Clip and sash assembly for mounting components between glazing panes

Techniques are provided for mounting simulated muntin bars, preassembled muntin grids and the like between parallel glazing sheets in an integrated multipane window sash. Among the mounting techniques disclosed are clips for holding simulated muntin components to a spacing and mounting structure of an integrated multipane window sash. Clip-less embodiments are also presented, as well as a one-piece sash that includes integral muntins and an integral spacing and mounting structure for the glazing sheets.

BACKGROUND OF THE INVENTION

The present invention relates generally to residential, commercial and architectural windows and doors, and more particularly to methods and apparatus for fabricating integrated multipane window unit and sash assemblies with simulated muntins.

The methods and apparatus disclosed herein are particularly well suited for integrated sash window designs, such as those disclosed in commonly assigned U.S. Pat. Nos. 6,286,288 and 6,536,182, both incorporated in their entirety herein by reference. In an integrated sash multipane window of the type disclosed in the aforementioned U.S. patents, a spacing and mounting structure is provided for two or more spaced, parallel glazing panes or sheets. The panes can be, e.g., glass or plastic and are typically transparent, although they may be frosted, translucent, colored, etc. as known in the art. When the panes are transparent it is often desired to provide simulated muntins in the space between the panes in order to provide a colonial or other decorative look. In manufacturing such windows, doors and the like, some means must be provided for mounting the simulated muntins (sometimes referred to as “muntin bars” or “divided lights”) within the space between the glazing panes. The simulated muntins can be provided as individual bars (either straight, curved, or a combination thereof), partial assemblies of bars, or an entire prefabricated grid.

It would be advantageous to provide low-cost, reliable and easy to assemble components for mounting simulated muntins between glazing panes in a multipane window, door or the like. It would be further advantageous to provide such components that can be used in multipane windows, doors and the like which are fabricated using integrated sash technology. The present invention provides muntin mounting components and methods for using such components which enjoy the aforementioned and other advantages.

SUMMARY OF THE INVENTION

In accordance with the invention, various mounting techniques are provided for simulated muntin bars and the like, i.e., components placed between glazing sheets to provide the look of true divided lights. Hereinafter, the term “muntin” when used alone is intended to refer to a simulated muntin, rather than a true muntin which is defined as a strip of wood, metal or plastic for separating and holding panes of glass in a window. Among the mounting techniques disclosed are various muntin retaining clips for holding simulated muntin components to a spacing and mounting structure for the glazing panes (sheets) of a multipane window, door, or the like. Also disclosed are various clip-less mounting methods for muntins, as well as a one-piece sash frame with an integral spacing and mounting structure and integral muntins.

According to the present invention, there is provided a multipane sash frame adapted to receive parallel glazing sheets. The sash frame includes a spacing and mounting structure having a base and two glazing pane mounting surfaces, at least one opening extending through at least one of the base or mounting surfaces, and interconnect structure for mounting a muntin bar or muntin grid assembly to the at least one opening.

In this embodiment, the interconnect structure comprises a muntin clip having a base support with a muntin retainer projecting outward therefrom and an interconnect pin affixed there under for attaching the muntin clip to at least one opening extending through at least one of the two glazing pane mounting surfaces.

Still further according to this embodiment, the interconnect pin extends beyond opposite sides of the base support so that the interconnect pin can be interconnected in at least one opening extending through at least one of the two glazing pane mounting surfaces.

Also according to this embodiment, the interconnect pin extends beyond opposite sides of the base support so that it can be interconnected in at least one opening extending through each of the two glazing pane mounting surfaces.

Still further according to this embodiment, the at least one opening includes a hole and a notch configuration to receive the interconnect pin of the muntin clip whereby the interconnect pin can be pressed through the notch and seated in the hole.

Moreover, according to this embodiment, the interconnect pin extends beyond opposite sides of the base support so that the interconnect pin can be interconnected to an opening in one of the two glazing pane mounting surfaces and to the hole and notch configuration in the other of the glazing pane mounting surfaces whereby first the interconnect pin extending from one side of the base support can be inserted in the opening in the one of the glazing pane mounting surfaces and then the interconnect pin extending from the other side of the base support can pressed through the notch and seated in the hole.

Also according to this embodiment, the interconnect structure comprises a muntin clip formed as an L-shaped body having first and second perpendicular disposed legs. A muntin retainer is attached to one end of the first leg for attachment to the muntin bar and an interconnect clip pin is affixed to a free end of the second leg for attaching the muntin clip to at least one opening extending through one of the glazing pane mounting surfaces.

Still further according to this embodiment, a sealant director projects outward from and is disposed along the length of at least one of the two glazing pane mounting surfaces having one or more notches. The sealant director prevents sealant from entering the notch into the space between the two glazing pane mounting surfaces.

Moreover, according to this embodiment, at least one of the two mounting surfaces each have at least two openings extending therethrough; and the muntin clip has two parallel disposed clip pins that extend beyond at least one of the sides of the base support so that they interconnect in the at least two openings through the at least one of the two glazing pane mounting surfaces.

Also according to this embodiment, the muntin clip has two parallel disposed clip pins that extend beyond opposite sides of the base support so that they interconnected in the at least two openings through both of the two glazing pane mounting surfaces to prevent pivotal rotation of the muntin clip about the pins.

Still further according to this embodiment, the base of the spacing and mounting structure has one or more openings therethrough; and one or more muntin clips are mounted to the one or more openings through the base of the spacing and mounting structure.

Moreover, according to the present invention, the one or more muntin clips mounted to the one or more openings through the base of the of the spacing and mounting structure each have a clip pin that extends from the muntin clips and engages the one or more openings through the base to secure the muntin clip to the base.

According to the present invention, a multipane sash frame is adapted to receive parallel glazing sheets. The sash frame has a spacing and mounting structure having a base. An interconnect structure is provided for mounting a muntin bar or muntin grid assembly to the base. The interconnect structure includes at least one bracket secured to the base of the spacing and mounting structure for attaching a muntin clip thereto.

Still further according to the present invention, the interconnect structure for mounting a muntin bar or muntin grid assembly includes a clip pin projecting outward from the muntin clip, the clip pin engaging the bracket to secure the muntin clip to the base.

Moreover, according to the present invention, the interconnect structure includes a plurality of the brackets. In one embodiment, the bracket is a closed channel having a slot opening. In that case, the clip pin has a clip end that is received within the closed channel so that the pin extends through the slot opening to secure the muntin bar to the base.

Also according to the present invention, the bracket is an L-shaped bracket having a first leg that is attached at its free end to the base of the spacing and mounting structure and a second leg that extends substantially perpendicular to the first leg. The clip pin has a lower section that slips under the second leg to attach the muntin clip to the base.

Still further according to the present invention, the interconnect structure is a notched grid end formed in the end of the muntin bars for securing the muntin bars to the closed channel.

Also according to the present invention, a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure thereof. The spacing and mounting structure has a base and two glazing pane mounting surfaces. An interconnect structure is provided for mounting a muntin bar or muntin grid assembly to the base mounting surface. The interconnect structure includes a muntin clip having a base support with a muntin retainer encased and within the base support and projecting outward therefrom. The base support is constructed of a foam material impregnated with an adhesive and/or a desiccant and/or a sealant. Still further according to the present invention, the base support is an elongated strip extending substantially the length of the base mounting surface and having a plurality of muntin inserts integrally formed therein.

Moreover, the base support can be an elongated strip extending substantially the length of the base mounting surface. This embodiment can incorporate an elongated muntin retainer integrally extending substantially the length of the base mounting surface and integrally formed within the base support. In this case, pairs of spaced notches are cut in the elongated muntin retainer strip to attach muntin bars.

According to the present invention, a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure thereof. The spacing and mounting structure has a base and two glazing pane mounting surfaces. An interconnect structure is provided for mounting a muntin bar or muntin grid assembly to the base mounting surface. The interconnect structure comprises an elongated strip having an inverted T-shaped cross section with a base section and an upstanding leg section disposed on the upper surface the base section. Pairs of spaced notches are formed in the upstanding leg section strip for attaching muntin bars. The elongated strip is constructed of a foam material impregnated with an adhesive and/or a desiccant and/or a sealant to provide sealant properties.

According to the present invention, a multipane sash frame is adapted to receive parallel glazing sheets. The sash frame includes a spacing and mounting structure having a base and two glazing pane mounting surfaces. An interconnect structure is provided for mounting a muntin bar or muntin grid assembly between the two glazing pane mounting surfaces. The interconnect structure includes a muntin clip having a base support with a muntin retainer projecting outward therefrom and an interconnect pin affixed thereunder for attaching the muntin clip to the at least one opening extending through at least one of the two glazing pane mounting surfaces.

According to the present invention, a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs. The sash frame includes an interconnect structure is provided for mounting a muntin bar or muntin grid assembly to the spacing and mounting structure. The interconnect structure includes a mounting projection extending outward from one end of a muntin bar. A notched opening is formed between the glazing legs for receiving the mounting projection to secure the muntin bar between the two glazing legs.

According to the present invention, a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs. The sash frame includes an interconnect structure for mounting a muntin bar or muntin grid assembly to the spacing and mounting structure. The interconnect structure includes an upstanding post that projects upward from between the glazing legs to which a muntin bar is secured. Further, the interconnect structure can include a channel formed with spaced sides walls disposed at the free end of the post. The channel is adapted to insert an end of a muntin bar therein whereby the muntin bar is secured to the sash frame. Moreover, the upstanding post can include an elongated channel substantially extending the length of the sash frame. The elongated channel is adapted to secure a plurality of muntin bars to the sash frame. Further, the interconnect structure can include a muntin bar retainer that projects from a glazing leg. The muntin bar retainer has a retainer base secured at one end to the glazing leg and an upstanding retainer tip secured to the opposite end of the retainer base. The retainer tip is adapted to being attached to an end of a muntin bar.

In another embodiment, the upstanding post of the interconnect structure has one end secured to the base of the glazing chamber and an opposite end with a barbed tip adapted for attachment to a hollow end of a muntin bar.

In yet another embodiment, the interconnect structure includes a muntin clip formed integrally with the glazing legs. The upstanding post projects upward from between the glazing legs to which a muntin bar is secured to a muntin retainer element.

In yet another embodiment, the interconnect structure includes a muntin clip formed integrally with the glazing legs. The muntin clip comprises upstanding projections, a back support and two side supports being adapted to receive the end of a muntin bar. Also, the muntin clip can include a front retaining ridge to allow a muntin bar to be frictionally pressed in place.

According to the present invention, a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs. The sash frame comprises an interconnect structure is provided for mounting a muntin bar or muntin grid assembly to the spacing and mounting structure. The interconnect structure includes a muntin clip disposed between two adjacent glazing legs. The muntin clip has a lower resilient finger and an upper resilient finger. The upper and lower fingers are attached to each other. A muntin retainer projects from the upper surface of the upper resilient finger.

In one embodiment, the upper finger has a notched out portion that is adapted to rest upon the upper surface of a glazing leg. An end portion of the lower resilient finger is notched and adapted to fit within a notch on the inner surface of a glazing leg so that the clip is securely held in a proper position.

In another embodiment, the upper finger extends between the two glazing legs. The lower resilient finger is notched and adapted to fit within a notch on the inner surface of a glazing leg so that the clip is securely held in a proper position.

In still another embodiment, the upper finger is adapted to rest upon the upper surface of one glazing leg. An end portion of the lower resilient finger is notched and adapted to fit within a notch on the inner surface of the one glazing leg so that the clip is securely held in a proper position.

According to the present invention, a muntin clip for a sash frame adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs. The muntin clip comprises a base portion with a ridge extending along a length of the bottom thereof. A retaining wall at one end of the base portion projects substantially perpendicular downward from the bottom surface of the base portion. A muntin retainer projects upward from the base portion in the opposite direction from the ridge. The ridge is adapted to be received in a locating notch in the upper end of one of the glazing legs. The retaining wall is adapted to rest against an outer surface of the one of the glazing legs and an opposite end of the of the base portion is adapted to rest against a second of the glazing legs.

In one embodiment, a notch is formed in the ridge at the opposite end from the wall whereby when the muntin clip is mounted on the locating notch, the notch in the ridge rests against the inner surface of the second glazing wall for maintaining the muntin clip in a proper position.

According to the present invention, a muntin clip is provided for a sash frame adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs. The muntin clip has a central body portion and two clip legs extending therefrom. An upstanding muntin retainer is disposed on the upper surface of central body portion for securing the end of a muntin bar. The width of the central body portion is selected so that the central body portion fits between the two glazing legs and the two clip legs engage the glazing legs.

In one embodiment, the central body portion of the muntin clip has a flat upper section, a triangular shaped lower section that tapers to a point integrally connected to the flat upper section and two notches that separate the flat upper section from the triangular shaped lower section to form the two clip legs. The muntin clip is adapted to be mounted on the top surface of the glazing legs so that the point rests on the base.

In another embodiment, one of the clip legs is L-shaped to overhang one of the glazing legs and secure the muntin clip to the glazing legs.

In still another embodiment, one of the clip legs is L-shaped to overhang one of the glazing legs and the other of the clip legs extends outward to rest upon the other of the two glazing legs. If desired, both of the clip legs are L-shaped to overhang the glazing legs.

According to the present invention, a muntin clip for a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and a single glazing leg extending upward therefrom. A muntin clip is provided having a horizontally disposed platform with a downward extending lip at one end that overhangs the single glaze leg. A support leg rests against the base of the sash frame for stabilization and retention of the muntin bar. An upstanding retainer is provided on the muntin clip for attachment to the end of a muntin bar.

According to the present invention, a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs. A strip of material is provided with a plurality of spaced receptacles along the length of the strip of material. The strip of material is adapted for placement along the base between the two glazing legs. Muntin clips are secured to the receptacles in the strip of material. The muntin clips can be secured to the receptacles by a protrusion on the bottom of the muntin clip.

According to the present invention, a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs. A pin is secured between the two glazing legs. A muntin clip has a base support with an muntin retainer projecting outward from one side and an attachment support projecting outward from the other side. The attachment support includes a channel for snapping onto the pin.

According to the present invention, a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure thereof. The spacing and mounting structure has a base surface and two glazing legs. Each of the glazing legs has a recess adjacent the base surface. A muntin retaining clip has a muntin retainer attached to a support surface for attachment to a muntin bar. The support surface has two support legs which extend downward therefrom. Each of the support legs has two projections at each end adapted to be received within the recess when the retaining clip is attached to the spacing and mounting structure.

According to the present invention, a method for forming one or more holes or slots in a sash frame includes the following steps. A sash frame is placed on a work surface. A plurality of muntin grid punching stations are provided along a front portion of the work surface. The portion of the sash frame being worked on is disposed towards a rear section of the work surface. The sash frame is moved in the direction of the front section so that the sash frame is aligned in the punch station stations. The sash frame is punched. Also the method can include the following steps. The sash frame is then moved toward the rear section. Next, the sash section is rotated. Further, the sash frame is moved in the direction of the front section so that the sash frame is aligned in the punch station stations. Further, receptacles are punched in the sash frame.

According to the present invention, a multipane sash frame with parallel glazing sheets, comprises a spacing and mounting structure having a base and two glazing pane mounting surfaces. An interconnect structure is provided for mounting a muntin bar or muntin grid assembly between the two glazing pane mounting surfaces. The interconnect structure includes a sealant between the base and two glazing pane mounting surfaces into which ends of the muntin bar or muntin grid assembly are embedded. In this embodiment, a mounting clip can be embedded into the sealant and secured to the end of the muntin bar. The sealant can be impregnated with a desiccant.

According to the present invention, a multipane sash frame with parallel glazing sheets, comprises a spacing and mounting structure having a base and two glazing pane mounting surfaces. An interconnect structure is provided for mounting a muntin bar or muntin grid assembly between the two glazing pane mounting surfaces. The interconnect structure includes a sealant between the base and two glazing pane mounting surfaces into which ends of the muntin bar or muntin grid assembly are embedded.

According to the present invention, a multipane sash frame adapted to receive parallel glazing sheets includes a spacing and mounting structure having a base and two glazing pane mounting surfaces. An interconnect structure is provided for mounting a muntin bar or muntin grid assembly between the two glazing pane mounting surfaces. Each of the pane mounting surfaces has an end projecting over the base and towards the opposite end. The interconnect structure includes a muntin retaining clip having four tabs and a muntin retainer. The muntin retaining clip is disposed between the two glazing pane mounting surfaces so that two of the tabs engage the base and the other two tabs engage the end projecting over the base whereby the retaining tab is secured between the base and the glazing pane mounting surfaces.

In this embodiment, the first and second tabs of the muntin retaining clip can be curved to project upward and the third and fourth tabs of the muntin retaining clip are curved like the first and second tabs but project downward.

Also in this embodiment, the first and second tabs can have protrusions extending on their outward side to engage notches formed in the end of each of the pane mounting surfaces projecting over the base in the general plane. The third and fourth tabs of the muntin retaining clip are curved like the first and second tabs but project downward.

Still further in this embodiment, the first and second tabs each have two protrusions extending on their outward side to engage notches formed in the end of each of the pane mounting surfaces projecting over the base in the general plane. The third and fourth tabs of the muntin retaining clip are curved like the first and second tabs but project downward.

According to the present invention, a multipane sash frame is adapted to receive parallel glazing sheets. A spacing and mounting structure has a base and two glazing pane mounting surfaces. A interconnect structure is provided for mounting a muntin bar or muntin grid assembly between the two glazing pane mounting surfaces. Each of the pane mounting surfaces has an inner surface with a plurality of ratchet-like indentations thereon. The interconnect structure includes a muntin retaining clip having a substantially planar clip platform with a muntin retainer projecting therefrom. Opposite sides of the planar clip platform engage the plurality of ratchet-like indentations on the inner surface of the pane mounting surfaces to secure the muntin retaining clip to the spacing and mounting structure.

In this embodiment, the planar clip platform of the muntin retaining clip can have a v-shaped end on opposite sides to fit into two, spaced ratchet-like indentations.

According to the present invention, a multipane sash frame with parallel glazing sheets comprises a spacing and mounting structure having a base and two glazing pane mounting surfaces. Each of the pane mounting surfaces has an inner surface with a plurality of ratchet-like indentations thereon. An interconnect structure includes a muntin retaining clip having a substantially planar clip platform with a muntin retainer projecting therefrom. Opposite sides of the planar clip platform engage the plurality of ratchet-like indentations on the inner surface of the pane mounting surfaces to secure the muntin retaining clip to the spacing and mounting structure. A muntin bar or muntin grid assembly is secured to the muntin retainer projecting from the spacing and mounting structure.

According to the present invention, a multipane sash frame adapted to receive parallel glazing sheets comprises a spacing and mounting structure of a foam material. The spacing and mounting structure has a top surface, a base surface and two glazing pane mounting surfaces. An interconnect structure is provided for mounting a muntin bar or muntin grid assembly to the spacing and mounting structure whereby the muntin bar or muntin grid assembly project outwards from the top surface.

In this embodiment, the foam material of the base support is impregnated with an adhesive and/or a desiccant and/or a sealant.

Further in this embodiment, the interconnect structure for mounting a muntin bar or muntin grid assembly to the spacing and mounting structure can include a muntin clip secured to the spacing and mounting structure whereby the muntin bar or muntin grid assembly project outwards from the top surface.

Still further in this embodiment, the interconnect structure for mounting a muntin bar or muntin grid assembly to the spacing and mounting structure can include a channel extending a length of the base support to receive the muntin bar or muntin grid assembly whereby the muntin bar or muntin grid assembly projects outwards from the top surface.

According to the present invention, a method of constructing a sash frame with glass sheets and a muntin bar or muntin grid assembly comprises the following steps. A sash frame with a spacing and mounting structure having a base and two glazing pane mounting surfaces is provided. One of the glazing pane mounting surfaces is longer than the other mounting surface. The sash frame is placed on a working surface so that the longer glazing pane mounting surface of the spacing and mounting structure is closer to the working surface. A first glass sheet and glazing compound is installed against the longer glazing pane mounting surface of the spacing and mounting structure. A muntin bar or grid assembly is installed between the two glazing pane mounting surfaces of the spacing and mounting structure in registration with at least one muntin locating element. A second glazing sheet and glazing compound is installed against the shorter glazing pane mounting surface of the spacing and mounting structure.

According to the present invention, a method of installing a muntin grid frame in a sash frame between two glass sheets comprises the following steps. An integral sash frame and muntin grid assembly having integral spacing and mounting structure is provided to attach glazing sheets. A sealant is applied to the integral spacing and mounting structure of the sash and muntin grid assembly. The glazing sheets are applied to the integral spacing and mounting structure.

According to the present invention, a method of installing a muntin grid frame in a sash frame between two glass sheets comprises the following steps. A sash frame having integral spacing and mounting structure to attach glazing sheets is provided. A muntin grid assembly is mounted to the integral spacing and mounting structure. The muntin grid assembly is secured to the integral spacing and mounting structure with a plurality of clips. An adhesive sealant is applied to the integral spacing and mounting structure of the sash frame. The glazing sheets are applied to the integral spacing and mounting structure with an adhesive sealant.

According to the present invention, a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs. The sash frame comprises a notch on each of the glazing legs extending across an inner surface in alignment with the notch in the opposite glazing leg. Interconnect structure is provided for mounting a muntin bar or muntin grid assembly to the spacing and mounting structure. The interconnect structure includes a muntin clip disposed between two adjacent glazing legs. The muntin clip has a base with opposite sides. Each of the sides is disposed within a notch on the inner surface of one of the glazing legs so that the muntin retainer projects outward from the base of the muntin clip.

According to the present invention, a sash frame adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs. Interconnect structure is provided for mounting a muntin bar or muntin grid assembly to the spacing and mounting structure. The interconnect structure includes a muntin clip disposed between two adjacent glazing legs. An adhesive material is disposed between the two adjacent glazing legs to cover the muntin clip so that the muntin retainer projects outward from the base of the muntin clip to receive an end of a muntin bar.

In this embodiment, the two glazing legs each have a support section at one end that extends in the direction of the other glazing leg and forms a slot therebetween. The muntin retainer projects outward of the slot so that the bottom of the muntin bar rests on the support sections.

Also in this embodiment, the muntin retainer projects into the space between the two glazing legs.

According to the present invention, a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs. Interconnect structure mounts a muntin bar or muntin grid assembly in a space between the two glazing legs and the base. An adhesive material is disposed between the two adjacent glazing legs and around an end of a muntin bar secures the muntin bar to the spacing and mounting structure.

In this embodiment, a support surface is disposed above the base and between the two glazing legs; and the adhesive material is disposed between the two adjacent glazing legs and on the support surface and around an end of a muntin bar to secure the muntin bar to the spacing and mounting structure.

According to the present invention, a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs. Interconnect structure is provided for mounting a muntin bar or muntin grid assembly to the spacing and mounting structure. The interconnect structure includes a support section at one end of each of the two glazing legs that extends in the direction of the other glazing leg and forms a slot therebetween. The muntin bar has a slot formed on opposite sides near the end of the muntin bar whereby the slots in the muntin bar are secured in the slot between the glazing legs. An adhesive material is disposed between the two adjacent glazing legs and around an end of a muntin bar to secure the muntin bar to the spacing and mounting structure.

According to the present invention, a sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base with a rectangular support box extending therefrom. Interconnect structure is provided for mounting a muntin bar or muntin grid assembly atop the rectangular support box. A sealant material is disposed on the base and around at least two sides and across a top of the rectangular support box to cover the end of a muntin bar so that the muntin bar projects outward from the rectangular support box. One glazing sheet seated on the sealant material is disposed on the base and another glazing sheet seated on the sealant material is disposed on the base and against a second side of the rectangular box. A pair of clips engage the first and second glazing sheets and to press the glazing sheets against the sealant material.

In this embodiment, a muntin clip is secured by the sealant material atop the rectangular support box; and the muntin clip is attached to the end of the muntin bar.

According to the present invention, a sash frame adapted to receive parallel glazing sheets on a spacing and mounting structure has a base and two glazing legs and a support surface disposed above the base and between the two glazing legs. A muntin clip is disposed between the two glazing legs and above the support surface. A sealant material is disposed on the outer surface of the glazing legs, between the two adjacent glazing legs and around the muntin clip to secure the muntin bar to the spacing and mounting structure.

According to the present invention, a sash frame adapted to receive parallel glazing sheets on a spacing and mounting structure has a base and two glazing legs. Each of the glazing legs has a notch extending across an inner surface in alignnment with the notch in the opposite glazing leg. Interconnect structure is provided for mounting a muntin bar or muntin grid assembly to the spacing and mounting structure. The interconnect structure includes a muntin clip disposed between two adjacent glazing legs. The muntin clip has a base with opposite sides. Each of the sides is disposed within a notch on the inner surface of one of the glazing legs so that the muntin retainer projects outward from the base of the muntin clip.

According to the present invention, a method of installing a muntin grid frame in a sash frame between two glass sheets includes the following steps. A two part integral sash frame having integral spacing and mounting structure to attach glazing sheets is provided. A muntin grid assembly in one part of the sash frame is provided. The two part sash frame is secured together.

In this embodiment, sealant is applied to the integral spacing and mounting structure of the two part sash frame. Also the glazing sheets are applied to the integral spacing and mounting structure.

According to the present invention, a multipane sash frame adapted to receive glazing sheets comprises: a spacing and mounting structure having glazing pane mounting surfaces; at least one opening extending in the upper ends of each of the mounting surfaces; and a clip comprising a base, an H-shaped base support that includes two side walls and an interconnecting wall disposed on a bottom side of the clip for mounting the clip to the opening extending in the upper ends of each of the mounting surfaces.

In this embodiment, the clip has a muntin retainer projecting outward therefrom for mounting a muntin bar.

In another aspect of this embodiment, the clip has a plurality of upstanding blocks disposed thereon for holding an additional glazing pane.

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1 and 2illustrate an integrated, multipane window sash frame10, which may be fabricated from vinyl, e.g., polyvinyl chloride (PVC) or any other material used for window frames. Such materials can comprise, for example, aluminum, wood, other plastics and the like. The sash frame is provided for use in manufacturing an insulating glass window. The sash frame10can be fabricated in any known manner, for example, by extrusion or injection molding. Although only a short section of the sash frame10is illustrated, it should be appreciated that the frame material will be provided in various lengths necessary to assemble a complete sash frame, which may be square, rectangular, oval, circular, or any other custom window shape. The illustrated frame10may include a channel15for retaining a glazing bead or clip (not shown), as is well known in the art.

Referring toFIG. 1, a muntin retaining clip20is shown. The muntin retaining clip20includes an muntin bar retainer24projecting from a clip base25and a clip pin18affixed thereunder. The muntin bar retainer24projects outwardly from the clip base25for attachment to the hollow (female) end of a muntin bar22. It should be appreciated that the reverse configuration can be used instead; i.e., a female receptacle on the clip base25with a corresponding muntin retainer projecting from the muntin bar22. The clip pin18extends beyond the ends of the clip base25so that it can be interconnected with holes or notches16in the glazing legs12,14.

To mount the muntin retaining clip20, first, one side of the clip pin18is inserted into a hole16, such as for example in glazing leg14and then the other side of the clip pin18is snapped or otherwise fitted into the opposing hole in glazing leg12.

Although the illustrated embodiment shows glazing legs12,14of the same height, glazing legs of different heights (“stepped structure”) can also be provided, with corresponding receptacles, such as hole(s) and/or notch(es), in one or both glazing legs to accommodate a muntin retaining clip of any of the various embodiments disclosed herein (and equivalents thereof) and/or the muntin bar itself. Such a stepped structure may be particularly suitable, for example, in a triple-pane embodiment.

The clip pins18can extend beyond the confines of the glazing legs12,14, so that if glazing sheets (not shown) are drawn against sealant disposed between the glazing sheets and the glazing legs using a vacuum or a mechanical press, the pins will serve as stops for the glazing sheets.

FIG. 2illustrates an embodiment that is essentially the same asFIG. 1except for the use of a combination of hole27and notch28in glazing leg12to receive the clip pin18of muntin grid clip20. The hole27is formed through the body of the glazing leg12and the notch28extends upward and opens at the upper end the glazing leg. The hole27and notch28allow for the easy insertion of the clip pin18which preferably is shaped to snap into the hole27. Typically, one end of the clip pin18is first inserted in the hole27in glazing leg14by a twisting/tilting method, then the other end of the clip pin can be pressed down or snapped into the notch28, which may be of slightly smaller width than the diameter of the pin, and then pushed down to seat in the hole27.

FIG. 3illustrates an embodiment similar to that ofFIG. 2, except the combination of hole27and notch28are provided in both glazing legs12and14to receive both ends of the clip pins18of muntin retaining clip20. Alternatively, holes and notches and corresponding clip pins could be provided on only one side of the sash frame/muntin retaining clip, although such an embodiment may not be as stable as the structure shown here.

FIG. 3Aillustrates an embodiment where a sealant director32is provided below the notches27on one or both glazing legs12and14to limit the whet-out of sealant and/or to prevent a sealant34from flowing through the notches into the space between the glazing legs and thereby into the viewing area of the glazing panes. The sealant director32can be formed as a separate construction and then attached to the glazing leg or alternatively, formed integrally with the leg (e.g., as the sash profile is extruded or otherwise formed). The sealant director32can be disposed above the sealant bead to decrease stress cracks from occurring and improve performance of the system, i.e., better sealant coverage on the glazing pane (e.g., glass) surface when the glazing pane is mounted to the glazing leg. Although the sealant director32is shown with a muntin retaining clip type embodiment, it is within the terms of the present invention to use it with any of the embodiments disclosed herein, including clip-less embodiments.

FIGS. 4A and 4Billustrates an embodiment of the invention wherein muntin retaining clips42are mounted to the base surface43of the spacing and mounting structure of a stepped sash frame44via clip pins46that project from the muntin retaining clips and engage receptacles, holes, slots, or fastening positions48in the base surface43of the sash frame. The clip pins46have a leg section46a, a base support46bthat is substantially perpendicular to and integrally attached to one end of the leg section46a, and an end attachment section46cthat extends substantially perpendicular to and is integrally attached to the opposite end of leg section46a. The base support46bis attached to muntin bar retainer24and the end attachment section46cis sized to be force fitted through receptacles48in the base surface43of sash frame44. Any other suitable configuration of the clip pins and corresponding receptacles in the base surface43may be used instead of the particular configuration illustrated.

As shown inFIG. 4B, any combination of muntin bars22and/or a pre-assembled muntin grid(s) may be mounted to the base surface43of the glazing chamber which is disposed between the glazing panels (not shown). Such glazing panels will be mounted (e.g., using adhesive sealant) to receiving surfaces41,43of the spacing and mounting structure. Receptacles, holes, slots, or fastening positions48may be punched, drilled, or milled into the base surface, as required. As in the other embodiments disclosed herein, the illustrated muntin retaining clips42are only an example of a suitable clip and other shapes and structures of mounting clips as disclosed herein are suitable substitutes.

FIGS. 5A and 5Billustrate an embodiment of the invention wherein the muntin retaining clips42are mounted to the base surface44aof the glazing chamber of a stepped sash frame44using clip pins46extending from the muntin retaining clips. The clip pins46are shaped so that the lower section46cis adapted to engage a slot54in a channel56that may be extruded or otherwise provided on the base surface44a. The lower section46ccan be inserted into one end of the channel56and moved into position or alternately forced through the slot54. Alternatively, the slot54may receive a corresponding notched end formed in the end of the muntin bars (not shown, although in the manner of the embodiment shown inFIG. 51D), providing a clip-less solution for holding the muntin bars22.

FIG. 6illustrates a muntin retaining clip46adapted to mount an individual muntin bars or an entire grid assembly, as described elsewhere herein, to the base surface44aof the glazing chamber of a stepped sash frame44using an L-shaped bracket60onto which the muntin retaining clip46attaches. The bracket60has one leg60aattached at its free end to the base surface44aof sash frame44and another leg60bthat extends substantially perpendicular to the leg60a. The bracket60can be formed as a single partial bracket, a plurality of which are mounted individually to (or formed integrally with) the base surface44aor as an extrusion member and mounted in a manner shown inFIG. 5B. The clip pin46, as previously described, with the base support46battached to muntin retaining clip24and the lower section46cextending from the pin, is configured in such a manner that it slips under the leg60bor otherwise attaches to the bracket or extrusion member60. As in the other embodiments disclosed herein, the muntin retaining clip46as illustrated is only an example, and many other shapes and structures, as for example others disclosed herein, can also be used.

In a similar embodiment (not illustrated), a slot can be recessed directly into the base surface44ainstead of the slot extending above the base, as shown. Again, the muntins can either be mounted to the recessed slot with or without a muntin retaining clip. Instead of a slot, a closed channel, as shown inFIG. 5Bcan be recessed into the base surface44a.

FIGS. 7 and 7Aillustrate an embodiment of a muntin retaining clip70that is generally formed as an L-shaped body71of two perpendicular disposed glazing legs71cand71d. The muntin retaining clip70includes a muntin retainer24or other suitable mounting structure attached to one end71afor attachment to a muntin bar22and a clip pin or finger72attached to an opposite end71bof leg71d. The pin72is adapted to be inserted into corresponding receptacles or holes73in a side wall74of the glazing chamber of a stepped sash frame44. The free end of the pin72can include an optional end section71esized to prevent the pin72from being easily removed from the receptacle73into which the pin72is inserted. The muntin retaining clips70may be stamped, roll formed, pressed or molded and can be fabricated from any suitable material such as metal, plastic or foam. Advantageously, muntin retaining clips70can be installed on a pre-assembled muntin grid (not shown), and the whole grid and muntin retaining clip assembly can be placed on top of the sash frame44when the sash frame is laid down horizontally on a work surface with the holes73facing up. The pins72will then slide into the corresponding holes73of the sash frame44with the help of gravity. The muntin retaining clip70will provide improved support for the muntin bars because the leg71cof the L-shaped body71rests against the base surface of the frame44. It is also with the terms of the invention to assemble the sash frame44and muntin bar structure in a vertical or any other desired position.

FIG. 8illustrates a plurality of muntin retaining clips70, as shown inFIGS. 7 and 7A, fitted into or attached to a corresponding hole, receptacle, punched slot or opening73in the side wall74. The design of the muntin retaining clip70enables it to be mounted to the sash frame by the application of a double-sided tape or liquid adhesive on the sash frame facing side of legs71cand/or71dwithout a locating hole73, or with a combination of a locating hole and the liquid adhesive or tape. In an embodiment without locating holes73, indicia (e.g., dots) can be printed or otherwise marked onto the sash profile at predefined locations to assist an assembler in placing the clips70in proper locations.

FIGS. 9A,9B, and9C illustrate that a plurality of mounting mechanisms90can be provided for retaining a muntin bar or grid. Such mounting mechanisms90may comprise, for example, clips or blocks92that include a muntin retaining clip retainer24. The blocks92can be of any suitable dimensions and shape, and can be made out of any one or combination of various materials, such as an adhesive foam. In one advantageous implementation, the blocks are formed from a material (e.g., adhesive foam) that includes a desiccant. As described hereinabove, the clip retainer24is secured to the mounting mechanism90by any means such as its upright leg24abeing secured within a slot (not shown) formed from the upper surface92aof the muntin retaining block92. The muntin retaining block92and the clip retainer24or other suitable mounting structure is attached to the female opening in muntin bar22. In the embodiment shown, the muntin retaining clip92is adhered to the glazing chamber surface44aof the sash frame44or to a surface one or both of the glazing panels94or96. As noted above, instead of providing the retainer24on the retaining block92, a female opening can be provided to receive a corresponding retainer projecting from the muntin bar22.

The muntin mounting structure (e.g., muntin retaining block92) may be glued, taped bonded, spot welded, sonically welded, heat welded, tacked, or pressure fit into position. Sealant, adhesive, peelable tape or any other suitable means for attaching the muntin retaining clip90to the glazing panels94,96and/or the glazing chamber surface44acan be used, including hardware fasteners. In the embodiment shown inFIG. 9A, sealant91is illustrated as an example only. As noted above, the muntin retaining block92itself can be desiccated. For example, if the muntin retaining clip or block is made of a foam material, it can be desiccated by impregnating it with a desiccant. A desiccated adhesive foam can be used to fabricate the muntin retaining clips or blocks92, and may reduce cost and facilitate the simple manufacture of windows using the integrated sash technology. The muntin bar22can be inserted onto the muntin retainer90either before or after the muntin retainer is mounted.

FIG. 10illustrates a muntin retaining clip100having a plurality of clip pins102,103disposed in parallel relationship and secured to the bottom surface of muntin retaining clip base support104, in a manner similar to the embodiment shown inFIG. 1. The muntin retaining clip100includes a clip retainer24or other suitable mounting structure (e.g., a female receptacle) for attachment to a muntin bar22. Receptacles such as holes101corresponding to the spacing between clip pins102,103, are provided on the glazing legs105,106of the spacing and mounting structure107to receive the clip pins102,103. This design provides additional stability for the muntin retaining clips100, preventing any pivotal rotation about the pins102,103. As shown in and described with regard toFIGS. 2 and 3, the holes101can be replaced by holes and slots, as desired.

The clip pins102,103can extend beyond the confines of the glazing legs105,106, so that if glazing sheets (not shown) are drawn against sealant disposed between the glazing sheets and the glazing legs using a vacuum or a mechanical press, the clip pins will serve as stops for the glazing sheets.

FIGS. 11A,1B, and11C illustrate an embodiment wherein instead of individual muntin retaining clips as described hereinbefore, an elongated clip strip110(e.g., adhesive foam) can be provided with a muntin clip retainer112for mounting a muntin grid or individual muntin bars. The clip strip110can advantageously include adhesive and/or sealant properties, so that it can serve to mount the glazing panels113,115to the sash frame116as well as to mount the muntin bars or grids between the glazing panels. Additional sealant(s) and/or adhesives can be used on the clip strip110, as required, to provide a structure with the desired finctionality. The clip strip110may also be desiccated. Extending and secured to clip strip110is the elongated muntin clip retainer112that has the same cross section as retainer24but has a length that can extend substantially the length of the clip strip110. The clip strip110can be extruded, injection molded or otherwise fabricated, with pairs of spaced notches114a,114b, as shown inFIG. 11B, in order to mount a plurality of muntin bars22. As in the previous embodiments, the munitn clip retainer112fits within the opening in the muntin grid or muntin bars22.

Although a continuous, elongated retainer112has been described, a plurality of discrete munitn retainers24, as described hereinabove, can be attached to the strip110, at appropriate spacings, for insertion into corresponding openings in the muntin grid or bars, seeFIG. 11C.

The elongated muntin retainer112, as shown inFIGS. 11A and 11B, and the individual muntin retainers24ofFIG. 11C, can be formed from the same material as clip strip110, or from a different material. For example, the muntin retainers may be extruded or injection molded of the same material together with the clip strip110. Alternatively, similarly shaped retainers can be extruded or injection molded directly into the sash frame itself, in which case they are integral with the sash frame and not separate component parts. In such an embodiment, the clip strip110is not required.

FIGS. 12A,12B, and12C illustrate a muntin retaining strip120shown having an inverted T-shaped cross section with a base section122and an upstanding leg section124disposed on the upper surface122aof the base section. The strip120can be extruded, injection molded or otherwise fabricated with pairs of spaced notches124a,124b(SeeFIG. 12B) formed in the upstanding strip124. The spaced notches124a,124bare adapted to mount a plurality of muntin bars (which can be separate or part of a prefabricated muntin grid assembly). Referring toFIG. 12C, there is shown the retaining strip120secured to the surface of a sash frame116. The end of the muntin bar126can be held in the spaced notches124a,124bby friction, adhesive, a snap fit, or simply by a pressure fit of the muntin bar between the spaced notches. As with the embodiments ofFIGS. 11aand11b,the strip120may be made of adhesive foam or other material, which may be desiccated and used to mount the glazing panes as well as the muntins.

FIG. 13illustrates a clip-less embodiment, wherein muntin bar130(which can be part of a prefabricated muntin grid assembly) has a projection132extending outward from one end130athereof. In a preferred embodiment, the projection132is formed integrally with the muntin bar130, although it could alternatively be a separate element such as a pin that mounts to the one end130aof muntin bar130. The projection132is configured (e.g., with a pointed head as shown) to lock into a notch, slot or other suitable opening133formed in or between the glazing legs134a,134bof a sash frame135. In the illustrated example shown inFIG. 13, a slot136is provided between opposed projections137a,137bthat can be extruded or otherwise fabricated into the sash frame135. The slot136receives the projection132and secures the muntin bar130in place. Other clip-less structures can be realized by forming the sash frame in an appropriate manner and/or using a notch, routed receptacle, punched configuration or an injection molded sash element in conjunction with a muntin bar having a projection, for example as shown inFIG. 13.

FIG. 14illustrates a clip-less embodiment where one end of a muntin bar146(which can be part of a prefabricated muntin grid assembly) is mounted to a post141that projects from the sash frame142between the glazing legs144a,144bof the sash frame142. The muntin bar146is inserted into a channel140, formed with spaced side walls140a,140b, disposed at the free end of the post141. Instead of a plurality of separate posts141disposed along the length of the sash frame142, one for each separate muntin bar146, an elongated post with a continuous channel (not shown) can be provided along the entire length of the sash frame. In either case, the spaced posts141or the elongated post with a continuous channel can be manufactured as an integral part of the sash frame142when the sash frame itself is molded, extruded, etc. Alternatively, the plurality of posts141or the continuous channel can be a separate component attached to the sash frame142using adhesive, hardware fasteners, ultrasonic or chemical welding, or the like. The end of the muntin bar146can be held in the channel140by friction, adhesive, a snap fit, or simply by a pressure fit of the muntin bar between the channel shown and a similar channel in the sash frame at the opposite end of the bar (not shown). Where the muntin bar or grid is held by pressure fit between opposite channels, it may be necessary to bow the muntin bar or grid slightly to insert both ends thereof into their respective channels. Once the muntin bar or grid is seated in the opposite channels, it will straighten back out. For such an embodiment, it will be necessary for the muntin bar or grid to be resilient enough to enable the bowing to occur without breaking.

FIG. 15illustrates a clip-less embodiment where a muntin bar retainer150extends from glazing leg151bof the sash frame152. The muntin bar retainer150can be constructed of a retainer base150asecured, e.g., at one end to the glazing leg151b. The opposite end of the retainer base150ahas an upstanding retainer tip150bof any desired shape to be inserted into the bottom of the muntin bar154. In the example shown, the hollow end154aof muntin bar154simply fits over the retainer tip150b. However, the retainer tip150bcould be shaped to frictionally engage the inside of the muntin bar with a press fit, or could provide a snap fit or the like. As noted above, the design can be reversed such that a female receptacle is provided for the retainer150and a corresponding male part is provided on the muntin bar. Moreover, the muntin bar retainer150can be attached at any suitable point along the glazing leg151bor to both glazing legs151band151a.Alternatively, the retainer muntin bar150could be attached to the bottom wall (base) of the sash frame152. The muntin bar retainer150can be integrally formed with the sash frame152, e.g., as part of the glazing leg151bwhen the sash frame is fabricated. Such fabrication can be done using injection molding or extrusion techniques, or any other suitable manufacturing method. Any number of variations to the structure and fabrication/mounting of the muntin bar retainer150within the scope of the invention will be apparent to those skilled in the art. Structures that are clip-less (as shown), as well as structures that use clips are envisioned. For example, a muntin bar retaining clip can be used to connect the end of a muntin bar to the retainer150, although such a design is less desirable in that it requires the use of an additional part (i.e., the clip). At least one surface of the retainer150could be notched to accept a clip or a mating element of a muntin bar.

FIG. 16illustrates a clip-less embodiment where a muntin bar retainer160with a barbed, pointed tip160aextends from the bottom wall (base surface)162aof the sash frame162between the glazing legs164a,164b. The retainer160shown can be one of a plurality of such retainers (e.g., posts) that extend from the base surface162aof the sash frame162along its length, in registration with the hollow end166aof a muntin bar166that simply fits over the retainer tip160a. Moreover, the retainer tip160acould be shaped to frictionally engage the hollow inside of the muntin bar with a press fit, or could provide a snap fit or the like. The retainer160can be attached at any suitable point along the base surface162a, and can be integrally formed with the sash frame162, e.g., as part of the base162awhen the sash frame is fabricated. A plurality of muntin bars166(which can be part of a refabricated muntin grid assembly) can be provided to be held within the sash frame between the glazing sheets. Alternatively, the retainer160can comprise a continuous wall that runs along the length of the sash frame162, with periodic barbed, pointed tips160aor the like for engagement with the ends of corresponding muntin elements. The design can alternatively be reversed, such that a female receptacle is provided for the retainer160and a corresponding male part is provided on the muntin bar.

FIGS. 17A and 17Billustrate an embodiment where muntin retaining clips170are formed integrally with the glazing legs172,174of the spacing and mounting structure175of a sash frame. Although a leg structure is shown for the spacing and mounting structure, other designs can be substituted, such as a block or stepped configuration. Each of the integral muntin retaining clips170, which can be fabricated together with the sash frame (e.g., by injection molding), includes a retaining element176for securing a muntin bar that will be attached thereto. As with the other embodiments discussed herein, the retaining element176can be a plug as shown, or it can be a pocket, a snap, an opening for a corresponding pin on the muntin bar, or any other suitable structure. The retaining element176can also be a surface that simply holds the muntin bar by frictional or spring force between a corresponding retaining element on the opposite side of the sash frame. Sealant178on the side wall of the leg174is provided for mounting a glazing sheet. It is noted that the sealant does not have to be applied to the leg during manufacture of a window or the like; it can be applied directly to the glazing sheet, or to both the glazing sheet and the leg. A second glazing sheet can be mounted to the leg172in a similar manner.

FIGS. 17A and 17Billustrate an integral (e.g., injection molded) sash frame that includes a muntin retaining clip176. Alternatively, the sash member could be fabricated without the clips, but with structure such as ribs, notches, pockets, snaps or the like for accepting a separate clip element or for accepting the end of a muntin bar directly. The sash frame can also be manufactured as one integral unit together with muntin grids. In another embodiment, muntin grids can be manufactured as a separate one piece unit that simply lays or snaps into the sash frame prior to completion of the glazing step.

FIGS. 18A and 18Billustrate an embodiment where an integral muntin retaining clip180is shown which receives the end of muntin bar182by a press in or snap fit. The muntin retaining clip180comprises upstanding nubs or projections183and a back stop184with a back wall184aand two side supports184band184c. An optional front retaining wall186can also be provided to frictionally press the muntin bar182in place once it is pressed past the ridge186in the direction of the arrow187. The muntin retaining clip180, including nubs183, back stop184and ridge186can be molded integrally with the sash frame, e.g., between glazing legs188aand188bof a spacing and mounting structure188as shown. Note that the muntin retaining clip180is shown extending above the top of side188ainFIG. 18B.

Instead of fabricating the muntin retaining clip180as part of the spacing and mounting structure, it can be provided as a separate component that is attached to the sash frame at a location between the glazing sheets. The muntin retaining clip180is intended to support the muntins and/or the muntin grid and keep them from sagging over time. Although the muntin retaining clip180is shown positioned between spaced glazing legs188a,188b, a similar type of muntin retaining structure can be used with a stepped or continuous spacing and mounting configuration. Moreover, the top of muntin retaining clip180could be recessed below the top ends188c,188dof glazing legs188a,188bso that the muntin retaining clip would not be noticeable when looking through the glazing panes from the side (i.e., from the perspective ofFIG. 18B). Indeed, virtually any of the embodiments disclosed herein can be adapted to recess the muntin bar mounting means into the sash frame, for example between glazing legs to which glazing sheets are mounted, so they are not visible from the side view.

FIG. 19illustrates an embodiment where a corner of a sash frame190has notches or pockets192provided therein. The sash frame190may, for example, be injection molded. The pockets192are designed to accept corresponding muntin bars of a prefabricated muntin grid, which can be simply pressed into the pockets192. The pockets are designed to insure that the muntin bars or muntin grid is located in exactly the desired location. Alternately, indicia such as for example colored dots or dashed lines can be used to locate the muntin bars or muntin grid. For example, the pockets192can be designed to accept the ends of the muntin bars that form the grid. The muntin grid elements may alternatively snap into the pockets192, or be frictionally or adhesively secured within the pockets. Another option is to mount the muntin grid via muntin retaining clips (not shown) that are attached to the pockets. Such muntin retaining clips could be desiccated to provide a desiccant for the insulating space between the glazing sheets that are mounted to the sash frame.

FIG. 20Aillustrates an embodiment where a muntin retaining clip200has a lower resilient finger202attached at one end to one end of an upper resilient finger204. The muntin retaining clip200is adapted to snap between glazing legs203a,203bof the sash frame203so that the upper finger204, which has a notched out portion204aon a lower side, is supported by the upper surface of leg203bas best seen inFIG. 20A. The muntin bar retainer205is inserted into the end of a muntin bar (not shown). The muntin retaining clip200can be provided in different widths, depending on the mechanical and/or aesthetic requirements of the window or door design. A locating notch207can also be provided in one or both glazing legs203a,203b, if desired, to receive an end portion202aof the lower resilient finger202so that the muntin retaining clip200is securely held in a proper position. As with the other embodiments described herein, a female receptacle can be substituted for the muntin bar retainer205, in which case the muntin bar would contain structure that engages with the female receptacle.

FIGS. 21A and 21Billustrate an embodiment where the muntin retaining clips210snap between the glazing legs203aand203bthat form the spacing and mounting structure203. In this design, as compared to the embodiment illustrated inFIGS. 20A and 20B, however, there is no extension which overhangs the leg203b. Instead, the lower portion210aof the muntin retaining clip210fits within a locating notch207provided in one of the glazing legs, as in the embodiment illustrated inFIGS. 20A and 20B, while the upper portion of the muntin retaining clip210bdoes not extend the width of the spacing between glazing legs203aand203b, as best shown inFIG. 21A.

FIGS. 22A and 22Billustrate an embodiment where the muntin retaining clips220are similar to those ofFIGS. 20A and 20B, but the design of the upper resilient finger222is slightly different from the upper resilient finger204ofFIGS. 20A and 20B. Since finger222does not have a notch on its lower surface222a, it rests on the top of wall203band therefore has a different resiliency for the snap-in action.

FIGS. 23A and 23Billustrate an embodiment of a muntin retaining clip230that is secured to one glazing leg232bof the sash frame232and merely rests on the upper surface of a second glazing leg232a. The muntin retaining clip230has a base portion230awith a narrow ridge-like protrusion230cextending along the length of the bottom surface of the base portion. The narrow ridge230chas a notched out portion230bat one end. At the other end of the clip230is a retaining wall230dthat projects substantially perpendicularly downward from the bottom surface of the base portion230a. A muntin bar retainer234projects upwardly from the base portion230ain the opposite direction from the ridge230c. A locating notch236can be provided in the upper end of the leg232bto receive the ridge230c, as shown inFIG. 23B, whereby the retaining wall230drests against the outer surface of leg232band the notch230brests against the inner surface of wall232a, as shown inFIG. 23A, so that the base portion230arests upon the top of wall232afor maintaining the muntin retaining clip in a proper position.

FIGS. 24A and 24Billustrate an embodiment where a muntin retaining clip240is constructed of a flat upper section240aand a triangular shaped integrally connected bottom section240bthat tapers to a point240c. Two notches240dand240eseparate the flat upper section240afrom the triangular section240b. An upstanding retainer242is disposed on the upper surface of upper section240afor holding the end of a muntin bar. As best seen inFIG. 24B, the muntin retaining clip240can be mounted on the sash frame242so that the notches240dand240eare disposed upon the top surface of glazing legs242aand242bwhereby the ends of the upper section240aoverhang both glazing legs of the sash frame. Also if desired, the point240cof the muntin retaining clip240can rest on the base of the sash frame between the glazing legs242aand242b.

FIGS. 25A and 25Billustrate an embodiment where a muntin retaining clip250has a central body portion250aand two L-shaped glazing legs250b,250cextending therefrom. An upstanding retainer254is disposed on the upper surface of central body portion250afor holding the end of a muntin bar. The width of the central body portion250ais selected to fit within the space between glazing legs252aand252bof the sash frame252as shown inFIG. 25B. The two L-shaped legs250b,250coverhang and engage the glazing legs252aand252b.

FIG. 26illustrates an embodiment somewhat similar to that ofFIGS. 25A and 25B, but in which a muntin retaining clip260has a central body portion260a, one L-shaped leg260band one projecting leg260c. An upstanding retainer264is disposed on the upper surface of central body portion260afor holding the end of a muntin bar. The width of the central body portion260ais selected to fit within the space between glazing legs262aand262bof the sash frame262. The L-shaped leg260bof the clip260overhangs and engages the leg262bof the sash frame spacing and mounting structure. The other projecting leg260cis disposed on top of leg262aof the spacing and mounting structure.

FIG. 27illustrates an embodiment of a muntin retaining clip270that has a horizontally disposed platform270awith a downward extending lip270bat one end that overhangs a single glazing leg272extending upward from the base of the sash frame274. The muntin retaining clip270also has an extending support leg270cthat rests against the base of the sash frame for stabilization and retention of the muntin bar and an upstanding retainer270dfor holding the end of a muntin bar.

FIG. 28illustrates an embodiment of a muntin retaining clip280which is secured to a strip282of any desired material such as plastic and/or metal with a plurality of spaced receptacles, holes or slots284extending the length of the strip of material282. The retaining clips280are secured to the strip282by any desired means, such as a protrusion (e.g., pin) on the bottom of the retainer that is secured to the hole or slot by means of a friction fit or any other typical means of attachment. The strip282, with the clip(s) secured thereto, is then placed and/or mounted on the bottom surface286of the sash frame288. For example, the strip282may be adhesively secured to the bottom surface286, or held in place adjacent bottom surface286by a friction fit within the channel between the glazing legs.

FIG. 29Aillustrates a sash frame290with glazing legs292a,292bhaving a nail (e.g., plastic or metal) or pin294extending therebetween. It should be understood that a plurality of nails or pins294can extend along the length of the glazing legs and spaced as desired. A muntin retaining clip296, as shown inFIG. 29B, includes a base296afrom which the retainer296bextends. An attachment support296cprojects downward below the base support296aand includes a substantially circular channel296dand slot having opposite facing projections296e,296f, which create a reduced space between them as compared to the rest of the channel296d. This configuration causes the muntin retaining clip296to snap onto the pin or nail294and the ends of the base support296ato be disposed between the two glazing legs292a,292b. Alternatively, the ends of the base support can be dimensioned to sit on top of the respective legs292a,292b.

FIGS. 30A and 30Billustrate a muntin retaining clip300having a muntin retainer302or other suitable mounting structure (e.g., a female receptacle) attached to a support surface303for attaching a muntin bar. The support surface303has two support legs303a,303b, which extend downwardly therefrom. Each of the legs303a,303bhas two projections303c,303d, respectively, at each end thereof. As shown inFIG. 30B, the sash frame306has two glazing legs306a,306b, each of which has a small recess307a,307btherein adjacent the base surface306cto receive the extensions303c,303dat the bottom of the clip support walls. Thus, the muntin retaining clip300can be inserted between the two glazing legs306a,306band secured therein by the mating of the ends of the muntin retaining clip303c,303dwith the two indents307a,307bin the glazing legs.

FIG. 31illustrates a production system for forming a series of singular or multiple receptacles, holes or slots in a leg or other portion of a sash frame310. The holes may be circular, oval, square, rectangular, or combinations thereof. The corresponding nipples or catch points on the muntin retaining clips, as described hereinabove but not shown inFIG. 31, may be of any shape, depth, material, flexibility, or dimension so as to fix, attach, ensnare, entrap, grasp, and/or hold the muntin retaining clip to the sash leg, within the sash leg, or against the sash leg. The pattern of holes and grid catch points may be singular, dual, tri, quad, or any combination on one, two, or both sides of the sash frame310. The nipples or locating points formed on the muntin retaining clips can protrude to the exterior of the sash frame310or simply partially engage the corresponding locating holes. The locating points or holes may be milled, drilled, punched, grooved, melted or formed from any combination of these or other manufacturing techniques. This method may be in combination with the spirit of U.S. Pat. No. 6,286,288, which is incorporated in its entirety by reference herein. The support portion of the muntin retaining clip may be of any shape or not present. The muntin bar mounting retainer is envisioned to be the customarily accepted means of attaching to the muntin grid or muntin grid member.

Although not illustrated, it is envisioned that the sizing will be automatically controlled by the order sequence and data supplied to and available to glass cutting machinery, order entry software programs, and/or muntin grid punching stations.

As shown inFIG. 31, the sash frame310can be placed on a work surface312, which has a plurality of muntin grid drill, punch or notching stations314disposed along the front portion312aof the work surface. The sash frame310is disposed so that the portion of the sash frame being worked on (310ainFIG. 31) is first moved closer to the rear section312bof the work surface and then pulled back in the direction of the front section312aso that the frame is aligned in the station314as shown inFIG. 32. The stations314are located so that receptacles, holes, notches or other openings for the muntin retaining clips can be positioned along the length of the side310a. Then, the sash frame is pushed back in the direction toward the back section312band rotated ninety degrees so that the sash section310bis positioned and moved into contact with the tools314as previously described. This process can continue with the sash frame310turning for 360 degrees in the direction shown, or if desired, in the opposite direction. Then the sash frame310can be moved down the assembly line to the next work station in either direction as indicated by arrow316.

FIG. 33illustrates an embodiment similar to the arrangement ofFIG. 31, except that the tools330are of a different type, such as a simple top or side drill, a punch, or a milling device, to cut the holes, slots or whatever is necessary to locate and/or retain the muntin clips in the sash frame.

FIG. 34illustrates a method for securing muntin bars352in an IST unit according to the present invention with a complementary interconnect, such as a muntin retaining clip, between the muntin bar352and the IST glazing pocket353of the sash frame354. If no clip (as described hereinbefore) is used, then a slot355can be placed in the upper lips356a,356bof the glazing pocket353to attach to corresponding notches352alocated at the end of the muntin grid352, as shown inFIG. 35. These notches or punched holes352aat the end of the muntin grid352may vary in shape and dimension. Punches or notches352amay be on both legs, one leg, or on the top of a cross bridge if the spacing structure extends across the top of the glazing legs. The notches352amay also only be in or in combination with other horizontal or vertical features that are part of the glazing legs356c.

FIG. 36depicts an end view of the frame of the extrusions for an IST unit360. Note that the sash and frame profiles are samples of numerous shapes and dimensions prevalent in the fenestration industry. IST focuses attention on integrating glazing legs and structures with corresponding air space integral to (with) the sash profile. The unique integrated glass-to-sash concept highlights the interaction or play that occurs between glass, sealant/adhesive and sash extrusion. The sealant/adhesive becomes a shock absorbing entity between the glass and the extrusion profile.

FIG. 36demonstrates at the lower extrusion detail the end(s) of the muntin bar361(which is typically part of a grid) embedded into sealant and/or desiccant matrix362within the cavity363of the glazing chamber365. Note that the matrix362may be on the top of a shelf or box364of the glazing chamber365onto which the ends of the muntin bars361may likewise be embedded or adhered within or upon or with a sealant that is designed to adhere the grid to the spacing structure formed in the glazing chamber. Clips of the type described before for attaching the muntin bar361to the lips366a,366bor any part of the IST glazing chamber365, will preferably be positive locking in nature, although a positive lock is not required. These clips may be attached to a top bridge, shelf, leg, or any part of the glazing chamber.

FIGS. 37A,37B and37C illustrate a “Butterfly” muntin retaining clip that is designed to perform a primary function for two glazing scenarios: 1) Integrated Multipane Window Unit, i.e. IST; and 2) C-shaped or U-shaped insulating glass spacer, as shown inFIG. 38. The first embodiment or basic “Butterfly” muntin retaining clip370, as shown inFIG. 37A, includes a set of wings or tabs371a,371b,372a,372bwith a perpendicular muntin retainer374that runs parallel to the spacer face. Two of the tabs371a,371bare curved to project upward and two of the tabs372a,372bare curved like tabs371a,371bbut project downward. The muntin retainer374is intended to be of various shapes and dimensions in order to receive a corresponding muntin or grid type.

In a second embodiment of a “Butterfly” Muntin retaining clip375, as shown inFIG. 37B, the sets of upward wings or tabs376a,376bhave a protrusion376c,376d, respectively, projecting upward from their free ends for engagement with a notch in another member such as a glazing chamber. Both protrusions376cand376dhave wings376c′ and376d′ extending outwardly from opposite sides in the general plane of the wings376aand376b, respectively. Both the sets of upward and downward wings or tabs376a,376b, and377a,377b, respectively, are generally more narrow than those in the embodiment shown inFIG. 37A. As with the embodiment shown inFIG. 37A, there is a perpendicular protruding muntin retainer374for attachment to a muntin bar.

In a third embodiment of a “Butterfly” muntin retaining clip376, as shown inFIG. 37C, the sets of upward wings or tabs378a,378bhave a protrusions378cand378don the upper side of each of the upper wings378a,378bthat project upward for engagement with a notch in another member such as a glazing chamber. Both the sets of upward and downward wings or tabs378a,378b, and379a,379b, respectively, are generally the same as those in the embodiment shown inFIG. 37A. As with the embodiment shown inFIG. 37A, there is a perpendicular protruding muntin retainer374for attachment to a muntin bar.

FIGS. 39A,39B and39C illustrate the “Butterfly” muntin retaining clip designs ofFIGS. 37A,37B and37C, respectively for use in C-shape and U-shape spaces. InFIG. 39A, retaining clip370is shown installed in a U-shaped spacer390. InFIG. 39B, the muntin retaining clip of375ofFIG. 37Bis shown in dotted lines installed in a U-shaped spacer394which has two notches395ato receive protrusions376cand376don the upper side of each of the upper wings376aand376b, respectively. InFIG. 39C, the muntin retaining clip of376is shown installed in a U-shaped spacer392which has four notches393ato receive protrusions378cand378don the upper side of each of the upper wings378aand378b, respectively.

FIGS. 41A and 41Bdepict the end view of two embodiments of a sash frame with a “ratchet muntin retaining clip.” In both embodiments, ridges, ratchets, or notches410extend as indentations on the inner face of the glazing leg/channel412. The ridges or ratchets410will communicate with the grid muntin retaining clip platform413and414of the ratchet muntin retaining clips415and416, respectively, as shown inFIGS. 41C and 41D, respectively. The grid muntin retaining clip platform413, as shown inFIG. 41C, is substantially planar while the grid muntin retaining clip platform414, as shown inFIG. 41D, has a v-shaped end on either side shaped to fit into two spaced ratchets. The communication of the ratchet410and the grid muntin retaining clip platform413,414allows for the muntin bar417to remain in a fixed location. The grid muntin retaining clip platform413,414will snap or lock into the appropriate ridge/ratchet level. The ridges and/or notches may curved, directed upward, downward, or in such a manner so as to provide a secure means of receiving and retaining the grid muntin retaining clip. They may be singular, multiple or numerous along the inside or outside surface of the glazing leg. A clip-less version of assembly may be incorporated wherein the end of the muntin bar is punched or shaped in such a manner that it itself is received into the ridged or ratcheted area of the sash glazing leg(s). It is also within the scope of the invention that one, two or more glazing legs may be ratcheted or notched, instead of the embodiment illustrated wherein a pair of legs is ratcheted or notched. Structure as shown inFIGS. 41A and 41Bmay be designed to accommodate any shape clip, such as illustrated by example inFIGS. 39A,39B and39C.

FIG. 42illustrates a floating grid muntin retaining clip420incorporated with an integrated sash421. As shown inFIG. 42A, the grid muntin retaining clip420can be constructed with a flat base421and an upstanding muntin retainer422. The grid muntin retaining clip420floats against the terminal end423of the glazing legs424. Pressure caused by the cut to length dimension of the muntin bar425causes the grid muntin retaining clip to remain in position. In any of the concepts disclosed herein, the grid muntin retaining clip can be adhered by adhesive, glue, sealant, desiccant matrix, or embedded within such materials so as to fix the location of the muntin grid at its appropriate horizontal and/or vertical position as viewed inFIG. 42.

As shown inFIG. 42B, the grid muntin retaining clip426can be constructed identical with the muntin retaining clip ofFIG. 42Aexcept it may also incorporate a set of legs or fins427perpendicular to the flat base. These legs or fins427are disposed against opposite inner surfaces of the opposing glazing legs and assist in preventing side-to-side movement of the muntin retaining clip toward the glazing legs.

FIG. 43illustrates an integral spacing structure430that is of a different substance, material, compound, or manufacture than the sash frame. The spacer430, as shown inFIG. 43, can be fabricated from foam or any other suitable material. The spacer may be provided in any shape that is capable of receiving a muntin bar or muntin bar clip. In the illustrated embodiment, the spacing structure430is configured with two spaced channels434and435to receive a muntin bar431or grid assembly that can be attached by a muntin clip432.

FIG. 44Aillustrates an integral spacer440that also functions as a sealant director when a glazing pane442is applied. In particular, when the glazing pane442is pushed (or vacuum drawn) towards the spacer440, the sealant445will whet-out within the channel provided between flange447and the base449of the sash profile446. The flange447will prevent the sealant from oozing into the insulating air space above the spacer440. A muntin bar444or grid assembly can be secured to the spacer440as shown. The muntin bars seated into the spacer440can be incorporated in a sash frame446as shown.

FIG. 44Billustrates an integral spacer447that functions as a sealant director like the spacer440ofFIG. 44A. Glazing panes442,443are mounted to the spacer with sealant. Alternatively, the spacer itself can be sufficiently adhesive to render the sealant optional. Muntin bars444or a grid assembly are secured to the spacer440as shown.

FIGS. 45A,45B and45C illustrate muntin grid access that is achieved by a stepped glazing leg mounting structure. A muntin retaining clip or mounting bracket may be required to properly locate and/or maintain the grid assembly within the air space. Any combination of clips and/or glazing leg configurations, such as notches or ratcheted legs (seeFIGS. 41A and 41B) may be incorporated on either both or multiple (three or more) legs, exterior or interior, so as to adequately receive or fix the muntin grid assembly. The stepped leg structure may be used to incorporate more than one glazing panel in the sash frame. For example, a triple pane unit or combinations of insulating glass units side by side yet spaced apart with grids within the sash frame can be accommodated. A stepped structure may also allow the window or door to be assembled from one side of the frame, without the need to flip the frame over to mount glazing panes to different sides.

FIGS. 45A,45B, and45C illustrate the assembly of an insulating window, door or the like by first placing the sash frame side components450down as shown inFIG. 45A. The glazing sheet451has already been installed, and is held by sealant and/or glazing bead452. Next, as shown inFIG. 45B, the muntin grid453is attached by a clip or other means, as previously described. Sealant457is applied between the leg456and the glazing sheet454, and the glazing sheet454is mounted onto the leg456. Finally, a glazing bead455is affixed to the sash frame.

FIGS. 46A and 46Billustrate that fully molded or formed grid frames460may be used. Such means as injection molding may produce the complete grid assembly460. The complete grid assembly460may be attached by the use of muntin clips470as illustrated inFIG. 47and/or as otherwise depicted herein (e.g., by adhesive or mechanical snapping of the grid into the sash frame). The grid assembly460may by adhered to the sash frame462by an adhesive desiccant matrix, vapor barrier, and/or any combination of such materials or other suitable materials.

It is further noted that an embodiment is envisioned where the muntin grid is built directly into the sash frame462. In particular, an integral sash and muntin grid assembly can be fabricated, e.g., by injection molding, which includes a complete window frame and muntin bars in one piece. Using the integrated sash technology discussed herein and in the aforementioned U.S. Pat. Nos. 6,286,288 and 6,536,182, a window having the muntin bars between the insulating glass sheets can be completed by simply applying sealant to the integral spacing and mounting structure of the sash (e.g., glazing legs or steps), and applying the glazing sheets. Alternatively, the sealant can be applied to the glazing sheets, which are then attached to the spacing and mounting structure of the sash. It is also possible to apply sealant to both the spacing and mounting structure and to the glazing sheets prior to mounting the glazing sheets. Since the muntins are an integral part of the sash frame, no clips or other muntin mounting components are required.

The grid attachment method may incorporate any means, e.g., as shown inFIG. 47, (including variations of the clips illustrated herein) to attach the grid to the spacing and mounting structure of the sash frame. The variations in muntin clips shown inFIGS. 49A-49Mare illustrative and other clip designs which are adapted to attach the muntin bar or grid to the sash frame fall within the scope of this invention. Any combination of the structures as shown inFIGS. 49A-49Mand methods illustrated herein can be used as desired. The grid muntin retaining clips illustrated inFIGS. 49A-49M, and50A-50C are depicted to be conceptual by design. The grid muntin retaining clips may be of any material, combinations of material, any form or degree of flexibility, rigidity, softness, hardness, or other makeup so as to provide a secure seat for the grid assembly or grid structure. Any combination of flexibility, rigidity, softness, hardness or other makeup may be incorporated so as to provide appropriate means of securing the muntin retaining clip to the sash assembly. Any of the illustrations shown may incorporate any combination of features illustrated in any other design depicted.

FIGS. 51A-51Hillustrate various means by which a grid assembly, muntin retaining clip or combination of grid assemblies or pre-molded grid units may be attached and/or adhered to or made integral to the sash member. Any combination of grid muntin retaining clips, no grid clips, or notched/machined and/or end manipulation of such grid bars for attachment or fastening to the sash member may be employed, and all such variations are intended to be within the scope of the present invention. The muntin retaining clip or grid bars for attachment or fastening to the sash member may be employed, and all such variations are intended to be within the scope of the present invention. The muntin retaining clip or grid member may be placed into and/or upon the desiccant matrix and/or sealant material that may serve as a desiccant and/or adhesive and/or vapor barrier and/or separate material solely for grid muntin retaining clip or grid member fastening.

For example,FIG. 51Ashows a sash frame511adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs. A muntin bar510is attached to a sash frame511with a muntin retaining clip512extending into the glazing box513of a spacing and mounting structure. A sealant material514is disposed between the two adjacent glazing legs to cover the muntin clip so that a muntin retainer projects outward from the base of the muntin clip to receive an end of a muntin bar. The muntin is held by the adhesive and supported by the glazing walls515. The two glazing walls or legs515each have a support section at one end that extends in the direction of the other glazing leg and forms a slot there between. The muntin retainer projects outward of the slot so that the bottom of the muntin bar rests on the support sections.

FIG. 51Bshows a muntin bar510attached to a sash frame516by a sealant material514in the glazing box of the spacing and mounting structure having a base and two glazing lets. An interconnect structure is provided for mounting a muntin bar or muntin grid assembly in the space between the two glazing legs and the base. The adhesive material is disposed between the two adjacent glazing legs and around an end of a muntin bar to secure the muntin bar to the spacing and mounting structure. A support surface517is disposed above the base and between the two glazing legs. The sealant material is disposed between the two adjacent glazing legs and on the support surface and around an end of a muntin bar to secure the muntin bar to the spacing and mounting structure.

FIG. 51Cshows a muntin bar510attached to a sash frame516with a muntin retaining clip extending into the glazing box. A sealant material514secures muntin bar510and the muntin clip without support of the glazing walls.

FIG. 51Dshows a muntin bar517attached to a sash frame511with a portion of the muntin bar517extending into the glazing box. The muntin bar517has grooves517aon the lower end to secure the muntin bar to glazing wall extensions515a,515bprojecting towards each other and inserted within the grooves517a. A sealant material514in combination with the glazing walls515supports the muntin bar517. The sash frame511is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs forming the glazing walls. The sash frame includes interconnect structure for mounting the muntin bar or muntin grid assembly to the spacing and mounting structure. The interconnect structure includes a support section515a,515bat one end of each of the two glazing legs that extends in the direction of the other glazing leg and forms a slot therebetween.

FIG. 51Eshows a muntin bar attached to a sash frame by a sealant material in the glazing box, similar to the embodiment shown inFIG. 51B.

FIG. 51Fshows a muntin bar mounted to a sash frame above the glazing box with a sealant518that also helps support the window panes. The sealant518forms a continuous seal from glazing pane to glazing pane, and can serve as a vapor barrier to prevent plasticizers or the like in the sash frame from migrating into the insulating air space and coating (e.g., fogging) the inside of the glazing panes. A sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base with a rectangular support box519extending therefrom. The sash frame comprises an interconnect structure for mounting a muntin bar or muntin grid assembly atop the rectangular support box. A sealant material514is disposed on the base and around at least two sides and across the top of the rectangular support box to cover an end of a muntin bar so that the muntin bar projects outward from the rectangular support box. One glazing sheet is seated on the sealant material disposed on the base and against a first side of the rectangular box and another glazing sheet seated on the sealant material disposed on the base and against a second side of the rectangular box. A pair of clips engage the first and second glazing sheets and press the glazing sheets against the sealant material. A muntin clip can be attached to the end of the muntin bar.

FIG. 51Gshows a muntin bar and muntin clip mounted to a sash frame within the glazing box and surrounded with a sealant that also helps support the window panes while providing a vapor barrier. The sash frame is adapted to receive parallel glazing sheets on a spacing and mounting structure having a base and two glazing legs and a support surface disposed above the base and between the two glazing legs. The sash frame includes a muntin clip disposed between the two glazing legs and above the support surface. The sealant material is disposed on the outer surface of the glazing legs, between the two adjacent glazing legs and around the muntin clip to secure the muntin bar to the spacing and mounting structure.

FIG. 51His similar toFIG. 51Fexcept it also incorporates a muntin clip to support the muntin bar.

FIG. 52Aillustrates a grid assembly520that may be injection molded or molded or formed as part of or integral to one section of the sash frame522. The assembly520mounts (e.g., snaps) into a second section524of the sash frame, to provide a completed sash frame shown inFIG. 52Bto which glazing panes can be mounted.

FIG. 53illustrates a concept (which may have any suitable size or shape) wherein the muntin retaining clip530for securing the muntin bar532to the sash frame534is constructed of an expanding material, such as a foam of any shape and/or dimension. The expanding muntin retaining clip530may be of any configuration such as those shown inFIGS. 49A-49M. Nevertheless, the concept revolves around the improved method of attaching the muntin grid to the sash frame534by the foam muntin retaining clip530. This can be accomplished by an expanding foam pressure fit between the muntin retaining clip530and the sash frame534due to a configuration of the clip that allows for the oversized expanding foam to be seated into its corresponding location. The foam muntin retaining clip530will generally be larger or greater in size than the location into which it will rest. Due to the characteristic of the expanding material (such as foam), the muntin retaining clip530will first compress to fit into any (if any) narrowing slot or recess or way, for example slot535as shown inFIG. 53, and then expand back into its new seat dimension, shape, or location536. In this manner, the pressure from the oversized foam muntin retaining clip530fitting into a smaller location seat536will provide the friction required to maintain the grid/muntin placement.

FIG. 54illustrates that the muntin retaining clip540may have a base structure541that will fit or wedge or slide into or be positioned into a recess or slot542that allows the muntin retaining clip to be wedged or friction set into position. In this embodiment, the muntin retaining clip540has one side sitting on the top of glazing wall544of sash frame545and the other side wedged into the slot542formed in the other glazing wall546.

In the embodiment ofFIG. 55, the muntin retaining clip550has a base structure551with an end portion552that bends down and has a projection554that faces towards the opposite end555of the muntin retaining clip. The muntin retaining clip550is secured to a muntin bar and is wedged into a slot557and held by a block558so that the grid frame is secured to the sash frame whether mounted vertically, horizontally, or otherwise.

FIGS. 56A and 56Billustrate a method of applying grid frames or individual grid members560to a sash frame562. The grid members560may be placed into the sash frame562to “build” the grid assembly or may be pre-built before insertion. A clip564or other securing means such as a staple, pin, screw, joining device, mechanism, fastener, glue, adhesive, tape or any other means may be used to attach or fasten or secure the grid assembly560after or simultaneously to the grid assembly insertion or placement. These functions or processes may be in any order, via a manual method, semi-automatic method, or completely automated operation.

FIGS. 57A,57B and57C illustrate a muntin retaining clip570with a central clip body571adapted to fit within the space between the two glazing legs572a,572bthat are integral with a sash frame of the type described herein. As shown inFIG. 57C, the clip570has an upstanding retainer573disposed on the upper surface of central body571for holding the end of a muntin bar. The width of the central body571is selected to fit between glazing legs or walls572aand572bof the sash frame. The bottom of the retaining clip570, as shown inFIG. 57A, has base support (e.g., H-shaped) that includes two side walls575a,575bextending the width of the clip. An interconnecting wall extends between the two side walls. As shown inFIG. 57B, the glazing legs572a,572beach have an oppositely disposed notch or slot576a,576b, respectively, formed in the upper portion of the glazing legs. The length of the slots576a,576bis slightly more than the width of the central body571so that the clip570can be inserted into the slots576a,576band between the glazing walls572a,572b. The clip570is mounted between the glazing walls572a,572bso that the two side walls575a,575bare both disposed in the opposite facing slots576a,576bto secure the clip570in place (i.e., to prevent the clip from sliding along the length of the legs572a,572b). The clip can be designed to simply sit upon the legs, within the slots576a,576b, or can be dimensioned to snap or friction fit within the slots to hold the clip tightly. If the clip is not held tightly within the slots, the pressure of the muntin bars having clips at opposite ends can be relied on to maintain (e.g., bias) the clips within the notches.

FIGS. 58A and 58Billustrate a triple glazing clip580with a central clip body adapted to fit within the space between the two glazing legs that are integral with a sash frame of the type described herein. As shown inFIG. 58A, the clip580has three upstanding blocks581a,581b,581c disposed on the upper surface of the central body for holding a glazing pane583, as shown inFIG. 58B. Preferably, the three blocks581a,581b,581care spaced so that two blocks581aand581bare aligned next to and spaced from each other and the third block581cis spaced from the first two and aligned opposite the spacing between the first two blocks. The central body is constructed in the same manner as central body571ofFIG. 57in order to fit between two glazing legs or walls, each having a slot, of a sash frame. The bottom of the retaining clip580has, for example, an H-shaped base support that includes two side walls585a,585bthat extend the width of the clip. In the same manner as shown inFIG. 57B, the central body portion of clip580can be mounted in the oppositely disposed slots of glazing legs to carry the weight of the glazing pane583.

If desired, muntin bars can be mounted in the space between the two blocks581aand581bor alternatively on one or two of the blocks. In another alternative embodiment, additional clips of any of the designs described herein can be provided to retain the muntin bars, such as for example clips570.

It should now be appreciated that the invention provides various embodiments for the mounting of muntin bars and/or grids to the spacing and mounting structure of an integrated sash for fabricating insulating windows, doors and the like. Embodiments both with and without clips and other mounting elements are provided. Methods of fabricating integrated sash units with muntin bars and grids are also disclosed. Moreover, the various clips of the present invention can also or alternatively be used to hold a glazing pane, e.g., to produce triple pane (or more) windows, doors and the like.

Although the invention has been described in connection with various embodiments, it should be appreciated that numerous modifications and adaptations may be made thereto without departing from the scope of the invention as set forth in the claims.