, LLC CORRECTIVE ASSIGNMENT TO CORRECT THE ASSIGNEE'S ADDRESS PREVIOUSLY RECORDED AT REEL: 032031 FRAME: 0648. ASSIGNOR(S) HEREBY CONFIRMS THE CHANGE OF NAME. Assignors: INFINITE EDGE TECHNOLOGIES, LLC
Assigned to GUARDIAN IG, LLC reassignment GUARDIAN IG, LLC CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: GUARDIAN IGU, LLC
Assigned to Guardian Glass, LLC reassignment Guardian Glass, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GUARDIAN IG, LLC
Abandoned legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/66—Units comprising two or more parallel glass or like panes permanently secured together
    • E06B3/663—Elements for spacing panes
    • E06B3/66304—Discrete spacing elements, e.g. for evacuated glazing units
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/66—Units comprising two or more parallel glass or like panes permanently secured together
    • E06B3/663—Elements for spacing panes
    • E06B3/66309—Section members positioned at the edges of the glazing unit
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/66—Units comprising two or more parallel glass or like panes permanently secured together
    • E06B3/663—Elements for spacing panes
    • E06B3/66309—Section members positioned at the edges of the glazing unit
    • E06B3/66314—Section members positioned at the edges of the glazing unit of tubular shape
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/66—Units comprising two or more parallel glass or like panes permanently secured together
    • E06B3/663—Elements for spacing panes
    • E06B3/66309—Section members positioned at the edges of the glazing unit
    • E06B3/66323—Section members positioned at the edges of the glazing unit comprising an interruption of the heat flow in a direction perpendicular to the unit
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/66—Units comprising two or more parallel glass or like panes permanently secured together
    • E06B3/663—Elements for spacing panes
    • E06B3/66309—Section members positioned at the edges of the glazing unit
    • E06B3/66342—Section members positioned at the edges of the glazing unit characterised by their sealed connection to the panes
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/66—Units comprising two or more parallel glass or like panes permanently secured together
    • E06B3/663—Elements for spacing panes
    • E06B3/66309—Section members positioned at the edges of the glazing unit
    • E06B3/66361—Section members positioned at the edges of the glazing unit with special structural provisions for holding drying agents, e.g. packed in special containers
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/66—Units comprising two or more parallel glass or like panes permanently secured together
    • E06B3/673—Assembling the units
    • E06B3/67326—Assembling spacer elements with the panes
    • E06B3/6733—Assembling spacer elements with the panes by applying, e.g. extruding, a ribbon of hardenable material on or between the panes
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/66—Units comprising two or more parallel glass or like panes permanently secured together
    • E06B3/663—Elements for spacing panes
    • E06B3/66309—Section members positioned at the edges of the glazing unit
    • E06B2003/6639—Section members positioned at the edges of the glazing unit sinuous
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49616—Structural member making
    • Y10T29/49623—Static structure, e.g., a building component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/19—Sheets or webs edge spliced or joined
    • Y10T428/192—Sheets or webs coplanar
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24174—Structurally defined web or sheet [e.g., overall dimension, etc.] including sheet or component perpendicular to plane of web or sheet
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24273—Structurally defined web or sheet [e.g., overall dimension, etc.] including aperture
    • Y10T428/24322—Composite web or sheet
    • Y10T428/24331—Composite web or sheet including nonapertured component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24628—Nonplanar uniform thickness material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/28—Web or sheet containing structurally defined element or component and having an adhesive outermost layer
    • Y10T428/2848—Three or more layers

Definitions

  • Thin and flat sheets of material are often used in the manufacture of a wide variety of products.
  • sheet metal is a common building material.
  • Stainless steel sheets are often used in the manufacture of appliances.
  • Such sheets often have two opposing surfaces that are generally flat and have a thickness defined by the distance between the two surfaces.
  • this disclosure is directed to a material having a small undulating shape.
  • the material is useful in a wide variety of different applications.
  • One aspect is a material sheet comprising a sheet of material having an undulating shape wherein the undulating shape has a peak-to-peak period in a range from about 0.005 inches to about 0.08 inches.
  • Another aspect is an appliance at least partially made from the material sheet.
  • Yet another aspect is a metal stud at least partially made from the material sheet.
  • a further aspect is a motorized vehicle comprising a body, wherein the body is at least partially made from the material sheet.
  • Yet another aspect is a shingle, wherein the shingle is at least partially made from the material sheet.
  • a further aspect is a method of making a material sheet, the method comprising forming an undulating shape in a sheet of material, wherein the undulating shape has a peak-to-peak period in a range from about 0.005 inches to about 0.08 inches.
  • Another aspect is a window spacer at least partially made from the material sheet.
  • Yet another aspect is a window component at least partially made from the material sheet.
  • a further aspect is an electronics enclosure at least partially made from the material sheet.
  • FIG. 1 is a schematic perspective view of an example sheet according to the present disclosure.
  • FIG. 2 is a schematic front view of the example sheet shown in FIG. 1 .
  • FIG. 3 is a schematic top plan view of the example sheet shown in FIG. 1 .
  • FIG. 4 is a schematic side view of the example sheet shown in FIG. 1 .
  • FIG. 5 is a schematic perspective view of an example appliance according to the present disclosure.
  • FIG. 6 is a schematic partial cutaway view of a segment of the appliance shown in FIG. 5 .
  • FIG. 7 is a schematic perspective view of an example building including siding according to the present disclosure.
  • FIG. 9 is a schematic perspective view of an example stud according to the present disclosure.
  • FIG. 10 is a schematic partial cutaway view of a segment of the stud shown in FIG. 9 .
  • FIG. 11 is a schematic side view of an example machine according to the present disclosure.
  • FIG. 12 is a schematic partial cutaway view of a segment of the machine shown in FIG. 1 .
  • FIG. 14 is a schematic partial cutaway view of a segment of the shingle shown in FIG. 13 .
  • FIG. 15 is a schematic perspective view of a portion of a window assembly including a window spacer according to the present disclosure.
  • FIG. 17 is a schematic plan view of the material sheet shown in FIG. 16 .
  • FIGS. 1-4 illustrate an example sheet 100 according to the present disclosure.
  • FIG. 1 is a schematic perspective view of example sheet 100 .
  • FIG. 2 is a schematic front view of example sheet 100 .
  • FIG. 3 is a schematic top plan view of example sheet 100 including an enlarged portion.
  • FIG. 4 is a schematic side view of example sheet 100 .
  • sheet 100 includes a surface 102 , surface 104 , edge 106 , edge 108 , edge 110 , and edge 112 .
  • sheet 100 is arranged in a vertical orientation.
  • Other embodiments include other orientations, such as a horizontal orientation, or any other orientation.
  • Surface 102 is on an opposite side of sheet 100 from surface 104 .
  • surfaces 102 and 104 are referred to as faces of sheet 100 .
  • Edge 106 is a side of sheet 100 .
  • Edge 108 is also a side of sheet 100 , and is located at the opposite side of sheet 100 from edge 106 .
  • edge 110 is the top edge of sheet 100 .
  • Edge 112 is a bottom edge of sheet 100 , and arranged opposite the first edge.
  • edges 106 , 108 , 110 , and 112 define a rectangular shaped perimeter.
  • Other embodiments have a square shaped perimeter.
  • Other embodiments have other shapes and more or fewer edges.
  • sheet 100 has only one edge (such as a circular, oval, or elliptical shape) having no corners.
  • sheet 100 has two, three, four, or more edges.
  • Some embodiments have complex shapes.
  • One preferred embodiment is very long, such that the sheet 100 can be stored in a roll, such as being wound around a spool or core.
  • sheet 100 is generally planar, such that sheet extends generally along two perpendicular axes. In other embodiments, sheet 100 is made planar and then rolled. The rolled sheet 100 is capable of being unrolled into a planar configuration in some embodiments.
  • sheet 100 typically includes an undulating shape.
  • the undulating shape is regular and repeating. Examples of undulating shapes include sinusoidal, arcuate, square, rectangular, triangular, and other desired shapes. Typically the undulating shape has very small undulations, much smaller than typical corrugated materials.
  • the undulating shape typically includes peaks separated by valleys.
  • the undulating shape of sheet 100 defines a waveform having a peak-to-peak amplitude and a peak-to-peak period.
  • the peak-to-peak amplitude A 1 is also the overall thickness of sheet 100 .
  • a 1 is typically in a range from about 0.005 inches (about 0.013 centimeter) to about 0.08 inches (about 0.25 centimeter), and preferably from about 0.02 inches (about 0.05 centimeter) to about 0.04 inches (about 0.1 centimeter).
  • P 1 is the peak-to-peak period of sheet 100 .
  • P 1 is typically in a range from about 0.005 inches (about 0.013 centimeter) to about 0.08 inches (about 0.25 centimeter), and preferably from about 0.02 inches (about 0.05 centimeter) to about 0.04 inches (about 0.1 centimeter). Larger waveforms are used in other embodiments. Yet other embodiments include other waveforms and dimensions than described in this example.
  • sheet 100 is made of stainless steel.
  • Other metals are used in other embodiments, such as titanium or aluminum.
  • a benefit of stainless steel in some embodiments is its strength and resistance to ultraviolet radiation. Titanium has a lower thermal conductivity, a lower density, and better corrosion resistance than stainless steel, which makes it useful in some embodiments.
  • An aluminum alloy is used in some embodiments, such as an alloy of aluminum and one or more of copper, zinc, magnesium, manganese or silicon. Other metal alloys are used in other embodiments.
  • Yet other embodiments of sheet 100 are made of other materials such as a polymer (such as plastic), carbon fiber, graphite, wood, wood particles or pieces, paper or cardboard or other fibrous materials (such as materials made from cellulose pulp). Other embodiments include other materials or combinations of materials.
  • the undulating shape greatly enhances the strength of sheet 100 , allowing sheet 100 to be made to have a thinner material thickness than if sheet 100 did not include the undulating shape. This allows some embodiments of sheet 100 to have much less material cost.
  • a sheet 100 has an undulating shape as shown in FIG. 3 .
  • the sheet 100 has approximately equal strength to another flat sheet (not shown) of the same material and having a material thickness that is twice that of sheet 100 .
  • sheet 100 has approximately equal strength to the flat sheet, but has a material cost that is half of that of the sheet without the undulating shape. As a result, large material cost savings are realized.
  • sheet 100 has a material thickness T 1 (also known as the gauge of the material).
  • T 1 is typically in a range from about 0.0001 inches (about 0.00025 centimeter) to about 0.01 inches (about 0.025 centimeter), and preferably from about 0.0003 inches (about 0.00075 centimeter) to about 0.004 inches (about 0.01 centimeter).
  • Other embodiments include other material thicknesses, depending on the material used and the required strength of the material needed for the particular application. For example, a thicker material sheet is used in some embodiments.
  • the material sheet has a thickness in a range from about 0.01 inches (about 0.025 centimeter) to about 0.06 inches (about 0.15 centimeter).
  • sheet 100 provides surprising results that are useful in a variety of applications.
  • sheet 100 has a clean visual appearance.
  • sheet 100 does not show fingerprints in some embodiments.
  • One reason that fingerprinting is reduced is that fingers generally only make contact with peaks of sheet 100 .
  • the peaks are spaced apart and the resulting imprint left from a finger or hand print is generally undetectable to the eye.
  • the light-diffusing nature of the undulating shape also makes smudges, particles, or fingerprints less noticeable in some embodiments.
  • dust, moisture, or other particles, residue, or liquids present on sheet 100 are less noticeable on sheet 100 due to the undulating shape than on a flat surface.
  • a surface of material sheet 100 has a brushed finish.
  • a surface of material sheet 100 is a polished surface.
  • sheet 100 Due to the undulating shape, light that shines onto sheet 100 is diffused in many directions. As a result, glare and reflections are reduced in some embodiments. For example, sheet 100 reduces glare from sunlight by diffusing the light across a wider area.
  • material sheet 100 acts to dampen noise.
  • the undulating shape of material sheet 100 suppresses echoes, reverberations, resonance, and reflection of sound.
  • the undulating shape of sheet 100 includes a plurality of valleys.
  • the valleys act, in some embodiments, to improve the ability of sheet 100 to shed water or other liquids.
  • the valleys provide a capillary force that advances water downward, particularly when the valleys are arranged vertically (as shown in FIG. 1 ).
  • moisture is retained in valleys, such as by arranging valleys in a horizontal orientation.
  • sheet 100 has much greater flexibility in a first direction than in a second direction.
  • FIG. 3 illustrates flexibility in a first direction. In this example, sheet 100 is flexible about point P 1 . In order to bend an angle A 1 , a force F 1 must be applied.
  • FIG. 4 illustrates flexibility in a second direction. In this example, sheet 100 has less flexibility about point P 2 in the second direction.
  • material sheet 100 has a high axial bend strength to resist axial bending.
  • the perpendicular bend strength is less than the axial bend strength.
  • the material sheet resists bending against the undulations more than bending with the undulations.
  • a 1 and A 2 are equal, such in a range from about 10 to about 20 degrees, the force F 2 that must be applied to bend sheet 100 in the second direction to an angle A 2 is much greater than the force F 1 that must be applied to bend sheet 100 in the first direction an angle A 1 .
  • sheet 100 will bend an angle A 1 in a first direction that is much greater than the angle that sheet 100 will bend in the direction A 2 .
  • sheet 100 is able to withstand a large compressive force F 3 applied to edge 110 in a direction parallel with the peaks and valleys of the elongate shape, without damaging sheet 100 .
  • damage includes bending, breaking, buckling, tearing, cracking, or significantly deforming. In other embodiments, damage includes significant plastic deformation.
  • material 100 includes multiple layers.
  • a metal layer and one or more coatings are provided in some embodiments.
  • An example of a coating is paint, sealant, asphalt, adhesive, oxide, enamel, powder coat, industrial coating, epoxy. Other coatings are used in other embodiments.
  • a coating is formed by electrocoating, cathodic electrodeposition, and electrophoretic coating, electrophoretic painting, plasma coating, deposition (chemical vapor, physical vapor, vacuum, etc), anodizing, electroplating, electron beam deposition, and other coating processes.
  • One method of making the material sheet 100 is to pass a sheet of material through one or more pairs of corrugated rollers, where the corrugated rollers have teeth that bend the sheet of material to have the desired undulating shape.
  • FIG. 5 is a schematic perspective view of an example embodiment of an appliance 500 .
  • Appliance 500 includes a exterior 502 made of a material sheet, such as material sheet 100 , shown in FIG. 1 .
  • a segment of appliance 500 is identified as segment S 1 .
  • appliance is 500 is a refrigerator.
  • the refrigerator includes an external surface that is made of one or more material sheets 100 .
  • material sheet 100 is stainless steel.
  • Other embodiments include other materials as discussed herein.
  • appliances include an air conditioner, dishwasher, clothes dryer, clothes washing machine, drying cabinet, freezer, stove (e.g., cooker, range, oven, cooking plate, or cooktop), water heater, trash compactor, and a microwave oven.
  • Other embodiments include other appliances.
  • Other embodiments use material 100 as the exterior of a cabinet or storage unit.
  • FIG. 6 is a schematic partial cutaway view of segment S 1 , shown in FIG. 5 , illustrating the undulating shape of material 100 . Examples of material sheet 100 are discussed in more detail above. In some embodiments, the peaks and valleys of the undulating shape extend vertically on appliance 500 .
  • FIG. 7 is a schematic perspective view of an example embodiment of a building 700 including siding 702 made of a material sheet, such as material sheet 100 .
  • Siding 702 is configured to be placed on an exterior of building 700 , as shown in FIG. 7 .
  • a segment of siding 702 is identified as segment S 2 .
  • Siding 702 is formed from material sheet 100 in some embodiments, such as by cutting material sheet 100 to desired dimensions and then bending the material sheet 100 to have the desired siding shape.
  • building 700 is a metal building.
  • the exterior of the building is formed by material sheets 100 .
  • building 700 is a straight-walled building in some embodiments, such as a pole barn.
  • building 700 is a metal arch building, such as for a warehouse, a shed, a garage, or an airplane hanger.
  • FIG. 8 is a schematic partial cutaway view of segment S 2 , shown in FIG. 7 , illustrating the undulating shape of material 100 . Examples of material sheet 100 are discussed in more detail above. In some embodiments, the peaks and valleys of the undulating shape extend vertically down an exterior side of siding 500 .
  • FIG. 9 is a schematic perspective view of an example embodiment of a stud 900 made from a material sheet, such as material sheet 100 .
  • stud 900 includes one or more sidewalls 902 , 904 , and 906 . Three or four sidewalls are included in some embodiments.
  • stud 900 includes flanges 908 and 910 . Stud 900 is used in some embodiments in the construction of a building. A segment of stud 900 is identified as segment S 3 .
  • stud 900 is formed of a material sheet 100 .
  • the material sheet 100 is cut or formed to size and is then bent to form the desired features of stud 900 , such as sidewalls 902 , 904 , and 906 and flanges 908 and 910 .
  • FIG. 10 is a schematic partial cutaway view of segment S 3 , shown in FIG. 9 , illustrating the undulating shape of material sheet 100 .
  • the peaks and valleys of the undulating shape extend longitudinally along the length of the stud to provide increased strength to resist compression in the longitudinal direction.
  • the peaks and valleys of the undulating shape extend laterally across the length of the stud to provide increased resistance to bending or warping of stud 900 .
  • Some embodiments include peaks and valleys that go both laterally and longitudinally in different segments of stud 900 (e.g., each side may have a different orientation of peaks and valleys).
  • FIG. 11 is a schematic side view of an example machine 1100 made from a material sheet, such as material sheet 100 .
  • machine 1100 is an automobile including an exterior body 1102 .
  • the exterior body is made from material sheet 100 .
  • a segment of the automobile body is identified as segment S 4 .
  • machine 100 includes other machines, such as another motorized vehicle (e.g., an airplane, semi-truck, or other motorized vehicle).
  • Other machines include tools, such as a power tool (e.g., table saw, drill, band saw, belt sander, chainsaw, scroll saw, planar), or other tools such as a ladder.
  • a power tool e.g., table saw, drill, band saw, belt sander, chainsaw, scroll saw, planar
  • tools such as a ladder.
  • FIG. 12 is a schematic partial cutaway view of segment S 4 , shown in FIG. 11 , illustrating the undulating shape of material sheet 100 . Examples of material sheet 100 are discussed in more detail above.
  • FIG. 13 is a schematic perspective view of an example shingle 1300 according to the present disclosure.
  • Shingle 1300 includes at least one layer 1302 that is made of material sheet 100 .
  • shingle 1300 includes multiple layers, such as layer 1302 and layer 1304 .
  • a segment of shingle 1300 is identified as segment S 5 .
  • shingle 1300 includes an outer layer 1302 that is made of material sheet 100 .
  • one or more additional layers are also provided, such as a layer 1304 of asphalt or other material.
  • Sand or other textures are applied to the exterior (e.g., top) surface of shingle 1300 in some embodiments.
  • An example configuration of shingle 1300 is a three-tabbed shingle, as illustrated in FIG. 13 , including three tabs 1306 . Other numbers of tabs 1306 (e.g., one, two, four, etc.) are provided in other embodiments.
  • shingle 1300 includes one or more self-sealing strips 1310 .
  • the self-sealing strip is, for example, an adhesive or sealant that forms a seal with another shingle when the other shingle 1300 is arranged on the self-sealing strip. More specifically, shingle 1300 includes an edge 1308 . When a second identical shingle is arranged above shingle 1300 , the edge 1308 of the second shingle overlaps self-sealing strip 1310 . Self-sealing strip 1310 seals the edge 1308 of the second shingle to shingle 1300 to reduce the chance of moisture intrusion between the shingle 1300 and the second shingle.
  • shingle 1300 is a hot-glue strip or other adhesive or sealant material.
  • FIG. 14 is a schematic partial cutaway view of segment S 5 , shown in FIG. 13 , illustrating the undulating shape of material sheet 100 . Examples of material sheet 100 are discussed in more detail above.
  • Another possible embodiment is an electronics enclosure at least partially made from the material sheet 100 .
  • electronics enclosures include computer cases, radios, DVD players, laptops, portable electronic devices, or other enclosures that house an electronic device.
  • FIG. 15 is a schematic perspective view of a portion of a window assembly 1500 according to the present disclosure.
  • Window assembly 1500 includes sheet 1502 , sheet 1504 , spacer 1506 , and sealant 1524 .
  • Window assembly 1500 defines an interior space 1503 .
  • Spacer 1506 includes body 1508 and defines an interior space 1509 .
  • Body 1508 includes inner portion 1510 , inner side portion 1512 , outer side portion 1514 , outer portion 1516 , outer side portion 1518 , and inner side portion 1520 .
  • interior space 1509 is filled with a filler 1526 .
  • Sheets 1502 and 1504 are typically formed of a material such as glass or plastic that allows at least some light to pass through. Some embodiments include an at least partially translucent or transparent material, while other embodiments include a substantially transparent material. Examples of suitable materials for sheets 1502 and 1504 are glass and plastic, or combinations of glass and plastic.
  • Spacer 1506 is arranged between sheet 1502 and sheet 1504 to maintain sheet 1502 in a spaced relationship with sheet 1504 .
  • Spacer 1506 together with sheets 1502 and 1504 define interior space 1503 , which is a sealed interior region of window assembly 1500 .
  • Interior space 1509 typically includes interior space 1503 because joint 1522 is formed with holes or a gap that allows air and moisture to pass through.
  • Sealant 1524 is used to seal the intersection between sheet 1502 and spacer 1506 and to seal the intersection between sheet 1504 and spacer 1506 .
  • one or more additional sealant or adhesive layers are arranged between spacer 1506 and sheets 1502 and 1504 (such as between inner side portion 1512 and sheet 1502 and between inner side portion 1520 and sheet 1504 ) to connect and seal spacer 1506 with sheets 1502 and 1504 .
  • Body 1508 includes inner portion 1510 , inner side portion 1512 , outer side portion 1514 , outer portion 1516 , outer side portion 1518 , and inner side portion 1520 .
  • Inner portion 1510 is connected between inner side portions 1512 and 1520 .
  • Inner side portion 1512 is connected between inner portion 1510 and outer side portion 1514 .
  • Inner side portion 1520 is connected between inner portion and outer side portion 1518 .
  • Outer portion 1516 is connected between outer side portion 1514 and outer side portion 1518 . Corners are formed between respective portions of body 1500 .
  • body 1508 is formed of a single sheet of material.
  • suitable materials include metal and plastic, having a material thickness T 1 .
  • the material is first obtained in an elongated strip form and is subsequently bent into the desired shape, such as using a roll former.
  • the elongated strip material typically has a length in a range from about 50 inches (about 130 centimeters) to about 250 inches (about 640 centimeters), although other lengths are used in other embodiments.
  • the elongated strip is passed through a roll former that bends the elongated strip to form corners between portions of spacer 1506 , and any other desired features of spacer 1506 .
  • Edges of the elongated strip are joined together at joint 1522 by any suitable means, such as by welding, gluing, fastening, and the like. Edges are slightly overlapped in some embodiments to improve the strength of joint 1522 . In some embodiments holes are formed at joint 1522 to allow gas and moisture to communicate between interior space 1509 and the rest of interior space 1503 .
  • spacer 1506 Due to the relatively long length of spacer 1506 , rigidity and strength of spacer 1506 is important. For example, when installing a spacer into a particular window, an end of the spacer is often inserted into a die to bend the spacer to match the windows shape. In doing so, a majority of the spacer is often suspended in the air. If a spacer is not rigid enough to support its own weight, the spacer will be damaged when it bends under the weight. A damaged spacer is typically discarded as waste. Therefore, embodiments of spacer 1506 include features that provide adequate rigidity or strength to resist damage during manufacture and use.
  • sealant 1524 is applied between spacer 1506 and sheets 1502 and 1504 to seal edges of window assembly 1500 .
  • sealant 1524 include polyisobutylene (PIB), butyl, curable PIB, holt melt silicon, acrylic adhesive, acrylic sealant, reactive hot melt butyl (such as D-2000 manufactured by Delchem, Inc. located in Wilmington, Del.), curative hot melt (such as HL-5153 manufactured by H.B. Fuller Company), silicon, copolymers of silicon and polyisobutylene, and other Dual Seal Equivalent (DSE) type materials.
  • PIB polyisobutylene
  • butyl curable PIB
  • holt melt silicon acrylic adhesive
  • acrylic sealant such as D-2000 manufactured by Delchem, Inc. located in Wilmington, Del.
  • curative hot melt such as HL-5153 manufactured by H.B. Fuller Company
  • silicon copolymers of silicon and polyisobutylene, and other Dual Seal Equivalent (DSE) type materials.
  • a filler 1526 (not shown in FIG. 15 ) is placed within interior space 1509 of spacer 1506 .
  • An example of a suitable filler material is a desiccant that acts to remove moisture from the interior space of window assembly 1500 .
  • Desiccants include molecular sieve and silica gel type desiccants.
  • One particular example of a desiccant is a beaded desiccant, such as PHONOSORB® molecular sieve beads manufactured by W. R. Grace & Co. of Columbia, Md.
  • an adhesive is used to attach beaded desiccant between elongate strips 1510 and 1514 .
  • Other examples of filler materials include an adhesive, foam, putty, resin, silicon rubber, or other material or combination of materials.
  • filler 1526 is a material that provides added support to spacer 1506 to provide increased structural strength.
  • the structural strength is increased because the filler resists compression and buckling of body 1508 .
  • spacer 1506 does not rely solely on the structural strength of body 1508 .
  • the added strength provided by the filler enables spacer 1506 to be formed using a thinner material for body 1508 , without reducing the overall strength of spacer 1506 .
  • Thinner material reduces heat transfer through the material (such as between sheets 1502 and 1504 ) and also reduces the amount of material required to make body 1508 , thereby reducing the cost of body 1508 .
  • filler 1526 is a matrix desiccant material that both provides structural support to body 1508 and also removes moisture from the interior space of window assembly 1500 .
  • Some filler materials are a desiccant or include a desiccant, such as a matrix material.
  • Matrix material includes desiccant and other filler material. Examples of matrix desiccants include those manufactured by W.R. Grace & Co. and H.B. Fuller Corporation. A beaded desiccant can also be combined with another filler material, if desired.
  • FIGS. 16 and 17 illustrate a material sheet 1600 that can be used to form an exemplary embodiment of spacer 1506 , shown in FIG. 15 .
  • FIG. 16 is a schematic cross-sectional view of material sheet 1600 .
  • FIG. 17 is a schematic plan view of a portion of material sheet 1600 .
  • An example of material sheet 1600 is material sheet 100 shown in FIGS. 1-4 .
  • material sheet 1600 is a relatively long and narrow strip of one or more layers.
  • Material 1600 has an undulating shape.
  • An example of an undulating shape is a sinusoidal shape.
  • Other examples of undulating shapes include triangular-wave, square-wave, or other shapes having a repeating or non-repeating pattern.
  • Material sheet 1600 is a material such as metal or plastic that can be formed to have an undulating shape.
  • the undulating shape is formed in a planar strip of material by bending, such as using a roll former to impress the undulating pattern into the strip of material.
  • the undulating shape is formed by molding or melting the material into the desired undulating shape.
  • the undulating pattern has small undulations in a range from about 10 to about 100 peaks per inch. In other embodiments, the undulating pattern has larger undulations, such as from about 0 to about 10 undulations per inch.
  • the peak to peak amplitude of the undulations are typically in a range from about 0.005 inches (about 0.013 centimeter) to about 0.08 inches (about 0.2 centimeter), and preferably from about 0.02 inches (about 0.05 centimeter) to about 0.04 inches (about 0.1 centimeter).
  • window spacer Although a particular example of a window spacer is shown herein, it is recognized that material sheets 100 or 1600 are beneficial for use in a variety of spacers and is not limited to the particular examples discussed herein.
  • another embodiment of a spacer includes two substantially parallel elongate sheets.
  • additional embodiments include other window components that are made from material sheet 100 .
  • muntin bars are made of material sheet 100 in some embodiments.
  • a sash or window frame is made from material sheet 100 .

Landscapes

  • Structural Engineering (AREA)
  • Engineering & Computer Science (AREA)
  • Civil Engineering (AREA)
  • Architecture (AREA)
  • Securing Of Glass Panes Or The Like (AREA)
  • Joining Of Glass To Other Materials (AREA)
  • Laminated Bodies (AREA)
  • Building Environments (AREA)
  • Sealing Material Composition (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Connection Of Plates (AREA)
  • Gasket Seals (AREA)
  • Cell Separators (AREA)
  • Drying Of Gases (AREA)
US12/270,393 2007-11-13 2008-11-13 Material with undulating shape Abandoned US20090123694A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US12/270,393 US20090123694A1 (en) 2007-11-13 2008-11-13 Material with undulating shape

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US98768107P 2007-11-13 2007-11-13
US3880308P 2008-03-24 2008-03-24
US4959908P 2008-05-01 2008-05-01
US4959308P 2008-05-01 2008-05-01
US12/270,393 US20090123694A1 (en) 2007-11-13 2008-11-13 Material with undulating shape

Publications (1)

Publication Number Publication Date
US20090123694A1 true US20090123694A1 (en) 2009-05-14

Family

ID=40219375

Family Applications (9)

Application Number Title Priority Date Filing Date
US12/270,315 Active 2029-07-16 US8151542B2 (en) 2007-11-13 2008-11-13 Box spacer with sidewalls
US12/270,289 Abandoned US20090120019A1 (en) 2007-11-13 2008-11-13 Reinforced window spacer
US12/270,215 Active 2029-06-06 US8596024B2 (en) 2007-11-13 2008-11-13 Sealed unit and spacer
US12/270,393 Abandoned US20090123694A1 (en) 2007-11-13 2008-11-13 Material with undulating shape
US12/270,362 Abandoned US20090120018A1 (en) 2007-11-13 2008-11-13 Sealed unit and spacer with stabilized elongate strip
US13/424,088 Active US8795568B2 (en) 2007-11-13 2012-03-19 Method of making a box spacer with sidewalls
US13/657,526 Active US9187949B2 (en) 2007-11-13 2012-10-22 Spacer joint structure
US14/071,405 Active US9127502B2 (en) 2007-11-13 2013-11-04 Sealed unit and spacer
US14/845,695 Active US9617781B2 (en) 2007-11-13 2015-09-04 Sealed unit and spacer

Family Applications Before (3)

Application Number Title Priority Date Filing Date
US12/270,315 Active 2029-07-16 US8151542B2 (en) 2007-11-13 2008-11-13 Box spacer with sidewalls
US12/270,289 Abandoned US20090120019A1 (en) 2007-11-13 2008-11-13 Reinforced window spacer
US12/270,215 Active 2029-06-06 US8596024B2 (en) 2007-11-13 2008-11-13 Sealed unit and spacer

Family Applications After (5)

Application Number Title Priority Date Filing Date
US12/270,362 Abandoned US20090120018A1 (en) 2007-11-13 2008-11-13 Sealed unit and spacer with stabilized elongate strip
US13/424,088 Active US8795568B2 (en) 2007-11-13 2012-03-19 Method of making a box spacer with sidewalls
US13/657,526 Active US9187949B2 (en) 2007-11-13 2012-10-22 Spacer joint structure
US14/071,405 Active US9127502B2 (en) 2007-11-13 2013-11-04 Sealed unit and spacer
US14/845,695 Active US9617781B2 (en) 2007-11-13 2015-09-04 Sealed unit and spacer

Country Status (15)

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US (9) US8151542B2 (zh)
EP (6) EP2220320B1 (zh)
JP (2) JP5577547B2 (zh)
KR (2) KR20100097153A (zh)
CN (3) CN101932787B (zh)
AU (2) AU2008320973A1 (zh)
BR (2) BRPI0820150A2 (zh)
CA (3) CA2909299C (zh)
DK (3) DK2220322T3 (zh)
ES (1) ES2751099T3 (zh)
MX (2) MX2010005259A (zh)
PL (3) PL2220322T3 (zh)
RU (2) RU2476659C2 (zh)
TW (5) TW200930869A (zh)
WO (5) WO2009064919A1 (zh)

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CN104727705B (zh) 2017-06-20
TW200930883A (en) 2009-07-16
BRPI0820152A2 (pt) 2015-05-12
US20120177827A1 (en) 2012-07-12
TW200934952A (en) 2009-08-16
MX2010005260A (es) 2010-11-12
US9127502B2 (en) 2015-09-08
CA2704970C (en) 2016-08-16
PL3318713T3 (pl) 2022-12-19
US9187949B2 (en) 2015-11-17
EP2220320A1 (en) 2010-08-25
US9617781B2 (en) 2017-04-11
DK3318713T3 (da) 2022-10-31
EP2220322B1 (en) 2017-10-11
AU2008320973A1 (en) 2009-05-22
TW200930869A (en) 2009-07-16
DK2220322T3 (en) 2018-01-08
EP2220324A1 (en) 2010-08-25
BRPI0820150A2 (pt) 2015-05-12
PL2220322T3 (pl) 2018-04-30
WO2009064915A1 (en) 2009-05-22
CN104727705A (zh) 2015-06-24
RU2010123824A (ru) 2011-12-20
US20130042552A1 (en) 2013-02-21
CN101918667A (zh) 2010-12-15
US20150376934A1 (en) 2015-12-31
BRPI0820152B1 (pt) 2018-11-21
WO2009064919A1 (en) 2009-05-22
US20140061349A1 (en) 2014-03-06
WO2009064921A1 (en) 2009-05-22
US8151542B2 (en) 2012-04-10
DK2220320T3 (da) 2019-11-04
JP5577547B2 (ja) 2014-08-27
KR20100097154A (ko) 2010-09-02
CN101932787B (zh) 2012-10-10
CA2704970A1 (en) 2009-05-22
TW200930882A (en) 2009-07-16
RU2483184C2 (ru) 2013-05-27
PL2220320T3 (pl) 2020-01-31
KR20100097153A (ko) 2010-09-02
CA2909299C (en) 2017-08-15
WO2009064905A1 (en) 2009-05-22
US20090120018A1 (en) 2009-05-14
AU2008320959A1 (en) 2009-05-22
EP2220320B1 (en) 2019-07-24
EP2220321A1 (en) 2010-08-25
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JP2011503403A (ja) 2011-01-27
RU2476659C2 (ru) 2013-02-27

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