Patent Description:
The present disclosure relates to insulating glass units and more particularly to a thermally efficient window frame that comprises a spacer frame with a thermal barrier to reduce heat transfer across the spacer frame and through the insulating glass units.

Insulating glass units (IGUs) are used in windows to reduce heat loss from building interiors during cold weather and to prevent the entrance of heat during warm 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.

One 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., a hot melt material) 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.

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 formed spacer was then placed between glass lites and the IGU assembly completed.

A typical insulating glass unit (IGU) <NUM> is illustrated in <FIG>. The IGU <NUM> includes a spacer assembly <NUM> sandwiched between glass sheets, or lites, <NUM>. The assembly <NUM> comprises a frame structure <NUM> and sealant material for hermetically joining the spacer assembly <NUM> to the lites <NUM> to form a closed space <NUM> within the IGU <NUM>. The prior art IGU <NUM> illustrated in <FIG> is in condition for final assembly into a window or door frame.

The assembly <NUM> maintains the lites <NUM> spaced apart from each other to produce the hermetic insulating "insulating air space" <NUM> between them. The typical frame <NUM> comprises a plurality of spacer frame segments, or members, 30a-d connected to form a planar, polygonal frame shape, element juncture forming frame corner structures 32a-d, and connecting structure <NUM> for joining opposite frame element ends to complete the closed frame shape. Traditionally a frame member <NUM> is has a channel shaped cross section defining a peripheral wall <NUM> and first and second lateral walls <NUM>, <NUM> (see <FIG>). The peripheral wall <NUM> extends continuously about the IGU <NUM> except where the connecting structure <NUM> joins the frame member ends.

The frame <NUM> extends about the unit periphery, such that, in an installed window, a lite <NUM> exposed to the external temperature is thermally connected to a lite <NUM> that is exposed to an internal temperature via the peripheral wall <NUM>. This thermal connection causes a thermal energy flow between the internal and external regions bound by the window, causing the internal desired temperature to be altered by the external not-desired temperature.

<CIT> 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.

<CIT> to Riegelman entitled "Insulated Channel Seal for Glass Panes" and <CIT> to McGlinchy concerns a structure having a channel for a frame which separates window panes to form an insulated window and has a plurality of openings through a wall of the channel that faces outward along the periphery of the frame and glass sandwich. In Riegelman, the openings are designed to prevent significant passage of sealant from the outside of the channel to the inside of the channel through the openings. This is done by the cross sectional area of each opening being so small that it resists viscous flow of the sealant through the opening, or by a cover over the opening.

Companies by the names of Edgetech and Nynex produce window spacer frames formed entirely of PVC having thermally efficient insulating characteristics. <CIT> entitled "Spacer Profile for a Spacer Frame for an Insulating Window Unit and Insulating Window Unit" concerns a mountable spacer profile for forming an intervening space.

<CIT> describes a spacer assembly comprising a first sidewall and a second sidewall and a first bridge and a second bridge. The first bridge and second bridge and the first sidewall and the second sidewall are separate members joined permanently to form a spacer preferably by welding. The bridge and/or have reduced thickness to reduce the heat loss and employ substantially high strength metal material. The bridge and sidewall may also employ different metal materials.

<CIT> describes an elongated spacer element for double glazing and, in an assembled condition of said double glazing, assigned to be fixed between the peripheral edges of two glass panels, mutually opposed, of the double glazing and comprising at least an elongated first section bar having at least an external face and two side faces respectively assigned to be directed outward of the double glazing and to be fixed between the edges of the glass plates of said double glazing; said spacer element being characterized in that at least the external surface of the external face of the first section bar is equipped with a layer means preferably made of impermeable polymer, for example of EVOH type or other polymer impermeable to vapor and/or gases and having poor thermal conductor capability and extended at least on the whole surface of the external face or on its median longitudinal portion.

<CIT> describes a spacer profile for a spacer frame of an insulating pane unit includes a hollow profile body made of plastic with a chamber defined therein. The hollow profile body extends in a longitudinal direction and includes an inner wall, an outer wall, a first side wall and a second side wall, which are connected to the inner and outer walls to form the chamber. First and second reinforcing layers made of a metallic material respectively extend on the first and second side walls and partially on the outer wall so as to be spaced apart by a first distance. A diffusion barrier layer is formed directly on the outer wall between the first and second reinforcing layers and is connected thereto in a diffusion-proof manner in order to form a heat-insulating diffusion barrier. An insulating pane unit includes at least two panes with such a spacer frame disposed therebetween.

<CIT> describes multipane, insulating glazing structures having exceptional thermal insulation performance are provided. The multipane structures comprise two substantially parallel rigid glazing sheets spaced apart by an interior spacer which includes a physically stable body of low thermal conductivity, closed cell, foamed polymer.

<CIT> describes an insulating unit having a pair of glass sheets about an edge assembly to provide a compartment between the sheets. The edge assembly has a U-shaped spacer made of metal, metal coated plastic, gas and moisture impervious polymer, or gas and moisture impervious film coated polymer. The outer legs of the spacer and the glass provide a long diffusion path to limit the diffusion of argon gas out of the compartment. The edge assembly has materials selected and sized to provide edge assembly having an RES-value of at least <NUM>.

A first aspect of the present invention comprises thermal sheet stock, being roll formed for use in forming a spacer frame for use in an insulating glass unit (IGU) the thermal stock comprising first and second flat frame stock portions comprising a first thermal conductivity, and a thermal interruption strip coupling the first frame stock portion to the second frame stock portion the thermal interruption strip spacing the first frame stock portion a gap distance from the second frame stock portion, the thermal interruption strip comprising a second thermal conductivity, the second thermal conductivity being less than the first thermal conductivity Wherein an intermediate wall portion comprising the thermal interruption strip may be covered by a film material for preventing fluid leakage.

One aspect of the present invention includes a spacer for separating first and second glass lites from each other in an insulating glass unit (IGU) for use in fabricating a window or door. The spacer frame comprising an elongated frame forming a multi-sided unit comprising a first outwardly facing surface for supporting the first glass lite. The first outwardly facing surface is contiguous with a first intermediate wall portion. The spacer frame further comprises a second outwardly facing surface for supporting the second glass lite. The second outwardly facing surface is contiguous with a second intermediate wall portion, wherein the first and second intermediate wall portions comprise a first material and are linked to each other and spaced from each other by a thermal interruption strip. The first and second intermediate wall portions and the thermal interruption strip comprise an intermediate wall that bridges the first and second outwardly facing surfaces. Additionally, the spacer frame may comprise a film for preventing fluid leakage, overlaying the intermediate wall portion.

Yet another aspect of the present invention comprises a method of forming thermal stock for use in insulating glass units according to claim <NUM>. The method comprises forming a first and second frame stock portion, laterally linking the first and second frame stock portions via a thermal interruption strip. The thermal interruption strip spacing the first frame stock portion from the second frame stock portion, and comprising a lower thermal conductivity material than the material first and second frame stock portions. The method may further comprise overlaying the thermal interruption strip and at least a portion of the first and second frame stock portions with a film.

Yet another aspect of the present invention comprises an insulating glass unit according to claim <NUM>. The Insulating glass unit comprising first and second glass lites spaced apart from each other having inner facing surfaces that bound an interior region, a multi-sided channel shaped composite spacer frame for arranging said first and second glass lites in a spaced apart, generally parallel relation to each other. The spacer frame comprising an elongated thermal interruption strip forming a middle portion of said composite spacer frame that extends around a periphery of the interior region bound by the first and second glass lites, a first elongated metal side wall member having a first outwardly facing side wall surface for orienting the first glass lite and a first inwardly facing side wall surface that bounds the interior region wherein the first elongated metal side wall member includes a first embedded portion securing the first metal side wall member to the thermal interruption strip, and a second elongated metal side wall member having a second outwardly facing side wall surface for orienting the second glass lite and a second inwardly facing side wall surface that bounds the interior region wherein the second elongated metal side wall member includes a second embedded portion securing the second metal side wall member to the thermal interruption strip. The spacer frame further comprising an adhesive material interposed between the outwardly facing side wall surfaces of said first and second metal side wall members and the first and second glass lites for arranging the first and second glass lites in spaced relation to each other. A vapor barrier may be provided overlying at least a portion of the thermal interruption strip to impede contaminants from reaching the interior region bounded by the first and second glass lites.

The thermal stock may include first and second frame stock portions that are substantially planar comprising first and second lateral ends, the first and second frame stock portions having a first thermal conductivity; a polymeric thermal interruption strip may be formed over and between the second lateral ends of the first and second frame stock portions, the polymeric thermal interruption strip may space the first and second frame stock portions by forming a gap between the second lateral ends, the gap being fixedly within the polymeric thermal interruption strip, the polymeric thermal interruption strip may comprise a second thermal conductivity, the second thermal conductivity may be less than the first thermal conductivity; the polymeric thermal interruption strip may further comprise spaced first and second mirrored converging lateral ends forming a sandwich connection with and over the second lateral ends of the first and second frame stock portions, the sandwich connection may extend toward the first lateral ends to cover a portion of the first and second metallic ribbons beyond the second lateral connection ends, the polymeric thermal interruption strip may further comprise a planar body that connects the first and second spaced mirrored converging lateral ends, the planar body may cover a portion of the metallic ribbons and the entire gap between the second lateral ends of the first and second metallic ribbons. A film material may cover a portion of first and second longitudinal sides of the first and second metallic ribbons and an entire first and second longitudinal sides of the polymeric thermal interruption strip.

The foregoing and other features and advantages of the present disclosure will become apparent to one skilled in the art to which the present invention relates upon consideration of the following description of the invention with reference to the accompanying drawings, wherein like reference numerals refer to like parts unless described otherwise throughout the drawings and in which:.

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.

Referring now to the figures generally wherein like numbered features shown therein refer to like elements throughout unless otherwise noted. The present disclosure relates to insulating glass units and more particularly to a thermally efficient window frame that comprises a spacer frame with a thermal barrier to reduce heat transfer across the spacer frame and through the insulating glass units.

A double pane insulating glass unit (IGU) <NUM> is illustrated in <FIG>. The IGU <NUM> includes a spacer assembly <NUM> sandwiched between glass sheets, or lites <NUM>. The assembly <NUM> comprises a frame <NUM> and sealant material (omitted for clarity) for hermetically joining the spacer assembly <NUM> to the lites <NUM> to form a closed space <NUM> within the IGU <NUM>. The IGU <NUM> is illustrated in <FIG> as in condition for final assembly into a window or door frame, not illustrated, for ultimate installation in a building. The IGU <NUM> as illustrated in <FIG> includes muntin bars "m" that provide the appearance of individual window panes. It would be appreciated by one having ordinary skill in the art that multi-pane IGUs were contemplated, and the frame structures used therein would be substantially the same as the frame <NUM> described with regard to the IGU <NUM>. Further discussion of multi-pane IGUs and their assembly process is found in <CIT><CIT>, which are assigned to the assignee of the present disclosure.

The assembly <NUM> maintains the lites <NUM> spaced apart from each other to produce the hermetic insulating "insulating air space" <NUM> between them. The frame <NUM> and the sealant body <NUM> (see <FIG>) co-act to provide a structure which maintains the lites <NUM> properly assembled with the space <NUM> sealed from atmospheric moisture over long time periods during which, the IGU <NUM> is subjected to frequent significant thermal stresses. A desiccant <NUM> (see <FIG>) removes water vapor from air, or other volatiles, entrapped in the space <NUM> during construction of the IGU <NUM>.

The sealant <NUM> both structurally adheres the lites <NUM> to the spacer assembly <NUM> and hermetically closes the space <NUM> against infiltration of airborne water vapor from the atmosphere surrounding the IGU <NUM>. One suitable sealant is formed from a "hot melt" material, which is attached to the frame <NUM> sides and outer periphery to form a U-shaped cross section.

The frame <NUM> extends about the unit periphery to provide a structurally strong, stable spacer <NUM> for maintaining the lites <NUM> aligned and spaced while minimizing heat conduction between the lites via the frame. The preferred frame <NUM> comprises a plurality of spacer frame segments, or members, 330a-d connected to form a planar, polygonal frame shape, element juncture forming frame corner structures 332a-d, and connecting structure <NUM> (see <FIG>) for joining opposite frame element ends <NUM>, <NUM> to complete the closed frame shape.

The frame member <NUM> is elongated and has a channel-shaped cross section, defining a peripheral wall <NUM> and first and second lateral walls <NUM>, <NUM> (see <FIG>, <FIG>, and <FIG>). The peripheral wall <NUM> comprises frame stock <NUM>, <NUM> spaced from each other and linked to each other by a thermal interruption strip <NUM> (see <FIG>, <FIG>, and <FIG>, and <FIG>). A film <NUM> overlays at least a portion of the stock <NUM>, <NUM>, and the thermal interruption strip <NUM> (see, for example, <FIG>). The peripheral wall <NUM> extends continuously about the IGU <NUM> except where the connecting structure <NUM> joins the frame member ends <NUM>, <NUM>. The lateral walls <NUM>, <NUM> are integral with respective opposite peripheral wall edges. The lateral walls <NUM>, <NUM> extend inwardly from the peripheral wall <NUM> in a direction parallel to the planes of the lites <NUM> and the frame <NUM>. The illustrated frame <NUM> has stiffening flanges <NUM> formed along the inwardly projecting lateral wall edges. The lateral walls <NUM>, <NUM> add rigidity to the frame member <NUM> so it resists flexure and bending in a direction transverse to its longitudinal extent. The flanges <NUM> stiffen the walls <NUM>, <NUM> so they resist bending and flexure transverse to their longitudinal extents.

Illustrated in <FIG> is the continuous metal ribbon or flat stock <NUM> that is roll formed into the channel shaped cross section defining the peripheral wall <NUM> and first and second lateral walls <NUM>, <NUM> (see <FIG>, <FIG>, and <FIG>). The flat stock <NUM> is passed through a stamping station and punched by a number of dies to form notches <NUM> and weakening zones <NUM> for corner folds <NUM>, a connecting structure <NUM>, a nose <NUM>, gas fill apertures <NUM>, <NUM>, and end cut <NUM>. The thermal interruption strip <NUM> is illustrated in dashed lines for clarity as the film <NUM> overlays said thermal interruption strip. A punch strip <NUM> of flat thermal stock <NUM> forms a thermal spacer frame assembly <NUM> as illustrated in repeating sections by dimension "L" from the continuous strip <NUM>. The punch strip <NUM> is eventually sheared to make a spacer frame assembly <NUM> at end <NUM> and the nose <NUM>, leaving scrap piece <NUM>. Alternatively, the punching or shearing operation is a single hit operation in which the width of the shear equals that of scrap piece <NUM>, leaving no scrap or need for a double hit operation. Further discussion relating to the shearing or punching operation is discussed in <CIT>. The gas fill apertures <NUM>, <NUM> comprise holes punched into the flat thermal stock <NUM>.

The frame <NUM> is initially formed as a continuous straight channel constructed from thermal stock <NUM>, wherein the thermal stock comprises two independent thin ribbons of stock material <NUM>, <NUM> (e.g., <NUM> stainless steel having a thickness of <NUM>-<NUM> (<NUM>-<NUM> inches)) linked via the thermal interruption strip <NUM>, and at least partially overlaid with the film <NUM>. It should be appreciated that the metal stock <NUM> could also be <NUM> steel, mild steel, hardened steel, aluminum, CrMo steel, nickel, carbon steel, and the like.

In one example embodiment, the frame stock <NUM>, <NUM> comprises other materials, such as galvanized and/or tin plated steel, aluminum and/or plastic. The thermal interruption strip <NUM> in one example embodiment comprises a non-thermally conductive material such as a polymer (e.g., aliphatic or semi-aromatic polyamides (Nylon), polyethylene, polyester, epoxy, etc.), a plastic (e.g., polyethylene terephthalate, high-density polyethylene, polyvinyl chloride, etc.) rubber, hardening agents (e.g., calcuim carboniate, talc, barium sulphate, glass fibers, etc.), bonding agents (e.g., polyvinyl acetate) or a combination thereof. The thermal interruption strip <NUM> comprises a durometer between <NUM>-<NUM> Shore D which has a sufficient rigidity at temperatures up to below <NUM>, to maintain the shape of the channel, and the walls <NUM>, <NUM>, yet provide the flexibility to bend when assembled (see <FIG>) at the corners C1-C4 without separation at corners C1-C4. The film <NUM> comprises an air tight film such as a metalized polyester film, to prevent loss of thermally efficient insulating fluids (e.g., He, Ne, Ar, Kr, Xe, or the like) from the space <NUM>, the flexibility of the film <NUM> also provides strength to the spacer frame and thermal interruption strip <NUM> to prevent fracturing during the bending at the corners C1-C4. In one example embodiment, the film <NUM> comprises a low moisture vapor transition rate (MVTR) barrier film. Examples of products that can be used as film <NUM> include Mylar resin (e.g., Polyethylene Terephthalate (PET)), <NUM>'s P Model #<NUM> Polyester film, and the like.

As described more fully below, the corner structures <NUM> are made to facilitate bending the frame channel to the final, polygonal frame configuration in the IGU <NUM> while assuring an effective vapor seal at the frame corners and properly aligning apertures <NUM>, <NUM>. The gas fill apertures <NUM>, <NUM> comprise holes punched into the thermal interruption strip <NUM>. The gas fill apertures <NUM>, <NUM> are used to either inject the space <NUM> in the IGU <NUM> with a liquid and/or solid, or to evacuate the space. In one example embodiment, the corner structures <NUM> are manually or automatically bent when the frame <NUM> is maintained at an elevated bending temperature. The bending temperature is determined based upon a melting temperature and/or a heat distortion temperature of the thermal interruption strip <NUM>. In this embodiment, the apertures <NUM>, <NUM> are formed while the thermal interruption strip <NUM> is at the bending temperature, to facilitate aperture formation. In another embodiment, the apertures <NUM>, <NUM> are formed through the thermal interruption strip <NUM> utilizing a punch and/or screw before or after roll forming.

In yet another embodiment, the apertures <NUM>, <NUM> are formed through the thermal interruption strip <NUM> via a hot or thermal punch, cold punch, and/or a hole drilling mechanism. Sealant <NUM> is applied and adhered to the channel before the corners <NUM> are bent. As shown in the illustrated embodiment of <FIG>, <FIG>, the corner structures <NUM> initially comprise notches <NUM> and weakened zones <NUM> formed in the walls <NUM>, <NUM> at frame corner locations. The notches <NUM> extend into the walls <NUM>, <NUM> from the respective lateral wall edges. The lateral walls <NUM>, <NUM> extend continuously along the frame <NUM> from one end to the other. The walls <NUM>, <NUM> are weakened at the corner locations <NUM> because the notches reduce the amount of lateral wall material, a portion of the film <NUM>, and eliminate the stiffening flanges <NUM> and because the walls are punched and stamped to weaken them at the corners. At the same time the notches <NUM> are formed, the weakened zones <NUM> are formed. These weakened zones are cut into the strip <NUM>, but not all the way through. When this strip <NUM> is rollformed, the weakened zones <NUM> can spring back and have an outward tendency.

The connecting structure <NUM> secures the opposite frame ends <NUM>, <NUM> together when the frame <NUM> has been bent to its final configuration. The illustrated example embodiment of <FIG>, the connecting structure <NUM> comprises a connecting tongue structure <NUM> continuous with and projecting from the frame structure end <NUM> and a tongue receiving structure <NUM> at the other frame end <NUM>. The illustrated example embodiment tongue and tongue receiving structures <NUM>, <NUM> are constructed and sized relative to each other to form a telescopic joint <NUM>. When assembled, the telescopic joint <NUM> maintains the frame in its final polygonal configuration prior to assembly of the unit <NUM>.

In a second embodiment, such as in the illustrated example embodiments of <FIG>, and <FIG>, the connecting structure <NUM> comprises a stop <NUM> that is formed by stamping dies at a stamping station <NUM> as described below. The connecting structure <NUM> is inserted into an opposite frame end <NUM> or the leg member 330d when the thermal spacer frame assembly <NUM> has been bent to its final configuration. That is, rotating the thermal spacer frame assembly <NUM> members <NUM> (from the linear configuration of <FIG>) in the direction of arrows A, B, C, and D as illustrated in <FIG> and particularly, inserting the frame structure end or nose <NUM> of the connecting structure <NUM> into an opposite channel <NUM> formed at the opposite end <NUM> of segment 330d with concomitant rotation of the segments (arrows A-D). This concomitant rotation continues until the connecting structure <NUM> slides into the opposite channel <NUM> of segment 330d at the opposite end <NUM>. In the illustrated example embodiment of <FIG>, the opposite end <NUM> engages positive stops <NUM> in the connecting structure <NUM> forming a telescopic union <NUM> and lateral connection <NUM> that is spaced from the corners <NUM>. It would be appreciated by one having ordinary skill in the art that the lateral connection <NUM> and/or the telescopic union <NUM> could be located anywhere between the first and fourth corners 332a, 332d. Further discussion as to the stop <NUM> and lateral connection <NUM> that is spaced from the corners <NUM> is discussed in <CIT>, <CIT>.

An operation by which elongated window components are made is schematically illustrated in <FIG> as a production line <NUM> through which thermal sheet stock <NUM> comprising the two thin, relatively narrow ribbons of sheet metal stock <NUM>, <NUM> linked by the thermal interruption strip <NUM> and the film <NUM> is fed endwise from a coil into one end of the assembly line and substantially completed elongated window components <NUM> emerge from the other end of the line <NUM>.

The line <NUM> comprises a stock supply station <NUM>, a first forming station <NUM>, a transfer mechanism <NUM>, a second forming station <NUM>, a conveyor <NUM>, a scrap removal apparatus <NUM>, third and fourth forming stations <NUM>, <NUM>, respectively. Wherein within the line <NUM>, partially formed spacer members are separated from the leading end of the thermal sheet stock <NUM>, the thermal sheet stock is roll formed, and frame corner locations are deformed. At a desiccant application station <NUM> desiccant is applied to an interior region of the spacer frame member, and at an extrusion station <NUM> sealant is applied to the yet to be folded frame member. A scheduler/motion controller unit <NUM> interacts with the stations and loop feed sensors to govern the spacer stock size, spacer assembly size, the stock feeding speeds in the line, and other parameters involved in production. A preferred controller unit <NUM> is commercially available from Delta Tau, <NUM> Lassen St, Chatsworth, CA <NUM> as part number UMAC. In one embodiment a separate controller <NUM>' controls the desiccant application and adhesive or sealant application. Additional details of a representative spacer frame fabrication system are contained in <CIT>.

In one example embodiment, the spacer assembly <NUM> enhances the thermal properties of the resulting window by interrupting thermal energy flow of energy through an installed window. The thermal energy flow between an interior wall and an exterior wall is interrupted by the presence of the thermal interruption strip <NUM>. For example, the thermal interruption strip <NUM> better maintains the temperature of the window's inwardly facing edge in winter by impeding heat flow from inside a home or other building and impeding the energy loss caused by lower temperature from the outwardly facing edge of the window.

In the illustrated example embodiment of <FIG>, heat flow disruption is accomplished by the thermal conductivity interruption created by the thermal interruption strip <NUM> of the peripheral wall <NUM> of the frame <NUM>. The thermal interruption strip <NUM> links an inner edge 303b of the first metal strip <NUM> and an inner edge 307b of the second metal strip <NUM> (see <FIG>). The links of the inner edges 303b and 307b in the illustrated example embodiment is in an alternating sinusoidal manner increasing the strength and support between the thermal interruption strip <NUM> and the ribbons <NUM>.

The thermal interruption strip <NUM> comprises a polymer bridge <NUM>. The polymer bridge <NUM> comprises a mechanically crimped polymer bridge with the frame member before or after roll forming, a co-extruded polymer bridge, a molded polymer bridge, or the like. In this embodiment, the thermal stock <NUM> is formed by an automated apparatus. In one example embodiment, such as illustrated in <FIG>, when the thermal interruption strip <NUM> comprises the mechanically crimped polymer bridge, the thermal interruption strip <NUM> comprises a central portion 302a, an upper portion 302b, and a lower portion 302c, wherein the lower portion is positioned to interact with bottom faces 306b, 308b of the frame stock <NUM>, <NUM>, the central portion is positioned between the frame stock and on top of the lower portion, and the upper portion 302a is positioned on to interact with top faces 306a, 306b of the frame stock and the central portion. The upper, central, and lower portions 302a-302c are mechanically crimped together, manually or automatically, to form the thermal interruption strip <NUM> and to bond the thermal interruption strip to the frame stock <NUM>, <NUM>, to form the thermal stock <NUM>.

In another example embodiment, when the thermal interruption strip <NUM> comprises the co-extruded polymer bridge, the thermal interruption strip <NUM> is formed as a single unit while interacting with the frame stock <NUM>, <NUM>. The frame stock <NUM>, <NUM> is aligned relative to an extrusion apparatus, and the polymer bridge material is extruded, manually or automatically, onto the frame stock to form the thermal interruption strip <NUM> linking the frame stock and the thermal interruption strip <NUM>.

In the illustrated example embodiment of <FIG>, <FIG>, the thermal interruption strip <NUM> is a polygon, and in particular, a hexagonal polygon that provides strength and support between the thermal interruption strip and ribbons <NUM>, <NUM>. This construction assists in providing support for high stress conditions that occurs on the strip, ribbon, and connection therebetween, especially at the corners when the spacer frame is bent for assembly. In the illustrated example embodiment, the hexagonal construction forms a hexagonal prism cross-section as seen in <FIG>. The hexagonal prism cross-section extends longitudinally around the entire profile of the spacer frame. Laterally, the hexagonal prism cross-section includes mirrored first and second ends having upper and lower transverse ends extending to a point forming a sandwich connection with the ribbons <NUM>, <NUM> starting at the first and second stability extents and extending to and beyond ends 303b and 307b (see <FIG> and <FIG>). The hexagonal prism cross-section further comprises a planar body that connects the spaced mirrored first and second ends and covers the stability extents and gap between the ends 303b and 307b as illustrated in <FIG> and <FIG>).

In yet another example embodiment, when the thermal interruption strip <NUM> comprises the molded polymer bridge, the thermal interruption strip <NUM> is formed by positioning the frame stock <NUM>, <NUM> relative to a thermal interruption strip mold, and filling the mold with the thermal interruption strip material. The frame stock <NUM>, <NUM> is aligned relative to the mold to obtain desired dimensions of the thermal interruption strip <NUM> relative to the frame stock. The polymer bridge material is injected, manually or automatically, onto the mold to form the thermal interruption strip <NUM> and, thus, the thermal stock <NUM>. In yet another example embodiment, the frame stock <NUM>, <NUM> is positioned after the mold has been filled, but while the thermal interruption strip material is still pliable (e.g., while a temperature of the thermal interruption strip material is over a temperature at which the material would become inflexible).

In the illustrated example embodiment of <FIG>, the thermal interruption strip <NUM> extends a first stability distance <NUM> over a top face 306a and/or a bottom face 306b of the first frame stock portion <NUM> and a second stability distance <NUM> over a top face 308a and/or a bottom face 308b of the second frame stock portion <NUM> to increase a strength of the linking of the first and second frame stock portion. The thermal interruption strip <NUM> provides a gap distance <NUM> between the inner edges 303b, 307b (see <FIG> and <FIG>) of the first and second frame stock portions <NUM>, <NUM>. The first and second stability distances <NUM>, <NUM>, and the gap distance <NUM> are proportional to a final width <NUM> of the spacer frame <NUM> and/or a stock width <NUM> of the stock <NUM> (see <FIG>). For example, a sum of the first and second stability distances <NUM>, <NUM>, and the gap distance <NUM> is between <NUM>/8th to about <NUM>/4th of the total stock width <NUM>. The first and second stability distances <NUM>, <NUM> are proportional to the gap distance <NUM> (e.g., at a ratio of between <NUM>:<NUM> to <NUM>:<NUM>). In one example embodiment, the greater the gap distance <NUM> the greater the first and second stability distances <NUM>, <NUM>. In another example embodiment, the first and second stability distances <NUM>, <NUM> are substantially equal to the gap distance <NUM>. In yet another example embodiment, the sum of the first and second stability distances <NUM>, <NUM>, and the gap distance <NUM> is less than final width <NUM> of the spacer frame <NUM>.

In another embodiment, the thermal interruption strip <NUM> is glued or adhered (e.g., with a pressure sensitive adhesive) to the frame stock <NUM>, <NUM> (see <FIG>, and <FIG>). In this embodiment, the thermal stock <NUM> is formed by an automated strip laminating apparatus. When the thermal interruption strip <NUM> is linked to the frame stock <NUM>, <NUM> via adhesives or glue, the lower portion 302c is positioned to interact with bottom faces 306b, 308b of the metal strips <NUM>, <NUM>, the central portion 302a is positioned between the frame stock portions and on top of the lower portion, and the upper portion 302b is positioned on top faces 306a, 306b of the frame stock and the central portion, wherein an adhesive or glue is disposed between the upper, central, and lower portions, and/or the frame stock. The upper, central, and lower portions 302a-302c are glued/adhered together, manually or automatically, (e.g., using pressure, such as a uniform pressure of <NUM>-<NUM> kPa (<NUM>-<NUM> psi)) to form the thermal interruption strip <NUM> and additionally, glued/adhered to the frame stock <NUM>, <NUM>, to form the thermal strip <NUM>.

In yet another example embodiment, the frame stock <NUM>, <NUM> (see <FIG>) comprise serrations or shapes that add surface area to aid adherence of the thermal interruption strip <NUM> to along the inner edges 303b, 307b of the frame stock <NUM>, <NUM>. In the illustrated example embodiment of <FIG>, the first frame stock portion <NUM> comprises intruding 306a and protruding 306b undulations. The second frame stock portion <NUM> comprises intruding 308a and protruding 308b undulations that are complementary intruding 306a and protruding 306b undulations of the first frame stock portion <NUM>. In an additional example embodiments, the frame stock portion <NUM>, <NUM> comprise interruptions (e.g., holes <NUM>, mesh material <NUM>, etc.) (see <FIG>) along and adjacent to the inner edges 303b, 307b of the metal strips <NUM>, <NUM> to provide added grip strength/bonding surface area to the thermal interruption strip <NUM>. The gap distance <NUM> between the inner edges 303b, 307b is variable and is a factor in minimum spacer width capability. For example, a larger gap distance <NUM> is more thermally efficient. In one example embodiment, the thermal interruption strip <NUM> provides the gap distance <NUM> having a range between about <NUM> (<NUM>/<NUM>" (inches)) to about <NUM> (<NUM>/<NUM>" (inches)). In another example embodiment, the thermal interruption strip <NUM> comprises a thermal interruption strip thickness <NUM> (see <FIG>). The thermal interruption strip thickness <NUM> having a range between about <NUM> (<NUM>/<NUM>" (inches)) to about <NUM> (<NUM>/<NUM>"( inches)). The thermal interruption strip <NUM> disrupts heat transfer across the wall from one side wall <NUM> to the opposed side wall <NUM> while maintaining a structural integrity of the wall <NUM>.

The film <NUM> is applied as the thermal interruption strip <NUM> is being formed, before, or after the thermal interruption strip has been formed. The film <NUM> is applied longitudinally along the linear extent of the thermal stock <NUM>. In one example embodiment, the film <NUM> is placed within the mold prior to injection of the thermal material. In this embodiment, a lower layer 304b of the film <NUM> (see <FIG>) is placed in the mold and in partial contact with the first and second metal stock portions <NUM>, <NUM> and an upper layer 304a of the film is placed over the thermal interruption strip <NUM> and over at least a portion of the first and second metal stock portions. The heat from the mold links the film <NUM> to the thermal interruption strip <NUM> and the first and second metal stock portions <NUM>, <NUM>. The film <NUM> is applied via at least one of glue or adhesive, thermal pressure, etc, and/or a combination thereof. In another example embodiment, the film <NUM> is applied prior to, during, or after the thermal stock <NUM> is roll formed into its channel shape. The film <NUM> is airtight and prevents fluid transfers from inside the IGU <NUM> to outside the IGU. Additionally, the film <NUM> prevents the desiccant <NUM> from escaping the IGU <NUM>. In one example embodiment, the film <NUM> comprises a sputtered metal barrier, and is applied to the thermal stock <NUM> before roll forming or around the perimeter of the unit <NUM> after roll forming but before folding the frame <NUM> into a rectangle. The film <NUM> stretches around the corners <NUM> as the frame <NUM> is bent, adding strength and support to the ribbons <NUM> and <NUM> with the thermal interruption strip <NUM>. An example of a suitable film <NUM> is <NUM>'s 'Very Low Outgassing High Shear Polyester Tape' sold as model <NUM>, 'Low Outgassing Polyester Tape' sold under model number <NUM>, 'Very Low Outgassing Linered Polyester Tape' sold as model number <NUM>, and 'Aluminum Foil Tape' sold as model number <NUM> or <NUM> (Linered).

In another example embodiment, the thermal interruption strip <NUM> forms first and second projections 371a, 372a, illustrated in dashed lines in <FIG>. In this illustrated example embodiment, the first gas fill aperture <NUM> comprises the first projection 371a through the base wall 340a into the channel and the second gas fill aperture <NUM> comprises a second projection 372a into the channel, wherein the first projection interweaves with the second projection when assembled. The interweaving provides a friction connection. The friction connection is a responsive tactile connection, in that it provides to the assembler feedback if there is over-travel or under-travel when advancing one or both of the connecting structure <NUM> and the opposite channel <NUM> towards each other. That is, the friction during assembly remains high during under-travel until the interweaving of the projections 371a, 372as achieved to form the friction or responsive tactile connection. Once the interweaving is achieved, the friction significantly diminishes between the base wall 340a and the second projection 372a. Similarly, if over-travel from the tactile connection occurs, the friction significantly increases. This tactile response occurs because the second projection 372a rubs the base wall 340a of the connecting structure <NUM>, until the tactile connection is reached between the first and second projections 371a, 372a. Further discussion as to the first and second projections, and the tactile connection is discussed in <CIT> and <CIT>.

Although the patterns and/or composition of the inner edges 303b, 307b of the metal stock portions <NUM>, <NUM> vary, an isotherm that simulates the thermal energy transfer of this spacer system can be generated by performing a thermal analysis. <FIG> illustrates an isotherm of the typical IGU <NUM> and <FIG> illustrates the thermal IGU <NUM>, both IGUs being subjected to boundary temperature of -<NUM> (<NUM>°F) outside 15a, 315a and <NUM> (<NUM>°F) inside 15b, 315b, respectively. The lines on the isotherms are joining points representing states of equal temperature, wherein the temperature in Fahrenheit corresponds to the line as shown in a box overlaying the line.

In the illustrated example embodiment of <FIG>, the model illustrates where the frame stock portions <NUM>, <NUM> are separated by the thermal interruption strip <NUM>, wherein the gap distance <NUM> is <NUM> (<NUM>/<NUM>" (inches)). It would be understood by one of ordinary skill in the art that a greater gap distance <NUM> would cause a greater interruption in the thermal energy transfer. Comparing the traditional IGU <NUM>, which has an inside lite 15b temperature of <NUM> (<NUM>. 9F), to the thermal IGU <NUM>, which has an inside lite 315a temperature of <NUM> (<NUM>. 3F), illustrates that less thermal energy is lost when the thermal IGU <NUM> is being utilized.

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.

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", "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 <NUM>%, in another embodiment within <NUM>%, in another embodiment within <NUM> % and in another embodiment within <NUM>%. 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.

Claim 1:
Thermal sheet stock (<NUM>), being roll formed for use in forming a spacer frame for use in an insulating glass unit (IGU)(<NUM>), the thermal stock (<NUM>) comprising:
first (<NUM>) and second (<NUM>) flat frame stock portions comprising a first thermal conductivity;
a thermal interruption strip (<NUM>) coupling the first frame stock portion (<NUM>) to the second frame stock portion (<NUM>), the thermal interruption strip (<NUM>) spacing the first frame stock portion a gap distance from the second frame stock portion, the thermal interruption strip (<NUM>) comprising a second thermal conductivity, said second thermal conductivity is less than the first thermal conductivity.