Patent Publication Number: US-11028638-B2

Title: Spacer frame and method of making same

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
     The present application is a continuation application claiming priority under 35 U.S.C. § 120 to co-pending U.S. nonprovisonal application Ser. No. 15/806,962 that was filed on Nov. 8, 2017 and published on Mar. 8, 2018 under publication number 2018-0066472 entitled SPACER FRAME AND METHOD OF MAKING SAME, which was a non-provisional application filed under 35 U.S.C. § 111 claiming priority under 35 U.S.C. § 120 to co-pending U.S. nonprovisonal application Ser. No. 15/224,783 that was filed on Aug. 1, 2016 and published on Nov. 24, 2016 under publication number US-2016-0340962 entitled SPACER FRAME AND METHOD OF MAKING SAME, that issued as U.S. Pat. No. 10,316,578 on Jun. 11, 2019, which was a non-provisional application filed under 35 U.S.C. § 111 claiming priority under 35 U.S.C. § 121 to co-pending U.S. nonprovisonal application Ser. No. 14/703,027 that was filed on May 4, 2015 and published on Dec. 17, 2015 under publication number US-2015-0361713 entitled SPACER FRAME AND METHOD OF MAKING SAME, which issued as U.S. Pat. No. 9,428,953 on Aug. 30, 2016, which was a non-provisional application filed under 35 U.S.C. § 111 claiming priority under 35 U.S.C. § 119(e) to U.S. provisional application Ser. No. 62/011,253 filed on Jun. 12, 2014 entitled SPACER FRAME AND METHOD OF MAKING SAME. Priority is claimed to all of the above-identified applications and publications, which all are also incorporated herein by reference in their entireties for all purposes. 
    
    
     FIELD OF DISCLOSURE 
     The present disclosure relates to a spacer frame and method of making same, and more specifically, a spacer frame and fabrication process for use with an insulating glass unit (“IGU”). 
     BACKGROUND 
     Insulating glass units (“IGUs”) are used in windows to reduce heat loss from building interiors during cold weather. IGUs are typically formed by a spacer assembly sandwiched between glass lites. A spacer assembly usually comprises a frame structure extending peripherally about the unit, a sealant material adhered both to the glass lites and the frame structure, and a desiccant for absorbing atmospheric moisture within the unit. The margins of the glass lites are flush with or extend slightly outwardly from the spacer assembly. The sealant extends continuously about the frame structure periphery and its opposite sides so that the space within the IGUs is hermetic. 
     There have been numerous proposals for constructing IGUs. One type of IGU was constructed from an elongated corrugated sheet metal strip-like frame embedded in a body of hot melt or sealant material. Desiccant was also embedded in the sealant. The resulting composite spacer was packaged for transport and storage by coiling it into drum-like containers. When fabricating an IGU, the composite spacer was partially uncoiled and cut to length. The spacer was then bent into a rectangular shape and sandwiched between conforming glass lites. 
     Perhaps the most successful IGU construction has employed tubular, roll formed aluminum or steel frame elements connected at their ends to form a square or rectangular spacer frame. The frame sides and corners were covered with sealant (e.g., butyl material, hot melt, reactive hot melt, or modified polyurethane) for securing the frame to the glass lites. The sealant provided a barrier between atmospheric air and the IGU interior which blocked entry of atmospheric water vapor. Particulate desiccant deposited inside the tubular frame elements communicated with air trapped in the IGU interior to remove the entrapped airborne water vapor and thus preclude its condensation within the unit. Thus, after the water vapor entrapped in the IGU was removed internal condensation only occurred when the unit failed. 
     In some cases the sheet metal was roll formed into a continuous tube, with desiccant inserted, and fed to cutting stations where “V” shaped notches were cut in the tube at corner locations. The tube was then cut to length and bent into an appropriate frame shape. The continuous spacer frame, with an appropriate sealant in place, was then assembled in an IGU. 
     Alternatively, individual roll formed spacer frame tubes were cut to length and “corner keys” were inserted between adjacent frame element ends to form the corners. In some constructions the corner keys were foldable so that the sealant could be extruded onto the frame sides as the frame moved linearly past a sealant extrusion station. The frame was then folded to a rectangular configuration with the sealant in place on the opposite sides. The spacer assembly thus formed was placed between glass lites and the IGU assembly completed. 
     IGUs have failed because atmospheric water vapor infiltrated the sealant barrier. Infiltration tended to occur at the frame corners because the opposite frame sides were at least partly discontinuous there. For example, frames where the corners were formed by cutting “V” shaped notches at corner locations in a single long tube. The notches enabled bending the tube to form mitered corner joints; but afterwards potential infiltration paths extended along the corner parting lines substantially across the opposite frame faces at each corner. 
     Likewise in IGUs employing corner keys, potential infiltration paths were formed by the junctures of the keys and frame elements. Furthermore, when such frames were folded into their final forms with sealant applied, the amount of sealant at the frame corners tended to be less than the amount deposited along the frame sides. Reduced sealant at the frame corners tended to cause vapor leakage paths. 
     In all these proposals the frame elements had to be cut to length in one way or another and, in the case of frames connected together by corner keys, the keys were installed before applying the sealant. These were all manual operations which limited production rates. Accordingly, fabricating IGUs from these frames entailed generating appreciable amounts of scrap and performing inefficient manual operations. 
     In spacer frame constructions where the roll forming occurred immediately before the spacer assembly was completed, sawing, desiccant filling and frame element end plugging operations had to be performed by hand which greatly slowed production of units. 
     U.S. Pat. No. 5,361,476 to Leopold discloses a method and apparatus for making IGUs wherein a thin flat strip of sheet material is continuously formed into a channel shaped spacer frame having corner structures and end structures, the spacer thus formed is cut off, sealant and desiccant are applied and the assemblage is bent to form a spacer assembly. U.S. Pat. No. 5,361,476 is incorporated herein by reference in its entirety. 
     U.S. Pat. No. 7,448,246 to Briese et al. further describes the process of corner fabrication of a spacer frame. U.S. Pat. No. 8,720,026 to McGlinchy discusses additional methods of producing spacer frames. Both U.S. Pat. Nos. 7,448,246 and 8,720,026 are incorporated herein by reference in their entireties. 
     Illustrated in  FIGS. 1A-1E  is a conventional spacer frame  1  fabricated for IGUs. The conventional spacer frame  1  is typically fabricated from an elongated metal strip and roll-formed into the orientation shown. The conventional spacer frame  1  includes five different legs,  2   a ,  2   b ,  2   c ,  2   d , and  2   e . Leg  2   a  is a tab that when the spacer frame is assembled is inserted into leg  2   e  to form a corner juncture or connection at CJ. Legs  2   b - 2   e  make up the four sides of the spacer frame. When the spacer frame is bent from a linear strip into the four-sided frame (as illustrated by the transition from  FIGS. 1A-1B ) the leg  2   e  includes a chamfered end  3 , typically as an angle α of 45 degrees from a longitudinal axis “LA” that extends along the center of leg  2   e . This allows the tab leg  2   a  to be completely inserted into leg  2   e  until end sides  3   a  and  3   c  of the leg  2   e  bottom out on corresponding ends  3   b  and  3   d  to form corner juncture CJ. 
     In the assembled position, the conventional spacer frame  1  includes four gaps g 1 , g 2 , g 3 , and g 4 . The gap g 1  is formed by the legs  2   a  and  2   b  and the passage the sliding of leg  2   e  over the leg  2   a  at end  3  of the corner juncture CJ.  FIG. 1 e    illustrates that the conventional spacer frame typically requires the passage of hot melt or sealant  4  along directions A and B along the end of the frame such that the corner juncture CJ is sealed along two directions. 
     Conventional spacer frames  1  if found defective, that is, allowing the passage of gas through an undesirable leak, such defect typically occurs where the one end  3   a  engages corner gap g 1  at the corner juncture. Failure at the corner juncture CJ can occur for a number of reasons. One likely reason is that leg  2   e  is oversized for assembly and the gap “d” can average fifty-thousands of one inch (0.050″), as illustrated in  FIG. 1D . As well, the width of leg  2   e  must be greater in size for assembly than the width of tab or leg  2   a  to allow leg  2   e  to easily slide over tab or leg  2   a . Thus, a gap is also possible along width “w”, as also illustrated in  FIG. 1D . 
     SUMMARY 
     One aspect of the disclosure comprises a spacer frame assembly and method of assembly that includes a substantially linear channel having first and second ends. The substantially linear channel that when assembled includes at least four sides and corresponding corners between each of the sides. The spacer frame assembly also has a connecting structure located at one of the first and second ends and an opposite frame end located at the other of the one of first and second ends. The opposite frame end has an inner channel for receiving a nose portion of the connecting structure. The spacer frame assembly also includes a stop extending from the connecting structure for locating the opposite frame end when in the assembled position. 
     Another aspect of the present disclosure includes a method of making a spacer frame assembly for bending into a multi-sided window or door spacer frame comprising the steps of: providing a supply of narrow metal strip coiled on a support; unwinding the metal strip from the support to provide an elongated metal strip and moving the elongated metal strip along a path of travel to a stamping station; stamping the strip at spaced apart corner locations by removing portions of the strip at the corner locations wherein inter-fitting leading and trailing ends of the spacer frame assembly are defined by a lead portion of the strip extending in front of a first corner location and a trailing portion of the strip extending behind a second corner location; additionally stamping at least one of the lead and trailing portions of the strip to form an abutment stop comprising a wide portion of the strip and a nose which extends into the wide portion of the strip for defining an amount of overlap of the leading and trailing ends an assembled spacer frame; roll forming the strip to form a channel shaped structure having side walls that include the abutment stop and a base wall extending between the side walls; and severing the frame assembly from the elongated metal strip. 
     While another aspect of the present disclosure includes a spacer frame assembly for bending into a multi-sided window or door spacer frame comprising an elongated metal strip bent to form a channel shaped frame element having a base wall that extends between two generally parallel side walls wherein the side walls include spaced apart corner locations defined by notches that extend from an edge of the metal strip into the side walls and wherein telescoping leading and trailing ends of the frame element are defined by a lead portion of the frame element in front and spaced from a first corner location and a trailing portion of the frame element behind and spaced from a second corner location wherein at least one of the lead and trailing portions of the frame element include an abutment stop defined by a notch which extends into a side wall of the frame element, the abutment stop for limiting movement of the leading and trailing ends as the leading and trailing ends are telescoped one within the other and thereby define a lateral connection spaced from the corners and an amount of overlap of the leading and trailing ends of the assembled spacer frame. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The foregoing and other features and advantages of the present disclosure will become apparent to one skilled in the art to which the present disclosure relates upon consideration of the following description of the disclosure with reference to the accompanying drawings, wherein like reference numerals, unless otherwise described refer to like parts throughout the drawings and in which: 
         FIG. 1A  is an elevation construction view of a conventional spacer frame; 
         FIG. 1B  is an elevation assembled view of the conventional spacer frame of  FIG. 1A ; 
         FIG. 1C  is a perspective assembled view of the conventional spacer frame of  FIG. 1A ; 
         FIG. 1D  is a magnified view of the assembled view of a portion of the conventional spacer frame of  FIG. 1C ; 
         FIG. 1E  is a perspective assembled view of the conventional spacer frame of  FIG. 1A , illustrating the required application of sealant; 
         FIG. 2  is a perspective view of an insulating glass unit including glass lites; 
         FIG. 2A  is a schematic block diagram of a production line for manufacturing a spacer frame in accordance with one example embodiment of the present disclosure; 
         FIG. 3  is a cross sectional view seen approximately from the plane indicated by the line  3 - 3  of  FIG. 2 ; 
         FIG. 4A  is a plan view of flat stock after a punching operation that will be formed into one or more spacer frame assemblies before the flat stock is roll formed or has sealant applied; 
         FIG. 4B  is a plan view of the spacer frame assembly of  FIG. 4A  after a roll forming operation in an unfolded condition; 
         FIG. 5  is side elevation view of the spacer frame assembly of  FIG. 4B ; 
         FIG. 6  is an enlarged elevation view seen approximately from the plane indicated by the line  6 - 6  of  FIG. 5 ; 
         FIG. 7  is a fragmentary elevation view of a space frame forming part of the unit of  FIG. 1  which is illustrated in a partially constructed condition; 
         FIG. 7A  is an elevation view of a three sided spacer frame constructed in accordance with one example embodiment of the present disclosure; 
         FIG. 7B  is an elevation view of a two sided spacer frame constructed in accordance with another example embodiment of the present disclosure; 
         FIG. 8  is a section view of  FIG. 7  along section lines  8 - 8 ; 
         FIG. 9  is a perspective view of a spacer frame assembly having sealant added in a prescribed position in accordance with one example embodiment of the present disclosure; 
         FIG. 10A  is another perspective disassembled view of a spacer frame assembly constructed in accordance with another example embodiment of the present disclosure; 
         FIG. 10B  is a partially assembled perspective view of the spacer frame assembly of  FIG. 10A ; 
         FIG. 10C  is an assembled perspective view of the spacer frame assembly of  FIGS. 10A and 10B ; 
         FIG. 10D  is a partial perspective view of an assembled spacer frame assembly of  FIGS. 10A-10C ; 
         FIG. 10E  is a side elevation view of different end profiles of a spacer frame assembly constructed in accordance with one example embodiment of the present disclosure; 
         FIG. 10F  is a side elevation view of different end profiles of a spacer frame assembly constructed in accordance with one example embodiment of the present disclosure; 
         FIG. 10G  is a side elevation view of different end profiles of a spacer frame assembly constructed in accordance with one example embodiment of the present disclosure; 
         FIG. 10H  is a side elevation view of a portion of connecting structure or tab constructed in accordance with one example embodiment of the present disclosure; 
         FIG. 10I  is an end perspective view of  FIG. 10H ; 
         FIG. 10J  is an end view of a conventional spacer frame assembly; 
         FIG. 10K  is an end view of a spacer frame assembly constructed in accordance with one example embodiment of the present disclosure; 
         FIG. 10L  is spacer frame having a stop constructed in accordance with another example embodiment of the present disclosure; 
         FIG. 10M  is a spacer frame having a stop constructed in accordance with another example embodiment of the present disclosure; 
         FIG. 11  is a left disassembled upper perspective view of a spacer frame assembly constructed in accordance with one example embodiment of the present disclosure; 
         FIG. 12  is a right disassembled upper perspective view thereof; 
         FIG. 13  is a right disassembled lower perspective view thereof; 
         FIG. 14  is a right assembled lower perspective view of a spacer frame assembly constructed in accordance with another example embodiment of the present disclosure; 
         FIG. 15  is a left upper assembled perspective view thereof; 
         FIG. 16  is a front elevation view thereof; 
         FIG. 17  is a rear elevation view thereof; 
         FIG. 18  is a left side elevation view thereof; 
         FIG. 19  is a right side elevation view thereof; 
         FIG. 20  is a top plan view thereof; 
         FIG. 21  is a bottom plan view thereof; 
         FIG. 22  is a magnified partial perspective view thereof; and 
         FIG. 23  is a flow diagram, illustrating the method for constructing a spacer frame assembly in accordance with one example embodiment of the present disclosure. 
     
    
    
     Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the present disclosure. 
     The apparatus and method components have been represented where appropriate by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. 
     DETAILED DESCRIPTION 
     Referring now to the figures generally wherein like numbered features shown therein refer to like elements having similar characteristics and operational properties throughout unless otherwise noted. The present disclosure relates to a spacer frame and method of making same, and more specifically, a spacer frame and fabrication process for use with an insulating glass unit (“IGU”). 
     The drawing Figures and following specification disclose a method and apparatus for producing elongated window components  8  (see  FIG. 2 ) used in insulating glass units  10 . Examples of elongated window components include spacer frame assemblies  12  and muntin bars  130  that form parts of insulating glass units  10 . The IGU components  8  are formed in one example embodiment from a production line which forms sheet metal ribbon-like stock material into muntin bars and/or spacers carrying sealant and desiccant for completing the construction of insulating glass units. 
     Illustrated in  FIG. 2A  is a schematic block diagram of a production line for manufacturing a conventional spacer frame and insulating glass unit as further described in U.S. Pat. No. 7,610,681, which is incorporated herein by reference. The production line  100  may be used to fabricate the insulating glass units  10  and spacer frame assemblies  12  of the present disclosure. A stock strip  48  of material is fed endwise from a coil from a supply station into the production line  100  and substantially completed elongated window components  8  emerge from the other end of the line. 
     The production line  100  comprises a stock supply station  102 , a stamping station  104  where various notches, hole indentations or lines of weaknesses, and tab profiles are punched into flat stock  48 , a forming station  106  where the flat stock  48  is roll formed to make a u-shaped channel, a crimping station  108  where corners are formed and swaging is performed on the u-shaped channel, a shearing  110  station where the individual spacer frames are separated from the flat stock and cut to length, a desiccant application station  112  where desiccant is applied between glass lites and the interior region formed by the lites and spacer frame assembly, and an extrusion station  114  where sealant is applied to the yet to be folded frame. 
     With reference to the operation of the stamping station  104 , dies on opposite side of the strip  48  are driven into contact with the metal strip by an air actuated drive cylinder enclosed within the stamping station. In the illustrated embodiment, two air actuated cylinders drive a die support downward, moving spaced apart dies into engagement with the strip  48  to form the punch strip  36 , which is backed by an anvil in the region of contact with the dies. Due to the need to fabricate spacer frame assemblies  12  of different width between the side walls,  42 ,  44 , the dies are movable with respect to each other so that the region of contact between die and strip  48  is controlled. Similarly, when the nose portion or tab  34  of the spacer frame assembly  12  is formed, separate dies on opposite sides of the strip  48  engage the punch strip  36  at controlled locations to form the nose profile seen in  FIG. 4A . When the width of the spacer frame between the side walls  42 ,  44  changes the relative position of these two dies is also adjusted. In the exemplary embodiment, stamping of the nose or tab  34  occurs at a separate time from stamping of the corners at the notches  50 . Stated another way, the four corners  32  are formed by a first die set controlled by controller  101  that also controls each station of the production line  100  and the nose or tab  34  is formed at another time by a separated air cylinder drive that moves a separate die pair into contact with the punch strip  36 . Coordination of these separate actuations is controlled by movement of the punch strip  36  through the stamping station  104  to appropriate positions for forming the corners and the nose portion of the spacer frame. 
     An insulating glass unit  10  illustrated in  FIG. 2  is constructed using the method and apparatus further described in  FIG. 2A  as discussed above and in U.S. Pat. Nos. 8,720,026 and 7,448,246, which are both incorporated herein by reference. In  FIGS. 2-6  the IGU  10  comprises a spacer frame assembly  12  sandwiched between glass sheets, or lites,  14 . The spacer frame assembly  12  comprises a frame structure  16 , sealant material  18  for hermetically joining the frame to the lites to form a closed space  20  within the unit  10  and a body  22  of desiccant in the space  20 , as illustrated in  FIG. 3 . The insulating glass unit  10  is illustrated in  FIG. 1  as in condition for final assembly into a window or door frame, not illustrated, for ultimate installation in a building. The unit  10  illustrated in  FIG. 2  includes muntin bars  130  that provide the appearance of individual window panes. 
     The assembly  12  maintains the lites  14  spaced apart from each other to produce the hermetic insulating “insulating air space”  20  between them. The frame  16  and the sealant body  18  co-act to provide a structure which maintains the lites  14  properly assembled with the space  20  sealed from atmospheric moisture over long time periods during which the unit  10  is subjected to frequent significant thermal stresses. The desiccant body  22  removes water vapor from air, or other volatiles, entrapped in the space  20  during construction of the unit  10 . 
     The sealant body  18  both structurally adheres the lites  14  to the spacer assembly  12  and hermetically closes the space  20  against infiltration of airborne water vapor from the atmosphere surrounding the unit  10 . The illustrated body or sealant  18  is formed from a number of different possible materials, including for example, butyl material, hot melt, reactive hot melt, modified polyurethane sealant, and the like, which is attached to the frame sides and outer periphery to form a U-shaped cross section. 
     The spacer frame assembly  16  extends about the unit periphery to provide a structurally strong, stable spacer for maintaining the lites aligned and spaced while minimizing heat conduction between the lites via the frame. In one example embodiment, the spacer frame  16  comprises a plurality of spacer frame segments, or members,  30   a - d  connected to form a planar, polygonal frame shape, element juncture forming frame corner structures  32   a - d , and connecting structure or tab  34  for joining opposite frame element ends or tail  30   d  to complete the closed frame shape (see  FIG. 7 ). 
     Each frame member  30  is elongated and has a channel shaped cross section defining a peripheral wall  40  and first and second lateral walls  42 ,  44 . See  FIGS. 2 and 6 . The peripheral wall  40  extends continuously about the unit  10  except where the connecting structure or tab  34  joins the frame member end  30   d . The lateral walls  42 ,  44  are integral with respective opposite peripheral wall  40  edges. The lateral walls  42 ,  44  extend inwardly from the peripheral wall  40  in a direction parallel to the planes of the lites and the frame. The illustrated frame  16  has stiffening flanges  46  formed along the inwardly projecting lateral wall  42 ,  44  edges. The lateral walls  42 ,  44  add rigidity to the frame member  30  so it resists flexure and bending in a direction transverse to its longitudinal extent. The flanges  46  stiffen the walls  42 ,  44  so they resist bending and flexure transverse to their longitudinal extents. 
     The frame is initially formed as a continuous straight channel constructed from a thin ribbon of metal or flat stock  48 . One example of suitable metal includes stainless steel material having a thickness of 0.006-0.010 inches. Other materials, such as galvanized, tin plated steel, or aluminum, plastic, or foam may also be used to construct the channel without departing from the spirit and scope of the present disclosure. 
     Illustrated in  FIG. 4A  is a continuous metal ribbon or flat stock  48  after it has passed through a stamping station and punched by a number of dies to form notches  50  and weakening zones  52  for corner folds  32 , clip notches  66  (used in securing mutin bars), tab or connecting structure  34 , nose  62 , apertures  70 ,  72 , and end cut  80 . The punch strip  36  of flat stock forms a single spacer frame assembly  16  as illustrated in repeating sections by dimension “L” from the continuous strip  48 . The punch strip  36  is eventually sheared to make a spacer frame assembly  16  at end  80  and the nose  62 , leaving scrap piece  82 . Alternatively, the punching or shearing operation is a single hit operation in which the width of the shear equals that of scrap piece  82 , leaving no scrap or need for a double hit operation. Further discussion relating to the shearing or punching operation is discussed in U.S. Pat. No. 8,720,026, which is incorporated herein by reference. 
     The nose or tab  34  and stops  64  are formed by stamping dies at a stamping station  104  as described above. Shown by dimension “g” in one example embodiment is a nose or tab  34  width, which is smaller than the width of the stop  64  illustrated by dimension “h” in  FIG. 4A . In one example embodiment, the width of the nose or tab  34  shown by dimension a is one inch 1.00″ and the width of the stops  64  shown by dimension b is one and three sixteenths of one inch 1.187″. Thus, the difference between the width of the nose  34  and stops  64  of the above example embodiment is approximately ninety-three thousands 0.093″ of one inch from the outside edge of the strip. 
     Clip notches  66  are formed to support flexible clips that reside within the spacer frame assembly  16  and IGU once assembled. The flexible clips are used to support, for example, mutin bars as further discussed in U.S. Pat. No. 5,678,377, which is incorporated herein by reference. Notches  50  and weakening zones  52  are punched and crimped into the continuous strip  48 , allowing for the formation of the corner structures  32 . Further discussion of the punching and crimping operations is discussed in U.S. Pat. No. 7,448,246, which is incorporated by reference. 
     Before the punch strip  36  is sheared from the continuous strip  48 , it is roll formed to the configuration illustrated in  FIGS. 4B, 5 and 6 , creating peripheral wall  40 , lateral walls  42 ,  44 , and stiffening flanges  46 . Further discussion as to the roll forming operation is discussed in U.S. Pat. No. 8,904,611, which is incorporated herein by reference. 
     The corner structures  32  are formed to facilitate bending the frame channel to the final, polygonal frame configuration in the unit  10  while assuring an effective vapor seal at the frame corners, as seen in  FIGS. 2 and 7 . The sealant body  18  is applied and adhered to the channel before the corners are bent. The corner structures  32  initially comprise notches  50  and weakened zones  52  formed in the walls  42 ,  44  at frame corner locations. See  FIGS. 3-5 . The notches  50  extend into the walls  42 ,  44  from the respective lateral wall edges. The lateral walls  42 ,  44  extend continuously along the frame  16  from one end to the other. The walls  42 ,  44  are weakened at the corner locations because the notches reduce the amount of lateral wall material and eliminate the stiffening flanges  46  and because the walls are stamped to form a line of weakness  53  (see  FIG. 5 ) to weaken them at the corners and inward flexing as the corners are formed. 
     The connecting structure or tab  34  secures an opposite frame end  54  or leg member  30   d  together with a first frame end  56  when the spacer frame assembly  16  has been bent to its final configuration. That is, rotating the linear spacer frame assembly  16  segments or members  30  (from the linear configuration of  FIGS. 4B and 5 ) in the direction of arrows A, B, C, and D as illustrated in  FIG. 7  and particularly, inserting a nose  62  of the connecting structure or tab  34  into the channel formed at the opposite end  54  of segment  30   d  with concomitant rotation of the segments (arrows A-D). This concomitant rotation continues until the channel of segment  30   d  at the opposite end  54  engages positive stops  64  in the connecting structure  34  first frame end  56  forming a telescopic union  58  and lateral connection  60  to make a compound lateral leg  31 . 
     The telescopic union  58  and lateral connection  60  are along the lateral leg  31  spaced from the corner structures  32 , which in the illustrated example embodiment of  FIG. 7  the completed frame corner is C 1 . When assembled, the telescopic union  58  maintains the frame in its final polygonal configuration prior to assembly of the insulating glass unit  10 . The compound lateral leg  31  has a length of dimensions “a” (first frame end  56  from the corner C 1  to the end of the stop  64 ) plus “b” (the fourth frame segment or member  30   d ), which equals the length of dimension “c” (see  FIG. 7 ), the length of a second and opposite side segment  30   b . Dimension “b” in the illustrated example embodiment, is the length of segment  30   d  and dimension “a” is the length of the connecting structure  34  less the length of the nose  62  (dimension d) that is inserted into the channel formed in segment  30   d.    
     In the illustrated example embodiment, the connector structure  34  further comprises a first aperture  70  and corresponding second aperture  72  in the segment  30   d  for a fastener arrangement (not shown) for both connecting the opposite frame end  54  with the first frame end  56  and providing a temporary vent for the evacuation of air or insertion of gas into the space  20  while the unit  10  is being fabricated. The apertures  70  and  72  are automatically aligned because of the configurable dimensions A and B that when summed equal C (see  FIG. 7 ) when the frame ends  54 ,  56  are properly telescoped together and the end  54  engages stops  64 . The stops  64  reassure concentric alignment of the apertures  70 ,  72 . 
     The stops  64  further reassure a repeatable length of the telescopic union of the lateral connection  60 . This advantageously reassures that all four corner structures  32  are identical in spacing, size, angle orientation, and construction, thus reducing the potential for failure. In conventional spacer frames without the union  58  and lateral connection  60 , over and under extension of the corners readily occurs. This over and under extension in convention frames is in part because of differences in tolerances because the last connecting leg  2   e  (see  FIGS. 1C-1D ) fails to bottom out, leaving a gaps d and w in  FIG. 1D . 
       FIG. 7A  is an elevation view of a three sided spacer frame assembly  16  constructed in accordance with one example embodiment of the present disclosure. The three sided  30   a ,  30   b , and  30   c  frame  16  includes a connecting structure or tab  34 , a lateral connection  60  spaced from a corner, union point  58 , and stops  64  of similar construction of the example embodiment of  FIG. 7 . 
       FIG. 7B  is an elevation view of a two sided spacer frame assembly  16  constructed in accordance with another example embodiment of the present disclosure. The two sided  30   a  and  30   b  frame  16  includes a connecting structure or tab  34 , a lateral connection  60  spaced from a corner, union point  58 , and stops  64  of similar construction of the example embodiment of  FIG. 7 . 
     The configurable dimensions “a” and “b” (see  FIG. 7 ) further provide assurance that the corner segments  32   a - 32   d  are all equally spaced and orthogonal, reducing any spacing or gaps on the lateral walls  42 ,  44 , peripheral wall  40  in the space from corner union point  58  or lateral connection  60 , thus reducing the opportunity for failure. Configurable dimensions “a”, “b”, and “c” are controlled by a controller or CPU in the firmware or software at the crimping station  108  (see  FIGS. 2A, 4A and 7 ), such that the tightest dimensions can be held at the lateral connection  60  and at the corner segments  32 . In addition configurable dimensions A 2  and L 3  (see  FIG. 10H ) can be controlled by the firmware or software in a crimping machine to provide a greater seal between the tab  34  and last member  30   d  and for ease of assembly. Tab  34  profile is configurable through a mechanical setup, and it is therefore possible to control A 1  (see  FIG. 10H ) in order to minimize the clearance between the back of the spacer and stiffening flanges  46 , which will minimize clearance when the tab  34  is inserted into the spacer  54  of the final member  30   d . This makes it possible to achieve a minimal clearance between the stiffening flanges  46  and the tab  34  when the spacer frame is assembled as shown in  FIG. 10K . 
     In yet another example embodiment, the width w of the tab  34  varies to a tapered fit such that it is relatively thinner (or swaged by a crimping operation after roll forming) along length L 1  in  FIGS. 10H and 10I  for ease of assembly. That is, along length L 1 , the width w of tab  34  is approximately 0.020″ smaller than the opening  92  at the opposite end frame  54 . Thus, the tab  34  is easily inserted into the last segment  30   d  as illustrated in  FIGS. 10A-10C  (in direction of arrow A). As the tab  34  proceed along its length L 2 , the width w 1  of the tab widens as illustrated in  FIGS. 10H and 10I , such that it becomes a snug fit between the tab and inner channel  92  formed in the last segment  30   d , as further illustrated in  FIGS. 10A-10C  (in the direction of Arrows B to C). The snug or substantially press-fit continues until the opposite end frame  54  engages the stops  64  as illustrated in  FIGS. 10C and 10D , eliminating any gaps around the profile of the lateral walls,  42 ,  44 , and peripheral wall  40 . 
     This tapered formation of the tab  34  occurs by swaging the front portion L 1  by, for example a crimping operation to snake the width w of L 1  smaller than the width w 1  of L 2 . As such, as the tab  34  enters the open channel  92 , the resistance increases as the tab proceeds to enter the opening passed L 1  into the L 2  region as illustrated in  FIG. 10H . 
       FIG. 10L  is spacer frame having stops  64  of a spacer frame assembly  16  constructed in accordance with another example embodiment of the present disclosure. In particular, the stops  64  project or extend outwardly from the lateral walls  42  and  44  of the nose or connecting structure/tab  34  and engage the stiffening flanges  46  of the opposite end  54  of the connecting leg  30   d . The stops  64  in  FIG. 10L  are constructed by the configuration of the dies in stamping station  104 . 
       FIG. 10M  is a spacer frame having a stop  64  constructed in accordance with another example embodiment of the present disclosure. More particularly, the stop  64  extends outward and transversely to the peripheral wall  40  from the nose or tab  34 . In the illustrated example embodiment, the stop  64  is a dent or bump formed without an opening in the peripheral wall by a pressing die in the production line  100 . The stop  64  engages or contacts the corresponding side wall  42  of the opposite end  54  of the connecting leg  30   d.    
     For the apertures  70 ,  72 , alignment is important and in conventional spacer frames typically requires an awl for manual alignment. The apertures provide a gas passage before a fastener, such as a rivet (not shown) is installed. The fastener once installed in the auto-aligned apertures  70 ,  72  is covered with sealant material  18  so that the seal provided by each fastener is augmented by the sealant material. The fasteners in addition to sealing further assist in holding tab  34  in connection with leg member  30   d.    
     As further illustrated in  FIG. 9  the need for sealant  18  to cover the telescopic connection  58  advantageously placed only along the lateral connection  60 , which along a single lateral direction (see arrow A in  FIG. 9 ). Thus, the dual direction applying and wiping of the seal  18  in conventional spacer frames (see  FIG. 1E  directions A and B) is eliminated by the lateral connection  60  spaced away from the corner structures  32  of the present disclosure. And as such, the number of failures in the corners of the spacer frame of the present disclosure is significantly reduced. That is, the possibility of failure at any of the four corners C 1 , C 2 , C 3 , or C 4  is minimal and the equally the same based on the construction (now that all the corners have the same and equal configuration) of the present disclosure and the addition of the lateral connection  60 . 
     Illustrated in  FIGS. 11-13  are left and right disassembled perspective views of a spacer frame assembly constructed in accordance with one example embodiment of the present disclosure. Illustrated in  FIGS. 14-22  is a spacer frame assembly constructed in accordance with another example embodiment of the present disclosure. 
     In yet another advantage of the present example embodiment is that the opposite frame end  54  of segment  30   d  is substantially orthogonal (see angle ϕ) about the lateral axis “LA” of the segment. As such, the possibility of a leak is reduced, because the overall opening is over a shorter amount compared to conventional spacer frames that have an angle α illustrated in  FIG. 1A . In addition, the positive stop  64  of the tucking member  34  reassures that the aperture alignment between apertures  70  and  72  is perfectly concentric with each assembly. While yet in another example embodiment, the final member  30   d  is swaged or narrowed along dimension “e” (see  FIGS. 4A and 4B ) during roll forming such that the tab  34  has a tighter fit when inserted into the channel formed in the final member end  54  (see  FIG. 10K ) when compared to conventional connections (see  FIG. 10J ). 
     Illustrated in  FIGS. 10E, 10F, and 10G  are three different example embodiments exemplifying unique final member  30   d  end  90  constructions and nose  62  constructions of the tab  34 . These various constructions permit different options for ease of assembly. In  FIGS. 10E and 10G , the end  90  is chamfered or transverse about the lateral axis LA. While the end  90  could also be rounded as illustrated in  FIG. 10F .  FIGS. 10E and 10G  illustrate a rounded nose  62  and a pointed nose, respectively. The nose  62  could also be orthogonal or blunted as illustrated in the example embodiment of  FIG. 10F . 
     Failure in the spacer frame assembly  12  is further reduced by the identical construction of all four corners C 1 -C 4  and the locating of the lateral connection  60  at a spaced distance (see  FIG. 7 ) from any of the four corners. In addition, failure is reduced because dimensions “a” and “b” are configurable dimensions that can be increased or decreased unlike conventional spacer frames in which the connection was located at a respective corner of the spacer frame (see  FIG. 1A-1E ). Stated another way, on conventional spacer frame assemblies, the connection location could not be varied or configurable because the location of the web or stamp lines define the fold and corner that must match the web or stamp lines in the other remaining corners in order to have a substantially orthogonal frame. Therefore, any run-out existed in the corner connection of the conventional spacer frame, making such connection less robust. 
     Illustrated in  FIG. 23  is a flow diagram, illustrating a method  200  for constructing a spacer frame assembly  12  having configurable dimensions “a”, “b” and “c” (see  FIG. 7 )  210 ,  212 ,  214 , respectively in accordance with one example embodiment of the present disclosure. The configurable dimensions a, b, and c  210 ,  212 , and  214  are controlled by a CPU or computer  220  in, for example the computer&#39;s hardware, software, firmware, and the like. Altering any of the configurable dimensions  210 ,  212 , and  214  does not influence or change the construction of the corner structures  32 . The method  200  receives the values or configurable dimensions for a, b, and c at  210 ,  212 , and  214 , respectively. The method at step  216  determines whether or not the sum of configurable dimensions a  210  and b  212  is equal to configurable dimension c  214 . If the determination of step  216  is an affirmative, step  218  occurs in which the flat stock from a continuous coil  48  is advanced to a punch station (not shown and configurable dimensions a  210 , b  212 , and c  214  are formed by punching dies to generate the punch strip  36  illustrated in  FIG. 4A . 
     If the determination of step  216  is a negative, determination  222  is performed to determine whether configurable dimensions a  210  plus b  212  is greater than configurable dimension c. If the determination at step  222  is an affirmative, step  224  occurs in which configurable dimensions a  210  and/or b  212  is decreased or configurable dimension c is increased. After the changes to the configurable dimensions occurs at  224 , step  218  as previously described is performed. If the determination at step  222  is negative, step  226  occurs in which configurable dimensions a  210  and/or b  212  is increased or configurable dimension c is decreased. After the changes to the configurable dimensions occurs at  226 , step  218  as previously described is performed. 
     While a spacer frame assembly  16  having only a four-sided assembled construction is shown with a lateral connection  60  spaced from a corner C is shown, it should be appreciated that other polygons of more or less sides having a lateral connection is intended to be within the spirit and scope of the present claims and disclosure. In addition, the spacer frame assembly  16  further forms the union point  58  of the lateral connection  60  from a single integrally continuous punch strip  36  that is roll formed to form lateral walls  42 ,  44 , peripheral wall  40 , and stiffing flanges  46  throughout without the need for additional joiner clips. 
     In the foregoing specification, specific embodiments have been described. However, one of ordinary skill in the art appreciates that various modifications and changes can be made without departing from the scope of the disclosure as set forth in the claims below. Accordingly, the specification and figures are to be regarded in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of present teachings. 
     The benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims. The disclosure is defined solely by the appended claims including any amendments made during the pendency of this application and all equivalents of those claims as issued. 
     Moreover in this document, relational terms such as first and second, top and bottom, and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “has”, “having,” “includes”, “including,” “contains”, “containing” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises, has, includes, contains a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a”, “has . . . a”, “includes . . . a”, “contains . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises, has, includes, contains the element. The terms “a” and “an” are defined as one or more unless explicitly stated otherwise herein. The terms “substantially”, “essentially”, “approximately”, “about” or any other version thereof, are defined as being close to as understood by one of ordinary skill in the art, and in one non-limiting embodiment the term is defined to be within 10%, in another embodiment within 5%, in another embodiment within 1% and in another embodiment within 0.5%. The term “coupled” as used herein is defined as connected, although not necessarily directly and not necessarily mechanically. A device or structure that is “configured” in a certain way is configured in at least that way, but may also be configured in ways that are not listed. 
     The Abstract of the Disclosure is provided to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.