Abstract:
The technology disclosed herein generally relates to methods of making a spacer. At least a portion of a first elongate strip and a portion of a second elongate strip are arranged to define a space there between. A first sidewall is extruded through a first extrusion nozzle in the space. The first sidewall is adhered to the first elongate strip and the second elongate strip and the first extrusion nozzle is moved relative to the first and second elongate strips while extruding the first sidewall.

Description:
RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application No. 60/987,681, filed on Nov. 13, 2007, titled “WINDOW ASSEMBLY AND WINDOW SPACER”; and to U.S. Provisional Application No. 61/049,593, filed on May 1, 2008, titled “WINDOW ASSEMBLY AND WINDOW SPACER”; and to U.S. Provisional Application No. 61/049,599, filed on May 1, 2008, titled “MANUFACTURE OF WINDOW ASSEMBLY AND WINDOW SPACER”; and to U.S. Provisional Application No. 61/038,803, filed on Mar. 24, 2008, titled “WINDOW ASSEMBLY AND WINDOW SPACER”; and to U.S. application Ser. No. 12/270,315, filed on Nov. 13, 2008, now U.S. Pat. No. 8,151,542, titled, “BOX SPACER WITH SIDEWALLS”; the disclosures of which are each hereby incorporated by reference in their entirety. 
     BACKGROUND 
     Windows often include two facing sheets of glass separated by an air space. The air space reduces heat transfer through the window to insulate the interior of a building to which it is attached from external temperature variations. As a result, the energy efficiency of the building is improved, and a more even temperature distribution is achieved within the building. 
     SUMMARY 
     In one embodiment the technology disclosed herein generally relates to methods of making a spacer. At least a portion of a first elongate strip and a portion of a second elongate strip are arranged to define a space there between. A first sidewall is extruded through a first extrusion nozzle in the space. The first sidewall is adhered to the first elongate strip and the second elongate strip and the first extrusion nozzle is moved relative to the first and second elongate strips while extruding the first sidewall. 
     In another embodiment, a method of making a spacer is taught where at least a portion of a first elongate strip and a portion of a second elongate strip are positioned in a spaced relationship, where the first elongate strip has a first surface and the second elongate strip has a second surface. A first sidewall is extruded through a first extrusion nozzle; and the first extrusion nozzle is moved relative to the first and second elongate strips while extruding to apply the first sidewall to the first surface of the first elongate strip and to the second surface of the second elongate strip to connect the first and second elongate strips. 
     In general terms, this disclosure is also directed to a window assembly and a window spacer. In one possible configuration and by non-limiting example, the window assembly includes a first sheet, a second sheet, and a spacer arranged between the first sheet and the second sheet. The spacer includes a first elongate strip, a second elongate strip, and continuous sidewalls or a plurality of sidewalls. 
     One aspect is a spacer comprising: a first elongate strip; a second elongate strip; and at least one extruded sidewall engaging the first elongate strip to the second elongate strip. 
     Another aspect is a sealed unit assembly comprising: a first transparent material; a second transparent material; and a spacer assembly disposed between the first and second transparent materials, the spacer assembly comprising: a first elongate strip having a first side adjacent the first transparent material and a second side adjacent the second transparent material; a second elongate strip having a first side adjacent the first transparent material and second side adjacent the second transparent material; and at least one sidewall connecting the first elongate strip to the second elongate strip. 
     Yet another aspect is a method of making a spacer, the method comprising: arranging at least a portion of a first elongate strip and a second elongate strip in a spaced relationship, the first elongate strip including a first surface and the second elongate strip including a second surface; extruding a material through an extrusion nozzle to form at least one sidewall; and moving the extrusion nozzle relative to the first and second elongate strips while extruding to apply the material to the first surface of the first elongate strip and to the second surface of the second elongate strip to connect the first and second elongate strips. 
     A further aspect is a method of making a spacer, the method comprising: forming a first sidewall portion onto a first elongate strip, the first sidewall portion including a protrusion; and forming a second sidewall portion onto a second elongate strip, the second sidewall portion including a notched portion. 
     Another aspect is a spacer comprising: a first elongate strip; a second elongate strip; a first sidewall portion having a first fastening mechanism, the first sidewall portion attached to the first elongate strip; and a second sidewall portion having a second fastening mechanism, the second sidewall portion attached to the second elongate strip, wherein the first fastening mechanism is arranged and configured to securely engage with the second fastening mechanism to connect the first sidewall portion to the second sidewall portion. 
     There is no requirement that an arrangement include all features characterized herein to obtain some advantage according to the present disclosure. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic front view of a window assembly according to the present disclosure. 
         FIG. 2  is a schematic perspective view of a corner section of the window assembly shown in  FIG. 1 . 
         FIG. 3  is a schematic cross-sectional view of a portion of the window assembly shown in  FIG. 1  including a first sealant. 
         FIG. 4  is a schematic front view of a portion of another embodiment of the spacer; 
         FIG. 5  is a perspective schematic of a spacer. 
         FIG. 6  is a schematic cross-sectional view of a portion of the spacer shown in  FIG. 5 . 
         FIG. 7  is a side view of a portion of the spacer shown in  FIG. 5 . 
         FIG. 8  is a perspective schematic of a spacer. 
         FIG. 9  is a schematic cross-sectional view of a portion of the spacer shown in  FIG. 8 . 
         FIG. 10  is a side view of a portion of the spacer shown in  FIG. 8 . 
         FIG. 11  is a perspective schematic of a spacer. 
         FIG. 12  is an exploded assembly perspective schematic of the spacer shown in  FIG. 11 . 
         FIG. 13  is an exploded assembly perspective schematic of the spacer shown in  FIG. 11 . 
         FIG. 14  is a schematic cross-sectional view of a portion of the spacer shown in  FIG. 11 . 
         FIG. 15  is a side view of a portion of the spacer shown in  FIG. 11 . 
         FIG. 16  is a schematic cross-sectional view of another embodiment of a window assembly including an intermediary member. 
         FIG. 17  is an exploded assembly perspective schematic of a spacer. 
         FIG. 18  is an exploded assembly perspective schematic of a spacer. 
         FIG. 19  is a schematic cross-sectional view of a portion of the spacer shown in  FIGS. 17 and 18 . 
         FIG. 20  is a side view of a portion of the spacer shown in  FIGS. 17 and 18 . 
         FIG. 21  is an exploded assembly perspective schematic of a spacer. 
         FIG. 22  is a schematic cross-sectional view of a portion of the spacer shown in  FIG. 21 . 
         FIG. 23  is a schematic cross-sectional view of a spacer. 
         FIG. 24  is a schematic cross-sectional view of a spacer. 
         FIG. 25  is a schematic cross-sectional view of a spacer. 
         FIG. 26  is a schematic cross-sectional view of a spacer. 
         FIG. 27  is a schematic front view of a portion of the spacer shown in  FIG. 4  arranged in a corner configuration. 
     
    
    
     DETAILED DESCRIPTION 
     Various embodiments will be described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims. 
       FIGS. 1 and 2  illustrate a window assembly  100  according to the present disclosure.  FIG. 1  is a schematic front view of window assembly  100 .  FIG. 2  is a schematic perspective view of a corner section of window assembly  100 . 
     Window assembly  100  includes sheet  102 , sheet  104 , and spacer  106 . Sheets  102  and  104  are made of a material that allows at least some light to pass through. Typically, sheets  102  and  104  are made of a transparent material, such as glass, plastic, or other suitable materials. Alternatively, a translucent or semi-transparent material is used, such as etched, stained, or tinted glass or plastic. 
     Spacer  106  includes elongate strip  110 , elongate strip  114 , and sidewalls  124  and  126 . In some embodiments, spacer  106  also includes filler  112 . Spacer  106  is disposed between sheets  102  and  104  to keep sheets  102  and  104  spaced from each other. Typically, spacer  106  is arranged to form a closed loop near to the perimeter of sheets  102  and  104 . Spacer  106  is able to withstand compressive forces applied to sheets  102  and/or  104  to maintain a desired space between sheets  102  and  104 . An interior space  120  is defined within window assembly  100  by spacer  106  and sheets  102  and  104 . 
     Elongate strips  110  and  114  are typically long and thin strips of a solid material, such as metal or plastic. An example of a suitable metal is stainless steel. An example of a suitable plastic is a thermoplastic polymer, such as polyethylene terephthalate. A material with low or no permeability is preferred in some embodiments. Some embodiments include a material having a low thermal conductivity. 
     On their own, elongate strips  110  and  114  are typically flexible, including both bending and torsional flexibility. In some embodiments, bending flexibility allows an assembled spacer  106  to be bent to form non-liner shapes (e.g., curves). Bending and torsional flexibility also allows for ease of window manufacturing. Such flexibility includes either elastic or plastic deformation such that elongate strips  110  or  114  do not fracture during installation into window assembly  100 . Some embodiments of spacer  106  include elongate strips that do not have substantial flexibility, but rather are substantially rigid. In some embodiments, elongate strips  110  and  114  are flexible, but the resulting spacer  106  is substantially rigid. In some embodiments, elongate strips  110  and  114  act to protect filler  112  from ultraviolet radiation. 
     Some embodiments include filler  112  that is arranged between elongate strip  110  and elongate strip  114 . In some embodiments, filler  112  is a deformable material. Being deformable may allow spacer  106  to be formed around corners of window assembly  100 . In some embodiments, filler  112  is a desiccant that acts to remove moisture from interior space  120 . Desiccants include molecular sieve and silica gel type desiccants. One example of a desiccant is a beaded desiccant, such as PHONOSORB® molecular sieve beads manufactured by W. R. Grace &amp; Co. of Columbia, Md. If desired, an adhesive is used to attach beaded desiccant between elongate strips  110  and  114 . 
     In other embodiments, filler  112  is a material that provides support to elongate strips  110  and  114  to provide increased structural strength. In embodiments that include filler  112 , filler  112  fills space between elongate strips  110  and  114  to support elongate strips  110  and  114 . As a result, spacer  106  does not rely solely on the strength and stability of elongate strips  110  and  114  to maintain appropriate spacing between sheets  102  and  104  and to prevent buckling, bending, or breaking Furthermore, thermal transfer through elongate strips  110  and  114  is also reduced. In some embodiments, filler  112  is a matrix desiccant material that not only acts to provide structural support between elongate strips  110  and  114 , but also removes moisture from interior space  120 . 
     Examples of a filler material include adhesive, foam, putty, resin, silicon rubber, or other materials. Some filler materials are a desiccant or include a desiccant, such as a matrix material. Matrix material includes desiccant and other filler material. Examples of matrix desiccants include those manufactured by W.R. Grace &amp; Co. and H.B. Fuller Corporation. In some embodiments a beaded desiccant is combined with another filler material. 
     In some embodiments, filler  112  is made of a material providing thermal insulation. The thermal insulation reduces heat transfer through spacer  106  both between sheets  102  and  104 , and between the interior space  120  and an exterior side of spacer  106 . 
     In some embodiments, elongate strip  110  includes a plurality of apertures  116  (shown in  FIG. 2 ). Apertures  116  allow gas and moisture to pass through elongate strip  110 . As a result, moisture located within interior space  120  is allowed to pass through elongate strip  110  where it is removed by desiccant of filler  112 . In another embodiment, apertures  116  are used for registration. In yet another embodiment, apertures provide reduced thermal transfer. In one example, apertures  116  have a diameter in a range from about 0.002 inches to about 0.050 inches. Apertures  116  are made by any suitable method, such as cutting, punching, drilling, laser forming, or the like. 
     Spacer  106  can be connected to sheets  102  and  104 . In some embodiments, spacer  106  is connected to sheets  102  and  104  by a fastener. An example of a fastener is a sealant or adhesive, as described in more detail below. In other embodiments, a frame, sash, or the like is constructed around window assembly  100  to support spacer  106  between sheets  102  and  104 . In some embodiments, spacer  106  is connected to the frame or sash by a fastener, such as adhesive. Also in possible embodiments, spacer  106  is fastened to the frame or sash prior to installation of sheets  102  and  104 . 
     In some embodiments, ends of spacer  106  can be connected together with a fastener to form a closed loop. As such, spacer  106  and sheets  102  and  104  together define an interior space  120  of window assembly  100 . Interior space  120  reduces heat transfer through window assembly  100 . 
     When the window assembly  100  is fully assembled, a gas is sealed within interior space  120 . In some embodiments, the gas is air. Other embodiments include oxygen, carbon dioxide, nitrogen, or other gases. Yet other embodiments include an inert gas, such as helium, neon or a noble gas such as krypton, argon, and the like. Combinations of these or other gases are used in other embodiments. 
       FIG. 3  is a schematic cross-sectional view of a portion of window assembly  100 . In this embodiment, window assembly  100  includes sheet  102 , sheet  104 , spacer  106 , and also includes sealants  302  and  304 . 
     Sheet  102  includes outer surface  310 , inner surface  312 , and perimeter  314 . Sheet  104  includes outer surface  320 , inner surface  322 , and perimeter  324 . In one example, W is the thickness of sheets  102  and  104 . W is typically in a range from about 0.05 inches to about 1 inch, and preferably from about 0.1 inches to about 0.5 inches. Other embodiments include other dimensions. 
     Spacer  106  is arranged between inner surface  312  and inner surface  322 . Spacer  106  is typically arranged near perimeters  314  and  324 . In one example, D 1  is the distance between perimeters  314  and  324  and spacer  106 . D 1  is typically in a range from about 0 inches to about 2 inches, and preferably from about 0.1 inches to about 0.5 inches. However, in other embodiments spacer  106  is arranged in other locations between sheets  102  and  104 . 
     Spacer  106  maintains a space between sheets  102  and  104 . In one example, W 1  is the overall width of spacer  106  and the distance between sheets  102  and  104 . W 1  is typically in a range from about 0.1 inches to about 2 inches, and preferably from about 0.3 inches to about 1 inch. Other embodiments include other spaces. 
     Spacer  106  includes elongate strip  110 , elongate strip  114 , sidewall  124 , and sidewall  126 . Elongate strip  110  includes external surface  330 , internal surface  332 , edge  334 , edge  336 , and apertures  116 . Elongate strip  114  includes external surface  340 , internal surface  342 , edge  344 , and edge  346 . In some embodiments, external surface  330  of elongate strip  110  is visible by a person when looking through window assembly  100 . External surface  330  of elongate strip  110  provides a clean and finished appearance to spacer  106 . A benefit of some embodiments of spacer  106  is that roll forming is not required to bend elongate strips  110  and  114 . However, other embodiments use roll forming. 
     In one example, T 1  is the overall thickness of spacer  106  from external surface  330  to external surface  340 . T 1  is typically in a range from about 0.02 inches to about 1 inch, and preferably from about 0.1 inches to about 0.5 inches. T 2  is the distance between elongate strip  110  and elongate strip  114 , and more specifically the distance from internal surface  332  to interior surface  342 . T 2  is also the thickness of filler material  112 . T 2  is in a range from about 0.02 inches to about 0.5 inches, and preferably from about 0.05 inches to about 0.15 inches. In some embodiments elongate strips  110  and  114  and filler  112  are not linear, some examples have an undulating shape such as described below and shown in  FIG. 4 . As a result, spacer  106  does not always have a constant thickness in all embodiments. As a result, T 2  is an average thickness in some embodiments. Other embodiments include other dimensions. 
     In this embodiment, a first sealant  302  and  304  is used to connect spacer  106  to sheets  102  and  104 . In one embodiment, sealant  302  is applied to an edge of spacer  106 , such as on edges  334  and  344 , and the edge of filler  112  and then pressed against inner surface  312  of sheet  102 . Sealant  304  is also applied to an edge of spacer  106 , such as on edges  336  and  346 , and an edge of filler  112  and then pressed against inner surface  322  of sheet  104 . In other embodiments, beads of sealant  302  and  304  are applied to sheets  102  and  104 , and spacer  106  is then pressed into the beads. 
     In some embodiments, sealants  302  and  304  are formed of a material having adhesive properties, such that sealants  302  and  304  acts to fasten spacer  106  to sheets  102  and  104 . Typically, sealant  302  and  304  is arranged to support spacer  106  is an orientation normal to inner surfaces  312  and  322  of sheets  102  and  104 . First sealant  302  and  304  also acts to seal the joint formed between spacer  106  and sheets  102  and  104  to inhibit gas or liquid intrusion into interior space  120 . Examples of first sealant  302  and  304  include polyisobutylene (PIB), butyl, curable PIB, holt melt silicon, acrylic adhesive, acrylic sealant, and other Dual Seal Equivalent (DSE) type materials. 
     First sealant  302  and  304  is illustrated as extending out from the edges of spacer  106 , such that the first sealant  302  and  304  contacts surfaces  330  and  340  of elongate strips  110  and  114 . Such contact is not required in all embodiments. However, the additional contact area between first sealant  302  and  304  and spacer  106  can be beneficial. For example, the additional contact area increases adhesion strength. The increased thickness of sealants  302  and  304  also improves the moisture and gas barrier. In some embodiments, however, sealants  302  and  304  do not extend beyond external surfaces  330  and  340  of spacer  106 . 
     In some embodiments, portions of elongate strip  114  are connected to elongate strip  110  without filler  112  between. For example, a portion of elongate strip  114  may be connected to elongate strip  110  with a fastener, such as a adhesive, weld, rivet, or other fastener. 
       FIG. 4  is a schematic front view of a portion of an example embodiment of spacer  106 . Spacer  106  includes elongate strip  110 , sidewall  124 , and elongate strip  114 . In this embodiment, elongate strips  110  and  114  have an undulating shape. In some embodiments, elongate strips  110  and  114  are formed of a metal ribbon, such as stainless steel, which is then bent into the undulating shape. Some possible embodiments of the undulating shape include sinusoidal, arcuate, square, rectangular, triangular, and other desired shapes. Some embodiments are formed of other materials, and can be formed by other processes, such as molding. Note that while  FIG. 4  shows elongate strips  110  and  110  having similar undulations, it is contemplated that elongate strip  114  may have an undulating shape that is much larger than the undulating shape of elongate strip  110  and vice versa. Another possible embodiment includes a flat elongate strip combined with either type of undulating strip. Other combinations and arrangements are also possible. 
     One of the benefits of the undulating shape is that the flexibility of elongate strips  110  and  114  is increased, including bending and torsional flexibility. The undulating shape resists permanent deformation, such as kinks and fractures. This allows elongate strips  110  and  114  to be more easily handled during manufacturing without damaging elongate strips  110  and  114 . The undulating shape also increases the structural stability of elongate strips  110  and  114  to improve the ability of spacer  106  to withstand compressive and torsional loads. Some embodiments of elongate strips  110  and  114  are also able to extend and contract, which is beneficial, for example, when spacer  106  is formed around a corner. In some embodiments, the undulating shape reduces the need for notching or other stress relief. 
     In one example, elongate strips  110  and  114  have material thicknesses T 7 . T 7  is typically in a range from about 0.0001 inches to about 0.010 inches, and preferably from about 0.0003 inches to about 0.004 inches. Such thin material thickness reduces material costs and reduces thermal conductivity through elongate strips  110  and  114 . The undulating shape of elongate strips  110  and  114  defines a waveform having a peak-to-peak amplitude and a peak-to-peak period. The peak-to-peak amplitude is also the overall thickness T 9  of elongate strips  110  and  114 . T 9  is typically in a range from about 0.005 inches to about 0.1 inches, and preferably from about 0.02 inches to about 0.04 inches. P 1  is the peak-to-peak period of undulating elongate strips  110  and  114 . P 1  is typically in a range from about 0.005 inches to about 0.1 inches, and preferably from about 0.02 inches to about 0.04 inches. As described with reference to  FIG. 7 , larger waveforms are used in other embodiments. Yet other embodiments include other dimensions. 
       FIGS. 5-7  illustrate an example embodiment of spacer  106  in which continuous sidewalls  124  and  126  are arranged at edges of elongate strips  110  and  114 .  FIG. 5  is a schematic perspective view of the example spacer  106 .  FIG. 6  is a cross-sectional view of the example spacer  106  shown in  FIG. 5 .  FIG. 7  is a schematic side view of the example spacer  106  shown in  FIG. 5 . Spacer  106  includes elongate strips  110  and  114  separated by sidewalls  124  and  126 . In this example, sidewalls  124  and  126  are continuous along the length of spacer  106 . Sidewalls  124  and  126  provide a uniform or substantially uniform spacing between elongate strips  110  and  114 . 
     Some embodiments of spacer  106  are made according to the following process. Elongate strips  110  and  114  are typically formed first. The elongate strips  110  and  114  are made of a material, such as metal, that is formed into a thin and long ribbon (or multiple ribbons), such as by cutting the ribbon from a larger sheet. The thin and long ribbon is then shaped to include the undulating shape, if desired. The thin and long ribbon may also be punched or drilled to form apertures  116  in elongate strip  110 , if desired. This is accomplished, for example, by passing the thin and long ribbon between a pair of corrugated rollers. The teeth of the roller bend the ribbon into an undulating shape. Different undulating shapes are possible in different embodiments by using rollers having appropriately shaped teeth. Example teeth shapes include sinusoidal teeth, triangular teeth, semi-circular teeth, square (or rectangular) teeth, saw-tooth shaped teeth, or other desired shapes. Elongate strips having no undulating pattern are used in some embodiments, in which case the thin and long ribbons typically do not require further shaping. The elongate strips  110  and  114  may alternatively be formed by other processes, such as by molding or extruding. 
     In some embodiments, elongate strips  110  and  114  are cut to a desired length while they are still in the long and thin ribbon form and prior to forming the undulating shape. In other embodiments, elongate strips are cut after forming the undulating shape. Another possible embodiment forms long and substantially continuous spacers  106  that are cut to length after forming spacer  106  including elongate strips  110  and  114  as well as sidewalls  124  and  126 . In some embodiments spacer  106  is formed to have a length sufficient to extend along an entire perimeter of a window. In other embodiments, spacer  106  is formed to have a length sufficient for a single side or portion of a window. 
     After the elongate strips  110  and  114  are formed, sidewalls  124  and  126  are formed between elongate strips  110  and  114 . In one possible embodiment, elongate strips  110  and  114  are passed through a guide that orients elongate strips  110  and  114  in a parallel arrangement and spaces them a desired distance apart. An extrusion die is arranged near the guide and between elongate strips  110  and  114 . As the elongate strips  110  and  114  pass through the guide, a sidewall material is extruded into the space between elongate strips  110  and  114 , such as shown in  FIG. 5 . Extrusion typically involves heating the sidewall material and using a hydraulic press to push the sidewall material through the extrusion die. In this example, continuous sidewalls  124  and  126  are formed at each end of elongate strips  110  and  114 . The guide presses the extruded sidewalls  124  and  126  against interior surfaces of elongate strips  110  and  114 , such that the sidewalls  124  and  126  conform to the undulating shape and adhere to elongate strips  110  and  114 . 
     In another possible embodiment, sidewalls  124  and  126  are extruded into the space between elongate strips  110  and  114 , while the elongate strips are held stationary in a guide or template that acts to maintain the appropriate alignment and spacing of the elongate strips  110  and  114  while sidewalls  124  and  126  are inserted therein. For example, a robotic arm is used to guide an extrusion die along the space between elongate strips  110  and  114 . The robotic arm moves the extrusion die to position the extruded sidewalls  124  and  126  within the elongate strips  110  and  114  that remain stationary during the process. In some embodiments, extruded sidewalls  124  and  126  are formed in separate steps. In other embodiments, extruded sidewalls  124  and  126  are formed simultaneously, such as using two extrusion dies. 
     In another possible embodiment, sidewalls  124  and  126  are formed by passing the sidewall material through a series of rollers, to roll form the sidewalls into a desired shape. The roll formed sidewalls are then inserted between elongate strips  110  and  114 . In some embodiments the sidewall material is heated and pressed against elongate strips  110  and  114  to shape and bond the sidewalls  124  and  126  to the elongate strips  110  and  114 . In other embodiments, an adhesive is used to bond sidewalls  124  and  126  to elongate strips  110  and  114 . 
     In another possible embodiment, sidewalls  124  and  126  are formed by molding. After molding, the sidewalls  124  and  126  are inserted into the space between elongate strips. In some embodiments a fastener, such as an adhesive, is used to bond sidewalls  124  and  126  to elongate strips  110  and  114 . In another possible embodiment, portions of sidewalls  124  and  126  are melted and pressed against elongate strips  110  and  114  such that they grip the undulating shaped surface. 
     In some embodiments, sidewalls  124  and  126  are rigid. When rigid sidewalls are mated with elongate strips  110  and  114 , the resulting spacer also becomes rigid because the sidewalls  124  and  126  act to prevent flexing of elongate strips  110  and  114 . Other embodiments, however, include sidewalls  124  and  126  that are formed of a material having elastic or plastic flexibility, such that spacer  106  is flexible. 
     Although two sidewalls are illustrated in this example, other embodiments include one or more sidewalls (e.g., three, four, five, etc.). Further, sidewalls need not be located at sides of spacer  106 . For example, one or more additional sidewalls are included at or about the center of spacer  106  in some embodiments. 
     Additional features are formed in spacers  106  in some embodiments. An example of an additional feature is a muntin bar hole for mounting of a muntin bar. Muntin bar holes can be formed in spacer  106  or in elongate strip  116  either during the formation of elongate strip  116  or spacer  106 , or after the formation of spacer  106 . 
     In some embodiments spacer  106  is connected to one or more sheets  102  and/or  104 , such as shown in  FIG. 1 . Spacer  106  can be connected to sheet  102  during or after the spacer  106  manufacturing processes discussed above. One or more sealant and/or adhesive materials are used in some embodiments to fasten spacer  106  to one or more sheets  102  and/or  104 . 
       FIG. 6  is a cross sectional view of the example spacer  106  shown in  FIG. 5 . Spacer  106  includes elongate strip  110 , elongate strip  114  sidewall  124  and sidewall  126 . Elongate strip  110  includes external surface  340  and internal surface  342 . Elongate strip  114  includes external surface  330  and internal surface  332 . In the example embodiment shown in  FIG. 6 , sidewalls  124  and  126  are flush with or substantially flush with edges of elongate strips  110  and  114 . 
     Example dimensions are now described with reference to  FIG. 6  for an example embodiment as shown, but other embodiments include other dimensions. In one example, W 1  is the overall width of spacer  106 . W 1  is typically in a range from about 0.1 inches to about 2 inches, and preferably from about 0.3 inches to about 1 inch. T 1  is the overall thickness of spacer  106  from external surface  330  to external surface  340 . T 1  is typically in a range from about 0.02 inches to about 1 inch, and preferably from about 0.1 inches to about 0.5 inches. T 2  is the distance between elongate strip  110  and elongate strip  114 , and more specifically the distance from internal surface  332  to interior surface  342 . T 2  is also the height of sidewalls  124  and  126 , which maintain the space between elongate strips  110  and  114 . T 2  is in a range from about 0.02 inches to about 0.5 inches, and preferably from about 0.05 inches to about 0.15 inches. In some embodiments elongate strips  110  and  114  and filler  112  are non-linear, such as having an undulating shape described below. In some of these embodiments, T 2  is an average thickness. G is the thickness of sidewalls  110  and  114 . G is typically in a range from about 0.01 inches to about 0.5 inches, and preferably from about 0.1 inches to about 0.3 inches. Other embodiments include other dimensions than those discussed in this example. 
       FIG. 7  is a schematic side view of the example spacer  106  shown in  FIG. 5 . The spacer  106  includes elongate strips  110  and  114  and sidewall  124 . This side view illustrates the undulating shape of example elongate strips  110  and  114 . Further details regarding the undulating shape are described herein with reference to  FIG. 4 . In this example, edges of sidewall  124  have an undulating shape that mates with the undulating shape of elongate strips  110  and  114 . 
       FIGS. 8-10  illustrate an example embodiment of spacer  106  in which continuous sidewalls  124  and  126  are arranged at intermediate positions between edges of elongate strips  110  and  114 .  FIG. 8  is a schematic perspective view of the example spacer of the example spacer  106 .  FIG. 9  is a cross-sectional view of the example spacer  106  shown in  FIG. 8 .  FIG. 10  is as schematic side view of the example spacer  106  shown in  FIG. 8 . Spacer  106  includes elongate strips  110  and  114  separated by sidewalls  124  and  126 . In this example, sidewalls  124  and  126  are continuous along the length of space or  106 . The sidewalls  124  and  126  provide a uniform or substantially uniform spacing between elongate strips  110  and  114 . 
     In the example embodiment of spacer  106 , shown in  FIGS. 8-10 , sidewalls  124  and  126  are offset from the edges of the wanted strips  110  and  114 . The offset is illustrated in  FIG. 9  by offset distance S. In one example, offset distance S is typically in a range from about 0.01 inches to about 0.5 inches, and preferably from about 0.1 inches to about 0.3 inches. Other example dimensions shown in  FIG. 9  are described in more detail herein, such as with reference to  FIGS. 3 and 6 . 
     In some embodiments, the offset of sidewalls  124  and  126  provides additional structural stability to toward the center of elongate strips  110  and  114 , such as to increase the resistance of space or  106  two pending or buckling under a load. In some embodiments, the offset also provides a space for adhesive, sealants, or other materials. For example, a space is defined between edges of elongate strips  110  and  114  and adjacent to offset sidewall  124 . A bead of sealant is applied to this space in some embodiments. The sheet of transparent material is then applied to the bead to connect and seal edges of spacer  106  to the sheet of transparent material. Sealant is also applied to a space formed adjacent to offset sidewall  126  in some embodiments, which is then used to connect and seal the edge of spacer  106  to another sheet of transparent material. 
       FIGS. 11-15  illustrate another example embodiment of spacer  106  including divided sidewalls.  FIG. 11  is a schematic perspective view of the example spacer  106  arranged in an assembled configuration.  FIG. 12  is a schematic perspective view of the example spacer  106  shown in  FIG. 11  arranged in an unassembled configuration.  FIG. 13  is another schematic perspective view of the example spacer  106  shown in  FIG. 11  arranged in an unassembled configuration.  FIG. 14  is a cross-sectional view of the example spacer  106  shown in  FIG. 11  arranged in an assembled configuration.  FIG. 15  is a side view of the example spacer  106  shown in  FIG. 11  arranged in an assembled configuration. 
     Spacer  106  includes elongate strips  110  and  114  and sidewalls  124  and  126 . In some embodiments elongate strip  110  includes apertures to allow moisture to pass through elongate strip  110 . Filler  112 , such as including a desiccant, is included within spacer  106  in some embodiments, but is not shown here. Some embodiments do not include filler  112 . 
     In this example, sidewalls  124  and  126  are located at an intermediate position between the edges of elongate strips  110  and  114 , but in other embodiments sidewalls  124  and  126  are flush with edges of elongate strips  110  and  114 . 
     Spacer  106  includes sidewalls  124  and  126 . The example spacer  106  shown in  FIGS. 11-13  includes non-continuous sidewalls  124  and  126 , including a plurality of spaced sidewall portions. Other embodiments, however, include continuous sidewalls without spaces. In some embodiments, the space between sidewall portions allows spacer  106  to utilize the flexibility of elongate strips  110  and  114  and provides room for the spacer  106  to bend. As a result, spacer  106  can be bent to form a corner (such as a 90 degree corner). 
     Sidewall  124  includes a first portion  801 , second portion  803 , and an example fastening mechanism. A particular example of a fastening mechanism includes a spline and a notched portion. However, it is recognized that a variety of other fastening mechanisms are used in other embodiments. Some alternate examples of fastening mechanisms are described herein. First portion  801  includes a spline  802  as part of the fastening mechanism, alternatively referred to as a protrusion, and is connected to elongate strip  114 . Second portion  803  includes a notched portion  804  as another portion of the fastening mechanism, and is connected to elongate strip  110 . First and second portions  801  and  803  are engageable with each other using the fastening mechanism to form sidewall  124 . In some embodiments, first and second portions  801  and  803  are also separable from each other to separate elongate strip  110  from elongate strip  114 . 
     Sidewall  126  includes a first portion  805  and a second portion  807 . First portion  805  includes a spline  806 , alternatively referred to as a protrusion, and is connected to elongate strip  114 . Second portion  807  includes a notched portion  808 , and is connected to elongate strip  110 . First and second portions  805  and  807  are engageable with each other to form sidewall  126 . In some embodiments, first and second portions  805  and  807  are also separable from each other to separate elongate strip  110  from elongate strip  114 . 
     During fabrication, first portions  801  and  805  are secured to elongate strip  114  and second portions  803  and  807  are secured to elongate strip  110 . In some embodiments, first and second portions  801 ,  805 ,  803 , and  807  are formed using an extrusion process, which forms the first and second portions  801 ,  805 ,  803 , and  807  onto the respective elongate strips  114  and  110 . The first portions  801  and  805  are extruded individually in some embodiments, but are extruded simultaneously in other embodiments. Similarly, the second portions  803  and  807  are extruded individually in some embodiments, but are extruded simultaneously in other embodiments. 
     Rather than extruding directly onto elongate strips  110  and  114 , some embodiments pre-form first and second portions  801 ,  805 ,  803 , and  807  and are later adhered or fastened to elongate strips  114  and  110 . Alternatively, a portion of the pre-made first and second portions is melted in some embodiments and then pressed onto the respective elongate strip  114  or  110 . 
     Once splines  804  are attached to elongate strip  110  and the notch  802  portion of plurality of sidewalls  124  and  126 , elongate strips  110  and  114  can be secured together. In one embodiment, a fabricator may press elongate strips  110  and  114  together. In other embodiments, a machine may be used to press elongate strips  110  and  114  together. 
     In some embodiments, when spline  804  is disconnected from sidewalls  124  and  126 , spacer  106  is flexible. Then, once spline  804  is connected to sidewalls  124  and  126 , spacer  106  locks in place and becomes substantially rigid. In this way the spacer  106  is easily manipulated into a desired configuration and once there, is connected to lock the spacer  106  in the desired configuration. 
     Example dimensions of spacer  106  are shown in  FIG. 14 . In one example, W 1  is the overall width of spacer  106  and the distance between sheets  102  and  104 . W 1  is typically in a range from about 0.1 inches to about 2 inches, and preferably from about 0.3 inches to about 1 inch. In one example, T 1  is the overall thickness of spacer  106  from external surface  330  to external surface  340 . T 1  is typically in a range from about 0.02 inches to about 1 inch, and preferably from about 0.1 inches to about 0.5 inches. T 2  is the distance between elongate strip  110  and elongate strip  114 , and more specifically the distance from internal surface  332  to interior surface  342 . In other words, T 2  is the height of sidewalls  124  and  126 . T 2  is in a range from about 0.02 inches to about 0.5 inches, and preferably from about 0.05 inches to about 0.15 inches. In some embodiments elongate strips  110  and  114  are not linear, such as having an undulating shape described below. Therefore, in some of these embodiments, T 2  is an average thickness. G is the thickness of sidewalls  124  and  126 . G is typically in a range from about 0.01 inches to about 0.5 inches, and preferably from about 0.1 inches to about 0.3 inches. Other embodiments include other dimensions. 
     In  FIG. 14 , sidewalls  124  and  126  are offset from the edges of elongate strips  110  and  114 . The offset distance S, is typically in a range from about 0.01 inches to about 0.5 inches, and preferably from about 0.1 inches to about 0.3 inches. Other embodiments, however, include sidewalls  124  and  126  that are flush with or substantially flush with edges of elongate strips  110  and  114 . 
     Some embodiments of spacer  106  include sidewalls  124  and  126  that are divided into first and second portions. As shown in  FIG. 14 , first portions  801  and  805  have a height M and second portions  803  and  807  have a height N. Height N does not include the height of spline  804 , such as shown in  FIG. 13 . The sum of M and N is equal to height T 1 . 
       FIG. 15  shows a side view of the spacer  106  shown in  FIG. 11  including a non-continuous sidewall  124 , including a plurality of spaced sidewall portions  1502  and  1504 . Additional sidewall portions are not visible in  FIG. 15 . Y is the spacing between adjacent sidewall portions—such as sidewall portion  1502  and sidewall portion  1504 . The space Y is typically in a range from about 0.001 inches to about 0.5 inches and preferably from about 0.01 inches to about 0.05 inches. J is the width of sidewall portions  1502  and  1504 . The width J is typically in a range from about 0.01 inch to about 1 inch, and preferably from about 0.05 inches to about 0.3 inches. 
       FIG. 16  is a schematic cross-sectional view of another possible embodiment of window assembly  100 . Window assembly  100  includes sheet  102 , sheet  104 , and an example spacer  106 . Spacer  106  includes elongate strip  110 , elongate strip  114 , sidewalls  124  and  126 , first sealant  302  and  304 , and second sealant  402  and  404 . In this embodiment, spacer  106  further includes fastener aperture  1002 , fastener  1004 , and intermediate member  1006 . In some embodiments spacer  106  includes filler  112 . 
     Some embodiments include an intermediary member  106  that is connected to spacer  106 . In one embodiment, intermediary member  1006  is a sheet of glass or plastic, that are included to form a triple-paned window. In another embodiment, intermediary member is a film or plate. For example, intermediary member  1006  is a film or plate of material that absorbs at least some of the sun&#39;s ultraviolet radiation as it passes through the window  100 , thereby warming interior space  120 . In another embodiment, intermediary member  1006  reflects ultraviolet radiation, thereby cooling interior space  120  and preventing some or all of the ultraviolet radiation from passing through the window. In some embodiments, intermediary member  1006  divides interior space into two or more regions. Intermediary member  1006  is a Mylar film in some embodiments. In another embodiment, intermediary member  1006  is a muntin bar. Intermediary member  1006  acts, in some embodiments, to provide additional support to spacer  106 . A benefit of some embodiments is that the addition of intermediary member  1006  does not require additional spacers  106  or sealants. 
     Connection of intermediary member  1006  to spacer  106  can be accomplished in various ways. One way is to punch or cut apertures  1002  in elongate strip  110  of spacer  106  at the desired location(s). In some embodiments, apertures  1002  are arranged as slots and the like. A fastener  1002  is then inserted into the aperture and connected to elongate strip  110 . One example of a fastener is a screw. Another example is a pin. Apertures  1002  are not required in all embodiments. In some embodiments, fastener  1004  is an adhesive that does not require apertures  1002 . Other embodiments include a fastener  1004  and an adhesive. Some fasteners  1004  are also arranged to connect with an intermediary member  1006 , to connect the intermediary member  1006  to spacer  106 . An example of fastener  1004  is a muntin bar clip. 
       FIGS. 17-20  illustrate another example embodiment of spacer  106 .  FIG. 17  is a perspective view of the example spacer  106  arranged in an unassembled configuration.  FIG. 18  is another perspective view of the example spacer  106  shown in  FIG. 17  arranged in an unassembled configuration.  FIG. 19  is a cross-sectional view of the example spacer  106  shown in  FIG. 17  arranged in an unassembled configuration.  FIG. 20  is a side view of the example spacer  106  shown in  FIG. 17  arranged in an unassembled configuration. 
     Spacer  106  includes elongate strips  110  and  114  and sidewalls  124  and  126 . In some embodiments, elongate strip  110  includes apertures  116 , such as to allow moisture to pass through elongate strip  110 . In this embodiment, spacer  106  includes non-continuous sidewalls sidewalls  124  and  126 , including a plurality of sidewall portions. Sidewalls  124  and  126  provide a uniform or substantially uniform spacing between elongate strips  110  and  114 . 
     In this example, each portion of sidewalls  124  and  126  includes a fastening mechanism including a pair of hooks  1702  and  1704 . Hooks  1702  and  1704  are configured such that hook  1702  is engagable with hook  1704 . When disengaged, first portions  801  and  805  are separable from second portions  803  and  807 . Hooks  1702  and  1704  are configured to be engageable by arranging first and second portions  801  and  803  and first and second portions  805  and  807  as shown in  FIG. 17 , and then pressing them together (such as by applying a force to elongate strips  110  and  114 ) to cause hooks  1702  and  1704  to latch together. In some embodiments the latching of hooks  1702  and  1704  is performed using a zipper mechanism. Similarly, a zipper mechanism can also be used to disengage hooks  1702  and  1704  in some embodiments. 
       FIG. 19  is a cross-sectional view of the spacer  106  shown in  FIG. 17 . In  FIG. 19  sidewalls  124  and  126  are offset from the edges of elongate sheets  110  and  114 , having an offset distance S. In other embodiments, sidewalls  124  and  126  are flush with the edges of elongate strips  110  and  114 . Q is the height of first portions  801  and  805 . P is the height of second portions  803  and  807 . 
       FIG. 20  is a side view of example spacer  106  shown in  FIG. 17 . Spacer  106  includes sidewall portion  2002  and sidewall portion  2004 . Additional side wall portions are not visible in  FIG. 20 . Y is the distance of a space between adjacent sidewall portions  2002  and  2004 . J is the width of sidewall portions  2002  and  2004 . Examples of Y and J are discussed herein. Note that while  FIGS. 17-20  show sidewalls  124  and  126  as being segmented into a plurality of sidewall portions, some embodiments include continuous sidewalls. In other words, in some embodiments, Y is equal to zero. 
     Elongate strips  110  and  114  can be fabricated from various materials including, but not limited to, metals, plastics, and ceramics. In addition, elongate strips  110  and  114  can be fabricated via various methods including, but not limited to, roll forming, extrusion, molding, stamping, or a combination of these. 
       FIGS. 21-22  illustrate another example embodiment of spacer  106 .  FIG. 21  is a schematic perspective view of the example spacer  106 .  FIG. 22  is a schematic cross-sectional view of the example spacer shown in  FIG. 21 . As discussed above, spacer  106  includes elongate strips  110 , elongate strip  114 , sidewall  124 , and sidewall  126 . Sidewalls  124  and  126  include first portions  801  and  803  and second portions  805  and  807 . 
     In this embodiment, elongate strip  110 , first potion  803 , and second portion  805  form a continuous piece. Elongate strip  114 , first portion  801 , and second portion  807  also form a continuous piece. In other embodiments, elongate strips  110  and  114  are formed separately from sidewalls  124  and  126 . For example, elongate strips  110  and  114  are first formed, such as by bending long and thin ribbons of material into an undulating shape. Sidewalls  110  and  114  are then formed by extruding the sidewalls onto the elongate strips  110  and  114 . Alternatively, a fastener is used, such as adhesive, to connect sidewalls  124  and  126  to elongate strips  110  and  114 . 
     First portions  801  and  803  of sidewalls  124  and  126  include a recessed region  2102  at an end. Second portions  805  and  807  include a protrusion  2104 . Protrusions  2104  are configured to mate with recessed regions  2102  to connect first portions  801  and  803  with second portions  805  and  807 . 
     As described above, sidewalls  124  and  126  are located along the edges of elongate strips  110  and  114  in some embodiments, and are offset by a distance S from the edges of elongate strips in other embodiments. In addition, spacer  106  shown in  FIGS. 21 and 22  may have dimensions W 1 , T, T 2 , and G similar to those describe above with regard to  FIG. 14 . Other embodiments include other dimensions. 
     In some embodiments, as shown in  FIGS. 21 and 22 , first portions  2102  of elongate strips  110  and  114  include recessed regions  2102  in the form of grooves. Second portions  2104  of elongate strips  110  and  114  include protrusions  2104  in the form of tongues  2106 . Recessed regions  2102  are formed such that they snap together with protrusions  2104  to form an assembled spacer  106 . In some embodiments recessed regions  2102  have a slightly smaller width than protrusions  2104  such that when protrusions  2104  are pressed into recesses  2102 , friction holds the pieces together. In other embodiments, protrusions  2206  and  2208  have prongs  2210  (shown in  FIG. 22 ) that engage receiver  2212  to hold elongate strips  110  and  114  together. 
     In some embodiments a zipper mechanism is used to connect first portion  2102  with second portion  2104 . In some embodiments the zipper is also used to disconnect first portion  2102  from second portion  2104 . 
     Elongate strips  110  and  114  are fabricated from possible materials including, but not limited to, metals, plastics, and ceramics. In addition, elongate strips  110  and  114  are fabricated via various possible methods including, but not limited to, casting, and extrusion. 
       FIG. 23  illustrates another example embodiment of spacer  106 .  FIG. 23  is a cross-sectional view of spacer  106  including elongate strip  110 , elongate strip  114 , sidewall  124 , and sidewall  126 . Sidewalls  124  and  126  include first portions  2302  and second portions  2304 . sidewalls  124  and  126 . 
     First portions  2302  of sidewalls  124  and  126  include recessed portions  2306 . Second portions  2304  of sidewalls  124  and  126  include protrusions  2308 . In this example, recessed portions  2306  are in the form of grooves. Protrusions  2308  are in the form of tongues. Protrusions  2308  are configured to mate with recessed portions  2306 . Some embodiments are configured to snap together. Once connected, spacer  106  remains connected due to friction or an additional fastener, such as adhesive or sealant. 
     In this embodiment, elongate strip  110  and second portions  2304  are formed of a continuous piece of material. Similarly, elongate strip  114  and first portions  2302  are formed of a continuous piece of material. In some embodiments spacer  106  is formed of long and thin ribbons of material that are bent, such as by roll forming, into the configuration shown. Other embodiments are made by processes such as extrusion or casting. 
       FIG. 24  illustrates another embodiment of an example spacer  106 .  FIG. 24  is a cross-sectional view of spacer  106  including elongate strip  110 , elongate strip  114 , sidewall  124 , and sidewall  126 . Sidewalls  124  and  126  include first portions  2402  and second portions  2404 . 
     First portions  2402  of sidewalls  124  and  126  include recessed portions  2406 . Second portions  2404  of sidewalls  124  and  126  include protrusions  2408 . In this example, recessed portions  2406  are in the form of grooves that extend longitudinally along an end of first portions  2402 . Protrusions  2408  are in the form of tongues that extend longitudinally along second portions  2404 . Protrusions  2408  are configured to mate with recessed portions  2406 . Some embodiments are configured to snap together. Once connected, spacer  106  remains connected due to friction. In another embodiment an additional fastener, such as adhesive or sealant, is used to connect first and second portions of spacer  106 . 
     In this embodiment, elongate strip  110  and first portions  2402  are formed of a continuous piece of material. Similarly, elongate strip  114  and second portions  2302  are formed of a continuous piece of material. In some embodiments spacer  106  is formed of long and thin ribbons of material that are bent, such as by roll forming, into the configuration shown. Other embodiments are made by processes such as extrusion or casting. 
       FIG. 25  is a cross-sectional view of another example spacer  106  including elongate strip  110 , elongate strip  114 , sidewall  124 , and sidewall  126 . In this embodiment, sidewalls  124  and  126  include first portions  2502  and second portions  2504 . First portion  2502  includes recessed region  2506 . Second portion  2504  includes recessed region  2508 . In some embodiments recessed region  2508  is in the form of a groove. In some embodiments protrusion  2506  is in the form of a tongue. Other embodiments include a plurality of grooves and a plurality of tongues. Other possible embodiments include a plurality of teeth and a plurality of spaced recesses configured to receive the teeth therein. 
     Elongate strips  110  and  114  may be made from materials including, but not limited to, metals and plastics. In addition, elongate strips  110  and  114  may be manufactured via methods including, but not limited to, rolling, bending, and extrusion. First portions  2502  including protrusions  2506  are formed directly into elongate strip  114  in some embodiments. Second portions  2504  are made by, for example, extruding a material onto elongate strip  110 . Recessed region  2508  is formed in some embodiments through the extrusion process. In other embodiments, recessed region  2508  is formed by cutting, drilling, routing, or grinding a groove into a face at an end of second portion  2504 . Second portion  2504  is made of a material such as metal, plastic, ceramics, or combinations of these materials. In some embodiments first portion  2504  is bonded to elongate sheet  110  by one or more fastening methods, such as thermal bonding, ultrasonic welding, adhesive, or use of another fastener. 
       FIG. 26  is a cross-sectional view of another example spacer  106  including elongate strip  110 , elongate strip  114 , sidewall  124 , and sidewall  126 . In this embodiment, elongate strip  114  includes recessed regions  2602  in the form of parallel grooves. Sidewalls  124  and  126  include protrusions  2604  extending out from the ends of the sidewalls  124  and  126 . In this embodiment protrusions  2604  are in the form of tongues. The protrusions  2604  are configured to engage with recessed regions  2602 .  FIG. 27  is a front view of an example spacer  106  and an example corner key  2702 . Some embodiments of spacer  106  are not flexible. In such embodiments, the spacer  106  may be connected to a corner fastener, such as a corner key  2702 . 
     Spacer  106  includes elongate strip  110 , sidewall  502 , and elongate strip  114 . In this embodiment, elongate strips  110  and  114  have an undulating shape. As shown, a corner key  2702  is used to form the corner. Some embodiments of spacer  106  can be arranged to form a corner without corner key  2702 . In these embodiments, sidewall  502  is made from a material that is able to bend and flex without kinking or breaking. 
     Elongate strips  110  and  114  include an undulating shape. As a result, elongate strips  110  and  114  are arranged to expand and compress as necessary. In embodiments employing continuous sidewalls  124  and  126 , to achieve the bending flexibility needed to form curves, continuous sidewalls  124  and  126  may be constructed of a flexible material that allows spacer  106  to be bent. In other embodiments employing continuous sidewalls  124  and  126 , the material used to fabricate continuous sidewalls  124  and  126  may be heated to soften the material thereby making in pliable. In still other embodiments employing continuous sidewalls  124  and  126 , the curves may be formed while the material is in a pliable form. The material may then be allowed to set and/or cure such that a ridge or semi flexible corner is formed. In still yet other embodiments employing continuous sidewalls  124  and  126 , the curves may be formed by cutting continuous strips of spacer  106  to form the corners. For instance, a continuous strip of spacer  106  may be cut along 45° angles to form a mitered corners. 
     In embodiments employing plurality of sidewalls  124  and  126 , to achieve the bending flexibility needed to form corners, portions of plurality of sidewalls  124  and  126  may be removed to form a corner. For instance, in  FIG. 11 , portions of sidewall  124  ( 124   a ,  124   b , and  124   b ) and sidewall  126  (removed portions not shown) may be removed from elongate strip  114 . With portions  124   a ,  124   b , and  124   c  removed elongate strip  114  can be bent to form a corner. Once elongate strip  114  is bent elongate strip  110  may be secured via spline  804 . In an embodiment, spline  804  may have protuberances that contact notch  802  such that spline  804  does not move within notch  802  thereby forming a ridged corner. In other embodiments, spline  804  may be allowed to move within notch  802  such that spacer  106  may be bent to form a corner or other non-liner shape. 
     Although the present disclosure refers to window assemblies and window spacers, some embodiments are used for other purposes. For example, another possible embodiment according to the present disclosure is a spacer for a sealed unit. 
     The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims attached hereto. Those skilled in the art will readily recognize various modifications and changes that may be made without following the example embodiments and applications illustrated and described herein, and without departing from the intended scope of the following claims.