Patent Description:
Spacer bars are one of the key components of windows now installed in buildings. A spacer bar is placed between two panes of a window to achieve a desired distance between glass panels. Individual sections making up the spacer bar can be connected, e.g., by bending, welding or with a plug-in connector.

Corner and longitudinal connectors for spacer bars are known in the art. It is essential for the connector to be strong, easy to install and to create a durable connection between individual sections of the spacer bar.

<CIT> discloses a longitudinal connector for glazed units. The connector has a U-shaped cross-section and comprises a middle wall and two side walls. Further, the disclosed connector is equipped with elastic wedge catches and stop catches which are both placed on the side wall and tilted to its plane. Longitudinal embossings to stiffen the structure of the connector are located on the middle wall, along its entire length, on both sides of the longitudinal axis. Further, there are transverse humps arranged in the middle wall of the connector, on both sides of the central axis, the humps in the form of hollows with a depth equal to the depth of the longitudinal embossings. The bottom of the transverse humps contacts the inner surface of the connected window frames thus preventing the desiccant from penetrating into the space between a window frame and the outer surface of the middle wall.

<CIT> discloses a method of making an insulated window space assembly. The window space piece is made of tubular members interconnected by corner pieces. The corner pieces are provided with flexible projections, which create an interference fit with the tubular member ends. Such a connection protects the assembly against forces, which tend to pull the assembly apart.

<CIT> discloses a corner connector for hollow double glazing frame section members. The corner connector comprises a basic body comprising two substantially convergent arms which are connected with a hinge element at a right angle. Projecting lamellae are arranged on the inner surface of the basic body. The distance between individual lamellae is in the range of <NUM> - <NUM>. The free upper edge of each lamellae is bevelled to form a slanting shape. Sawtooth-like serration is arranged on the outer surface of the corner connector. Further, the connector is equipped with a terminal element which fixedly connects both arms of the basic body.

<CIT> discloses a plug-in connector for hollow sections of spacer frames. The plug-in connector comprises a plurality of lateral retaining elements on its side walls, the retaining elements in the shape of hook-like bosses formed by recesses in the side walls. The retaining elements are arranged one after the other in the direction of plugging-in and they can protrude various distances from the surface of the side walls. The retaining elements are thus preferably arranged at different levels and so they act on the hollow section of spacer frames at different points.

<CIT> discloses a spacer frame arrangement, with a connector, for glass units of a fusable material. In the solution, the connector for spacer glasses is inserted into the hollow inner space of the spacer profile body, with the two elements being connected at least partially by fusing. The connector is provided with hook-like protrusions disposed on its outer surface, which have an inclination against the direction of insertion. Additionally, the protrusions are resilient such that they are bent, during the insertion, in a direction opposite to the direction of insertion. The tip of the connector is of a conical shape and the front protrusions have a lower height in relation to the other protrusions, which makes it easier to insert the element into the section. The cross-section of the connector is approximately corresponding to the cross-section of the spacer profile, to which the element is inserted.

<CIT> discloses a corner connector for connecting sections of spacer bars.

The technical problem facing the present invention is to provide a corner connector for glass units spacer bars that will be characterised by high strength and will withstand heavy loads. Furthermore, it is desirable that the connector should prevent the binder from getting beyond the area of contact with the connector. It is also desirable that the connector should easily fit into the free space of the spacer bar with a stable connection of the spacer bar being maintained at the same time. Moreover, it is desirable that the connection between the spacer bar and the connector should be sealed so that the hygroscopic material found in the inside of the spacer bar section cannot spill out. Additionally, it is desirable that the connector should be installed in the spacer bar in a non-invasive and easy manner. It is also desirable that the structure of the connector should ensure an easy process of its production so that the defect rate in the process of producing the connector be as low as possible.

The subject-matter of the invention is a corner connector for spacer bars according to claim <NUM>.

Preferably, the arithmetic average of profile deviations from the mean line of the side surface of the corner is in the range of <NUM> - <NUM> Ra.

According to the present invention, the upper projections are inclined at an angle in the range of <NUM>° - <NUM>° to the corresponding outer surface towards the corner.

According to the present invention, the side projections are inclined at an angle in the range of <NUM>° - <NUM>° to the corresponding side surface towards the corner.

Preferably, the side projections taper towards their apex.

Preferably, a first reinforcing rod, a second reinforcing rod and/or a third reinforcing rod are arranged transversely on the outer surface.

Preferably, the second reinforcing rod and the third reinforcing rod have a height lower than the height of the upper projections.

Preferably, longitudinal supports are additionally arranged on the outer surface. Preferably, at least one side projection located closest to the corner takes the form of a sealing projection.

Preferably, corresponding opposite sealing projections are connected with each other by the second reinforcing rod and/or the third reinforcing rod.

Preferably, the sealing projections have their upper surface bevelled towards their apex.

Preferably, a reinforcing element is arranged on the outer surface, in the area between the first reinforcing rod and the second reinforcing rod.

Preferably, at least one upper projection located furthest to the corner takes the form of an inserting stake, with the front wall of the inserting stake being bevelled towards its apex on the side opposite the corner.

The corner connector according to the present invention ensures a durable connection of spacer bars. With the side projections and upper projections, which are wider at their base, elasticity and high resistance of the element to cracking and breaking apart is ensured even with high loads of <NUM> (about <NUM> N). Additionally, the inclination of the side projections at an angle of between <NUM>° and <NUM>° to the side surfaces towards the corner contributes to an optimal connection between the element and the spacer bar such that the connection is sealed and durable, which means the hygroscopic material does not spill out from the inside of the spacer bar section and the connector fits easily into the free space of the section and remains fixed in relation to the spacer bar. Further, the upper projections are inclined to the outer surfaces at a relatively small angle of between <NUM>° and <NUM>° towards the corner and so the structure of the spacer bar formed using the present connector is compact and rigid. Moreover, the elastic side and upper projections contribute to mitigate the phenomenon of the spacer bar cracking while the connector is being inserted into it and while the connector is being pulled out of it. Importantly, the connector is additionally provided with sealing projections, which make sure the spacer bar is well sealed and the hygroscopic material is prevented from spilling out from it. A further advantage of the element is the fact that the arithmetic average of profile deviations from the mean line (roughness) of the side surface of the corner, said surface being in contact with the binder, is greater than the roughness of the surfaces of the other connector elements. The difference between these parameters for individual surfaces makes the binder durably fixed such that the binder does not run down off the detail and remains at the point of contact with the surface of the connector. Furthermore, the connector comprises transverse reinforcing rods and longitudinal supports to ensure improved resistance to twisting of the connector arms. Further, the second and/or the third reinforcing rod is connected to the sealing projections and also has a sealing function such that it additionally prevents the hygroscopic material from falling out from the spacer bar. To reinforce the connector and prevent it from twisting, there is the reinforcing element located on the surface of the connector, the element additionally facilitating and accelerating the removal of the connector from the slides of the mould when the connector has been produced such that the connector remains undamaged while being removed. Moreover, the connector is provided with the inserting stakes, which are bevelled towards their apex on the side opposite the corner, which facilitates inserting the connector to the spacer bar.

The solution according to the invention is presented in the following embodiments and is illustrated in the drawing, in which <FIG> shows an axonometric view of the corner connector according to the first embodiment, <FIG> shows a side view of the corner connector of <FIG> shows a top view of the corner connector of <FIG>, <FIG> shows an axonometric view of the corner connector according to the second embodiment, <FIG> shows a side view of the corner connector of <FIG> shows a top view of the corner connector of <FIG>, <FIG> shows an axonometric view of the corner connector according to the third embodiment, <FIG> shows a side view of the corner connector of <FIG> shows a top view of the corner connector of <FIG>, <FIG> shows an axonometric view of the corner connector according to the fourth embodiment, <FIG> shows a side view of the corner connector of <FIG> shows a top view of the corner connector of <FIG>.

The first embodiment of the corner connector for spacer bars according to the present invention is illustrated in an axonometric view in <FIG> and in a side view in <FIG> and in a top view in <FIG>. As shown in the figures, the corner connector comprises a first arm <NUM> and a second arm <NUM>, whose structure is essentially analogues. The arms are placed at an angle of <NUM>° to each other and a corner <NUM> is formed where they connect. Importantly, the first arm <NUM>, the second arm <NUM> and the corner <NUM> form an integral single element. To be durably and stably connected to the spacer bar, the connector is provided with a set of upper projections <NUM> and side projections <NUM>. The upper projections <NUM> are arranged in a row on the edge area of the outer surface 4a, 4b of each of the arms and are directed vertically to the corresponding outer surfaces 4a, 4b. Moreover, the side projections <NUM> are arranged in a row on the side surfaces 6a, 6b of the first arm <NUM> and the second arm <NUM> and are directed horizontally to the corresponding outer surfaces 4a, 4b. Importantly, the upper projections <NUM> and the side projections <NUM> are inclined towards the corner <NUM> at an angle of <NUM>° and <NUM>°, respectively. The angle of inclination of the upper projections <NUM> and the side projections <NUM> does not limit the invention and, in alternative embodiments, it can be lower or higher and be, e.g., <NUM>° or <NUM>° for the upper projections <NUM> and <NUM>° or <NUM>° for the side projections <NUM>. In this embodiment, in each row, there are fourteen upper projections <NUM> and, on each side surface 6a, 6b, there are nine side projections <NUM>. The number of the upper projections <NUM> and the side projections <NUM> does not limit the invention and, in alternative embodiments, there may be more of these, e.g., ten side projections <NUM> or less, e.g., eight side projections <NUM>, and twelve upper projections <NUM>, provided that a durable and stable connection between the connector and the spacer bar is maintained. The number of the upper projections <NUM> and the side projections <NUM> is dictated by the length of the arms. The distance between the individual upper projections <NUM> and between the individual side projections <NUM> is <NUM>; this, however, does not limit the invention and, in alternative embodiments, said value may be higher or lower provided that both high resistance of the connector to cracking and breaking apart and a durable connection between the connector and the spacer bar are maintained.

Importantly, the corner connector comprises the corner <NUM>, whose side surface has roughness of <NUM> Ra. Said value is higher than the value of roughness of the remaining surface of the connector, which is <NUM> Ra. Such a value of roughness of the side surface of the corner <NUM> ensures a durable adherence of the binder to the surface of the corner <NUM> and prevents the binder from running down off the detail. In this embodiment, the binder is butyl but the type of the binder does not limit the scope of the invention, and, in alternative embodiments, the binder can be other than that, such as, e.g., thiokol, provided that a durable fixation to the connector is ensured. The value of roughness of the side surface of the corner <NUM> does not limit the scope of the present invention and, in alternative embodiments of the invention, said value can be different and preferably in the range of <NUM> Ra -<NUM> Ra, provided that a durable fixation of the binder to the connector is ensured. The roughness of the side surface of the corner <NUM> is achieved by appropriately preparing an injection mould for the corner connector using drilling electrodes. By regulating the drilling speed of the drilling electrodes, an injection mould with prepared surfaces is obtained so that, once the corner connector is moulded, an element can be obtained with the corner <NUM> of roughness of the side surface higher than the roughness of the remaining surface of the corner connector.

Additionally, the corner connector comprises a first reinforcing rod <NUM>, a second reinforcing rod <NUM> and a third reinforcing rod <NUM> placed transversely on each outer surface 4a, 4b, the rods ensuring improved resistance to twisting of the connector arms such that the connector arms do not twist around the longitudinal axis of each of the arms. Further, the second reinforcing rod <NUM> and the third reinforcing rod <NUM> protect against the spilling out of the hygroscopic material which is found in the spacer bar. Moreover, the second reinforcing rod <NUM> has a height which is by <NUM> lower than the height of the upper projections <NUM> and the third reinforcing rod <NUM> has a height which is by <NUM> lower than the height of the upper projections <NUM>. The height of the second reinforcing rod <NUM> and of the third reinforcing rod <NUM> does not limit the invention and, in alternative embodiments, values of these heights can be lower or higher, provided that the function of both reinforcing rods is maintained, said function being to ensure stabilisation of the connector structure and protection against the spilling out of the hygroscopic material. The corner connector is also provided with longitudinal supports <NUM> extending from the corner <NUM> towards the ends of the corner arms, said supports also serving a reinforcing function. In this embodiment, the longitudinal supports <NUM> extend to the second reinforcing rod <NUM>.

The second embodiment of the corner connector for spacer bars according to the invention is shown in <FIG> in views analogous to the first embodiment. Generally, the structure of the corner connector is approximately similar to the structure of the corner connector presented in the first embodiment, which is why similar structural elements will not be repeated for the sake of clarity of the disclosure.

In this embodiment, in every row of the side projections <NUM>, two side projections <NUM> located closest to the corner <NUM> take the form of two sealing projections <NUM> respectively. The sealing projections <NUM> ensure a sealed connection with the spacer bar and prevent the adverse phenomenon of the hygroscopic material spilling out. The number of the sealing projections <NUM> does not limit the invention and, in alternative embodiments, there may be fewer of these, e.g., one on one side surface 6a, 6b, provided that their sealing function is maintained. At the point of connection with the side surface 6a, 6b, the sealing projections <NUM> have a height similar to the height of the second reinforcing rod <NUM> and/or the third reinforcing rod <NUM>, with the corresponding opposite sealing projections <NUM> being connected with each other via the second reinforcing rod <NUM> and/or the third reinforcing rod <NUM>, respectively. Additionally, the upper surface of the sealing projections <NUM> is bevelled such that at the point of the apex, the sealing projections <NUM> have a height corresponding to the height of the side projections <NUM>.

The third embodiment of the corner connector for spacer bars according to the invention is shown in <FIG>. Generally, the structure of the corner connector for spacer bars is approximately similar to the structure of the corner connector presented in the second embodiment, which is why similar structural elements will not be repeated for the sake of clarity of the disclosure.

In this embodiment, a round reinforcing element <NUM> is arranged on the outer surfaces 4a, 4b of both the first arm <NUM> and the second arm <NUM> of the corner connector in the area between the first reinforcing rod <NUM> and the second reinforcing rod <NUM>, said round reinforcing element <NUM> ensuring an additional reinforcement to the connector structure and used during the production of the connector. This is because the reinforcing element <NUM> ensures quicker removal of the finished connector from the slides of the mould after the connector has been moulded in the injection mould and additionally reduces the likelihood of the element being damaged in the final production stage. The ejectors that remove the element from the slides of the mould are put against the surface of the reinforcing element <NUM> and not directly against the outer surfaces 4a, 4b. This manner of removing the connector from the slides of the mould prevents the ejectors from being punched into the outer surfaces 4a, 4b of the connector.

The fourth embodiment of the corner connector for spacer bars according to the invention is shown in <FIG>. Generally, the structure of the corner connector for spacer bars according to the fourth embodiment is approximately similar to the structure of the corner connector for spacer bars presented in the third embodiment, which is why similar structural elements will not be repeated for the sake of clarity of the disclosure.

Claim 1:
A corner connector for connecting sections of spacer bars, said spacer bars being placed between two panels of a window to achieve a desired distance between glass panels, the corner connector comprising a first arm (<NUM>) and a second arm (<NUM>) connected with each other by a corner (<NUM>) and placed at an angle of <NUM>° to each other, wherein, on each edge area of the longitudinal outer surface (4a, 4b) of the first arm (<NUM>) and the second arm (<NUM>), there is a plurality of upper projections (<NUM>) inclined at an angle in the range of <NUM>° - <NUM>° to the corresponding outer surface (4a, 4b) towards the corner (<NUM>), and on the side surfaces (6a, 6b) of the first arm (<NUM>) and the second arm (<NUM>), there is a plurality of side projections (<NUM>) inclined at an angle in the range of <NUM>° - <NUM>° to the corresponding side surface (6a, 6b) towards the corner (<NUM>), wherein the arithmetic average of profile deviations from the mean line, i.e. the roughness Ra, of the side surface of the corner (<NUM>), said side surface being adapted to be in contact with a binder, is greater than the arithmetic average of profile deviations from the mean line, i.e. the roughness Ra, of the surfaces of the other elements of the corner connector.