Note: Descriptions are shown in the official language in which they were submitted.
2~9
71--
_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~
--4--
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
--5--
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
-6-
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~
--7--
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 ~ ~
--8--
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
, ~ ~
-10-
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
9 9
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
-12-
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.
-13-
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~
