Connector for joining multiple pane window spacers

A connector key for joining spacer member ends in multi-pane window units. A connector key and methods for joining spacer member ends are provided. The connector key can include a top central depression, side walls having top gaps, side shoulders having channels and recesses, all providing opportunity for sealant to flow from the central depression over the side regions of the connector key. Connector keys can also have holes through the bottom floor of the central depression to the bottom of a connector key and further through bottom channels provided in the connector key. Methods are provided which include sliding a spacer member over each end of the connector key up to a central flange. Holes may be punched through the spacer material, preferably forming jagged portions which secure the spacer members to the connecting key. Sealant may be injected through the punched holes, and through the through holes in the connector key central depression floor. Injected sealant may thus flow into the central depression, over the side walls into the side recesses, and into the bottom channels. The connector key can provide temporary mechanical joinder while the sealant is curing, as well as mechanical rigidity and insulative gas sealing after curing.

FIELD OF THE INVENTION

The present application is related generally to windows and doors. More specifically, the present application is related to spacers or frames used to separate the panes of multi-pane window units. The present invention includes a key or connector for joining together two ends of tubular spacers and methods for sealing the inserted connector and spacer.

BACKGROUND OF THE INVENTION

Multi-pane window units are well known. Multi-pane window units include insulating glass units which include at least two window panes separated by a spacer which extends around the periphery of the separated window panes. The spacer or profile is typically a tubular, substantially rectangular shaped, hollow member. The spacer is typically formed from thin sheet metal, and may be formed so as to have ribs and/or channels and fins imparted to increase the structural strength of the thin walled spacer.

Insulating glass units may be formed by combining a substantially linear, tubular, metallic spacer and two glass window panes. The insulating glass units are formed in many shapes, including rectangular, triangular, circular, arcuate, and combinations of these shapes. Rectangular shaped insulating glass units are the most common. In one method, the spacer is formed from a sheet metal strip into a substantially rectangular cross-sectional shape having a length approximately equal to the total perimeter of the glass panes to be joined. For use in a rectangular shaped insulating glass unit, the spacer can be run through a bending unit to form four substantially rectangular corners. In an illustrative example of one method, a metallic spacer member begins along the top, near the upper left corner of the insulating glass unit extends across to the upper right corner, bends to extend downward to the lower right corner, bends to extend leftward to the lower left corner, bends to extend upward to the upper left corner, and bends to extend rightward to meet the opposite end of the spacer at the top, left region of the insulating glass unit. The opposing ends of the spacer are typically joined together to form a sealed, mechanically sound joint.

A gap is inherently formed between the two abutting spacer ends. This gap may lead to unwanted gas exchange between the between pane space and the atmosphere. One path for this exchange is from the gap alongside a connector (if present), between the connector and the enclosing spacer wall, continuing into the interior of the spacer past the connector, then into the insulating gas space between the panes through the breather holes in the spacer wall. This gas exchange path is preferably very tight and long.

One connector joint is formed by inserting a mechanical connector between the abutting spacer ends, and wrapping the outward and sideward faces of the spacer with a metallic tape or metallic cap using a dedicated machine. The side edges of the spacer nearest the inward face of the spacer can be joined with sealant to the glass panes disposed on either side of the spacers. The dedicated machine can be difficult to operate and maintain.

In one method, the two spacer ends are held together in a jig, and a sealant material is injected into the spacer near the joined ends. The sealant may flow into both open spacer ends, and be allowed to cure. The resulting joint integrity may be limited by the structural strength of the sealant after curing. This method also may require a long curing time, as the facing ends of the opposite spacer may have little structural integrity until the sealant is cured.

In another method, a mechanical key or connector is inserted into both ends of the spacer. In one such method, sealant is applied into or onto the outward facing surface of the connector key and the connector key opposite arms inserted into the facing spacer openings. Each of the facing spacer members may then be crimped, thereby forcing the sealant to run from the opposite spacer openings into a central region between the two opposite spacer members. In this method, the sealant may reside primarily in the outside surface portion of the joined spacers and the joined spacers may suffer aesthetically from having been crimped. The crimping may, in some methods, also reduce the structural integrity of the joined members.

What would be desirable is an improved mechanical key or connector for joining multi-pane window spacer ends. What would be advantageous are improved methods for joining together window spacer members.

SUMMARY OF THE INVENTION

The present invention includes a connector key for joining together two tubular spacer members for spacing apart panes of multi-pane window units. The spacer members and connector keys may be considered to have an inwardly facing or inward portion disposed toward the interpane space and an outwardly facing or outward portion disposed toward the atmosphere. One connector key has a central flange for disposing the connector the same depth into each spacer end. The connector key can include an outward face having a central cavity or depression for receiving sealant, with the central depression having side walls. The side walls can have an inwardly disposed gap or recess on either side of the depression. One connector key has a side channel and a side channel floor for receiving sealant which flows from the central depression, over the side walls, over the side wall gaps, and into the side wall channels.

The connector key preferably has at least one hole extending from the central depression floor through to the inward portion of the connector key. A preferred embodiment has two holes extending from the central depression floor through to the connector key inward surface. The through holes can allow injected sealant to flow from the outwardly facing central depression to the inward face of the connector key and into the spacer interior between the connector key inward surface and the spacer wall. The connector key can also have inward face surface channels for distributing sealant along the inward surface of the connector key to better seal the connector key and the spacers. One connector key has a longitudinal channel extending on either side of the central flange, as well as transverse channels, all along the inwardly facing surface of the connector key.

The present invention includes a first connector embodiment for connecting two tubular window spacer ends, the connector comprising: an elongate body having a top face, a bottom face, at least two side faces, a first end, and an opposite second end; the elongate body extending from the first end to the opposite second end through an intermediate mid region, the body top face having a top cavity therein, the top cavity disposed between two cavity side walls each having a downwardly recessed upper region therein, wherein the body side faces each having a side channel in communication with the side wall top recess and the top cavity, for receiving sealant injected into the top cavity. In a second connector embodiment, the first connector has at least one hole extending through the body between the cavity and the bottom face. In a third connector embodiment, the second connector has at least one channel extending along the connector bottom face and in communication with the at least one hole. In a fourth connector embodiment, the third connector embodiment has the at least one channel transversely disposed between the two side faces. In a fifth connector embodiment, the first connector has a flange disposed on the bottom face.

A sixth connector embodiment is similar to the first connector embodiment, with the connector having a flange disposed on the bottom face, and having at least one hole extending through the connector on either side of the flange. In a seventh connector embodiment, the sixth connector embodiment bottom face includes a channel in communication with the at least one hole.

The present invention also includes an eighth connector embodiment, for connecting two window spacer ends, the spacer having a substantially hollow, tubular shape, the spacer having an inwardly facing wall for forming an insulating glass unit interior and an outwardly facing wall for forming an insulating glass unit exterior, the eighth connector comprising: a body shaped and dimensioned to fit within the tubular spacers, the body having two opposite ends, an inward face for facing the spacer inwardly facing wall, an outward face for facing the spacer outwardly facing wall; and at least two holes extending through the eighth connector and in communication with both the eighth connector inward face and connector outward face.

In a ninth connector embodiment, the eighth connector embodiment body has a cavity formed into the outward face and the cavity has a cavity floor, wherein the at least two holes are in communication with the cavity. In a tenth connector embodiment, the ninth connector embodiment body has at least one channel formed in the inward face and in communication with the body holes and outward cavity for receiving sealant injected into the holes. In an eleventh connector embodiment, the ninth connector embodiment body has at least two channels formed in the inward face and in communication with the body holes and outward cavity for receiving sealant injected into the holes. In a twelfth connector embodiment, the ninth connector embodiment body has at least two channels formed in the inward face and in communication with the body holes and outward cavity for receiving sealant injected into the holes, wherein the body has a longitudinal axis extending between the body opposite ends, wherein the two channels are disposed transversely to the body longitudinal axis.

The present invention also includes a thirteenth connector embodiment for connecting two tubular window spacer ends, the thirteenth connector embodiment comprising: an elongate body having a top face, a bottom face, at least two side faces, a first end section, and an opposite second end section; the elongate body extending from the first end section to the second end section through a mid region; the body top and side faces being recessed in the mid region relative to the first and second end sections; wherein the body has at least one hole extending between the bottom face and the top face, the at least one hole being in communication with the mid region recess.

In one method according to the present invention, a connector key is provided, consistent with a connector key as described above. A first end section of the connector key can be inserted into the first open end of a spacer. The connector key can be inserted until further travel is limited by the central flange. A second spacer end can be slipped over the second end section of the connector key until travel of the second spacer is also limited by the central flange. At this point, the two spacer members are both disposed over the connector key up to the central flange. The connector key is thus disposed within the interiors of the two opposing spacer members. In a preferred method, the two spacer member ends are actually opposite ends of a single spacer member which has been bent to form a rectangular frame.

In a preferred method according to the present invention, the connector key has two through holes extending from the central depression floor through to the inward surface of the connector key, each hole being disposed at an opposite end of the central depression. A hole can be punched through the metal of the spacer and into the central depression, near each end of the depression and over each through hole. The holes punched in this manner may have jagged, sheet metal protrusions caused or formed by the punching. The sheet metal protrusions can extend into the depression, preferably near the opposite ends of the depression, thereby forming a mechanical joinder of the metal spacers to the connector key. In one method, the two spacers cannot be easily pulled apart from each other after the holes have been punched.

A sealant material can be injected through a nozzle, cannula or hollow needle into the spacer holes previously formed. A sealant can be injected through the holes in the metal, into the central depression, with the sealant filling the depression, flowing through holes of the connector key and to the inward surface of the connector key. In one method, the sealant flows through connector key inward surface longitudinal and transverse channels, thereby adhering and sealing the inward surface of the connector key to the opposing metal of the spacer. In the outward region of the connector key, a sealant can flow over the depression side walls through an outwardly disposed wall gap, over the side walls into a side channel or groove area. The sealant can further flow over the depression side walls to a land area which is preferably longitudinally centrally disposed to the key, having some of each spacer extending thereover.

In one method, the injecting nozzle or a needle is extended into the depression, and near or into the through hole extending from the depression floor to the connector key inward surface. In this method, a sealant can be injected directly into the through hole and/or into the connector key inward surface area including the inward surface transverse and longitudinal channels. The sealant can thus seal the connector key and spacer at the central depression, the side channels outside of the central depression, and the inward surface of the connector key. With the sealant injected, the injecting nozzles can be withdrawn and the sealant allowed to cure. In one embodiment, the mechanical integrity at least during the curing process is provided substantially in part by the mechanical connector key disposed through the spacers.

Connection keys can have a mid region disposed between the opposite end sections, where the mid region has the inward face and side faces recessed relative to the surrounding end sections. The connector key thus provided includes a central area that is recessed relative to the enclosing spacer wall, leaving a void between the connector and the spacer wall. The void can be filled with sealant. The band of sealant thus provided can greatly reduce the gas exchange from the gap between the spacer ends and the interior space of the spacer members and insulating glass unit. The sealant can also enhance the spacer joint by providing adherence and structure to the joint

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following detailed description should be read with reference to the drawings, in which like elements in different drawings are numbered identically. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. Several forms of invention have been shown and described, and other forms will now be apparent to those skilled in art. It will be understood that embodiments shown in drawings and described above are merely for illustrative purposes, and are not intended to limit scope of the invention as defined in the claims which follow.

It is understood that connector keys are ultimately to be disposed within two abutting spacer ends. The spacer ends include generally a spacer wall having an inwardly facing or inward portion to face the inter-pane, insulating gas portion of an insulating glass unit. The spacer wall also has an outward portion, to face outwardly, toward the atmosphere, and likely to be further sealed. As used herein, the connector key “inward” surface refers to a portion facing toward the inter-pane space, with the connector key “outward” surface refers to a portion facing await from the inter-pane space.

FIG. 1illustrates a spacer joint or connector key30having generally a right arm or first end section39and an opposite left arm or second end section34. Right arm32includes generally a right end36and left arm34includes generally a left end38. Connector key30includes a central, inward surface flange40extending transversely along under connector key30which can be used to limit the travel of connector key30into the spacer interior. A central channel or depression42is formed in the outward surface80of connector key30and includes a left outside edge85, a right outside edge87, a rear side wall46, and a front side wall44. Front side wall44includes a front side wall gap60and rear side wall46includes a rear side wall gap62. Front side wall44includes a front side wall exterior face48extending down to a front side wall land56and having a front central side wall land recess64near the bottom. Connector key30also includes generally a front facet68and a front lower shoulder52. In the rear area, a symmetrical set of lands and shoulders may also be seen, illustrated in other figures. Connector key30may be seen to include a left end facet72, a right end facet74, and a nub75which, in some embodiments, is an artifact of the manufacturing process. At the bottom of connector key30, a bottom left channel76and a bottom right channel78may be seen disposed transversely to the longitudinal axis of the connector key. Gas exchange along the inward surface of the connector may be significantly restricted between flange40and the connector ends36and38by transversely disposed channels76and78filed with sealant.

FIG. 2illustrates connector key30, shown from the top. Central channel or depression42in the outward surface80may be seen to include a left through hole84and a right through hole86, both formed in a central channel floor82. Front side wall land56and central land recess64are further illustrated inFIG. 2, as is front shoulder52and a rear shoulder54. Rear side wall46may be seen to have rear side wall gap62near the top of the side wall. Through holes84and86may be seen to extend through connector key30entirely to the inward surface of the connector key. Left hole84and right hole86may be seen to be formed near left edge85and top right edge87. As will be discussed further, in a later step, an enclosing sheet metal spacer man have holes punched through, driving protruding pieces of metal down over holes84and86, with the protruding pieces of metal pressing against left edge85and right edge87, the protruding pieces of metal will secure the mechanical location of the connector key relative to the enclosing sheet metal.

FIG. 3illustrates connector key30from a bottom, perspective view.FIG. 3illustrates generally an inward surface90of connector key30. Connector key30may be seen to have an inward surface left longitudinal channel92and a right longitudinal channel94disposed on either side of connector key flange40. In some embodiments, as illustrated inFIG. 3, the right longitudinal inward surface channel94may extend entirely through to right end36, and left longitudinal channel92may extend entirely through to left end38. Left through hole84may be seen to be in communication with a transverse inward surface channel76, and through hole86may be seen to be in communication with an inward surface right transverse channel78. In the embodiment illustrated, left longitudinal channel92is in communication with left transverse channel76and transverse channel78is in communication with longitudinal channel94. The inward portion of connector key30may also be seen to have bottom indentations99,98,96, and97.

Inspection ofFIG. 3further illustrates how sealant may ultimately be disposed within and about connector key30. Sealant injected into left through hole84may flow through left longitudinal channel92to central flange40, and through transverse channel76. The sealant thus injected maybe seen to form bands of sealant in channels76and78, between the connector key and the enclosing spacer walls. Similarly, sealant injected through right through hole86may be seen to flow through right longitudinal channel94to central flange40, and through transverse channel78. The bottom of connector key30may, thus be seen to be well sealed to any enclosing spacer member after the sealant has been injected. In some embodiments, longitudinal channels92and94may be at least partially occluded by a central, indented channel formed into the spacer. In one embodiment, longitudinal channels92and94slidably receive a longitudinal indent or groove in the spacer, the groove having breathing or ventilation holes along its length.

FIG. 4illustrates connector key30as viewed from the top, right end. Right end facet74and front land recess64may be better viewed in FIG.4. Central recess or depression floor82, left through hole84, and left top edge85are further illustrated.

FIG. 5illustrates connector key30having the connector key left end inserted into a first spacer member100having a first spacer lumen or interior102within. First spacer100may be seen to have a side facet106which may be seen to fit rather closely over connector key30rear facet70, away from central cavity42. A central void104may be seen to be formed between first spacer facet106and connector key30in the area of central land recess64, providing space for sealant to flow against the interior of the spacer member. Connector key30may be seen to be inserted up to central flange40, which limits the travel of the connector key into first spacer member100. Sealant, later injected through the top or outward surface of first spacer member100, may be visualized to fill central channel42, spilling over rear side wall gap62into central land recess64and into void104. Sealant, injected into a through hole to the outside surface of connector key30, may flow through connector inside surface transverse right channel78and toward the side of the connector key30.FIG. 5thus illustrates how a sealant may flow through and around connector key30and within first spacer member100.

FIG. 6illustrates connector key30and first spacer member100having a second spacer member110slipped over connector key30up to central flange40. A gap112may be seen to be formed between first spacer member100and second spacer member110, having a gap which may approximately be equal to the width of flange40.FIG. 6also illustrates holes114and116punched through the spacer members100and110into the central depression42(not visible inFIG. 6) of connector key30. In some methods, the holes are punched so as to force protruding pieces of profile into the depression. In one method, the profiles are formed of a sheet metal material, and protruding jagged pieces of sheet metal are forced into and against the opposite edges of the central depression42of spacer30. As may be visualized with respect toFIG. 6, with the jagged pieces of metal bearing against the outside left edge85and outside right edge87(not illustrated in FIG.6), the joint is at least partially mechanically secured by the formation of the punched holes.

FIG. 7illustrates the joinder of first spacer member100and second spacer member110after injection of sealant into holes114and116. Sealant, represented at120, may be seen to fill holes114and116and may be seen to substantially fill gap112. In one method, a nozzle or hollow needle is used to inject sealant through holes114and116into central depression42. In some methods, the injecting nozzle is forced near or even within the through holes in connector30to better insure flow of sealant through the through holes and to the inward surface of the connector. As previously discussed, injecting sealant into the holes formed in the spacer members can fill the central depression with sealants spilling over the side wall gaps of the central depression into the central land region and void formed between the central land region and the profile side facets. The sealant may also flow into the outside surface transverse and longitudinal channels of the connector, and against the sheet metal portion of the spacer tubular member inside wall.

Any suitable material may be used for connector keys according to the present invention. In some embodiments, thermoplastic or thermoset polymeric materials are used to form the connector keys. Some suitable sealants include butyl rubber and polyisobutylene, however other sealants are within the scope of the invention. Two part, curable, and thermoset sealants may also be used. The connector keys according to the present invention may be used with any spacer members, however joining metallic spacer member is a preferred use of the present invention.

Connector keys according to present invention are preferably sized and dimensioned to fit within the spacer members they are to be utilized with. In one embodiment, the connector key is about 2 inches long, 0.43 inches wide at the inside, 0.24 inches wide at the outside, has a central depression width of 0.63 inches, and has a through hole diameter of about 0.08 inches. In one embodiment, the connector keys are formed of no. 6 nylon, 33% glass filled.