NOVEL MUNTIN BAR ASSEMBLIES
A muntin bar assembly, for example, included in an insulating glass unit, includes at least one weld joint joining a muntin bar keeper to a spacer; the keeper holds a muntin bar in a fixed relation with the spacer. A method for preparing the assembly includes steps of welding the keeper to the spacer and attaching the muntin bar to the keeper. The keeper may include a base, which accommodates welding of the keeper to the spacer, and at least one engaging element extending out from the base to hold the muntin bar.
The present application claims priority to provisional patent application Ser. No. 60/750,450, entitled WELDED MUNTIN KEEPER, and filed on Dec. 15, 2005.
TECHNICAL FIELDThe present invention pertains to glazing assemblies and more particularly to glazing assemblies incorporating muntin bar assemblies.
BACKGROUNDMuntin grids, or lattices, are often added to glazing assemblies, in order to increase the aesthetic appeal of the glazing assemblies. Muntin grids typically consist of lineal elements, or muntin bars, that subdivide a glazed opening created by a perimeter frame work assembly, particularly in the context of windows and doors. Insulated glass type glazing assemblies, or insulating glass units, often incorporate the muntin bars between two glass panes which are spaced apart by a spacer frame to which the muntin bars are attached. The muntin bars may be attached to the spacer frame by components called muntin keepers, which are cross-connecting pieces having one portion designed for attachment to the end of a muntin bar and another portion for attachment to the spacer frame; alternately muntin bar ends may be embedded within a sealing material extending along the inside perimeter of the spacer frame between the glass panes.
The secure attachment of muntin bars to spacer frames, before and after completing the assembly of insulating glass units, is important in preventing costly re-work along the assembly line, and to maintaining an aesthetically pleasing appearance of the final product assembled into a door or window that is subject to environmental loading. Furthermore, it is desirable that muntin bar attachment not compromise the integrity of other elements of the insulating glass (IG) assembly/unit, for example, that of the spacer frame or of the seal between the glass panes and the spacer frame, nor interfere with, or reduce the efficiency of, other processes required for IG unit production. Thus, there is a need for new methods and components providing for the secure attachment of muntin bars to spacer frames without compromising the integrity of IG unit components, or the efficiency of assembly processes.
BRIEF DESCRIPTION OF THE DRAWINGSThe following drawings are illustrative of particular embodiments of the present invention and therefore do not limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.
FIGS. 5A-B are schematics showing alternative welding process set ups, according to some embodiments of the present invention.
FIGS. 7B-C are a perspective view and an end view, respectively of another alternate embodiment of a muntin bar keeper.
The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides practical illustrations for implementing exemplary embodiments of the present invention.
FIGS. 2A-C further illustrate engaging element 200 of keeper 220 including a pair of opposing legs 226 in an A-frame structure to provide for a press fit, a friction fit, or an interference fit within an interior portion of a muntin bar, for example, within wall 401 of muntin bar 41. According to the illustrated embodiment, legs 226 act like a spring, bending toward one another, to allow for insertion into muntin bar 41, and pressing outward against muntin bar wall 401 once inserted. Each leg 226 is shown to include an extension 206, folding outward and over toward base 26, in order to facilitate the insertion into muntin bar 41 and to provide a contact surface between engaging element 200 and an inner surface of wall 401. According to exemplary embodiments of the present invention, keeper 220 is formed by a sheet metal stamping process, for example, from stainless steel sheet metal having a thickness from approximately 0.005 inch to approximately 0.020 inch. It should be noted that the present invention is not limited to exemplary configurations of engaging elements described herein, and that alternate embodiments include any type of friction fitting or interlocking member, either male, for example, as in the illustrated embodiments, or female, to alternately fit about an exterior surface of a muntin bar.
According to the flow chart of
Spacers for IG assemblies are typically formed from lineal sections of rolled aluminum or stainless steel that are cut to length, according to a specified dimension of the corresponding IG unit, and then bent into a frame for subsequent glazing. According to some assembly methods of the present invention, spacer lineal sections are cut to length, per step 501, and then one or more keepers are welded, per step 503, to the spacer, in lineal form, for example, as illustrated in the schematic of
According to some alternate assembly methods of the present invention, the spacer prep of step 501 further includes bending the spacer into a frame so that the one or more keepers are welded to the spacer when it is in frame form, for example, as is illustrated in the schematic of
According to some preferred embodiments of the present invention, resistance-type welding is used to join keepers to spacers. Those skilled in the art of resistance welding understand that resistance welding uses the application of electric current and mechanical pressure to create a weld between two pieces of metal, thus, according to the preferred embodiments, weld heads 65 are electrodes which conduct an electric current to keeper base 26 and spacer wall 32, while applying pressure to force base 26 and wall 32 together into intimate contact. A welding cycle first develops sufficient heat to raise a small volume of metal to the molten state, while pressure is applied; the metal then cools, while still under pressure, until it has adequate strength to hold the parts together. The current density and pressure must be sufficient to produce a weld nugget, but not so high as to expel molten metal from the weld zone.
Some assembly methods of the present invention further include a step to separate each keeper 220 from a cohesive group, for example, group 600 shown in
Keepers 720, 720′ may be more appropriate to support muntin bars having rectangular profiles, for example as illustrated in
With reference back to
In the foregoing detailed description, the invention has been described with reference to specific embodiments. However, it may be appreciated that various modifications and changes can be made without departing from the scope of the invention as set forth in the appended claims. For example, although various muntin bars are shown herein to extend orthogonally along two orthogonal planes which are approximately orthogonal to a surface of a spacer, to which a muntin bar keeper is attached, it is contemplated that engagement features of muntin bar keepers may be structured to allow muntin bars to extend in a plane skewed from one or both of the orthogonal planes.
Claims
1. A muntin bar assembly, comprising:
- a spacer including a surface;
- a muntin bar;
- at least one muntin bar keeper joined to the spacer and holding the muntin bar in a fixed relation with the spacer; and
- at least one weld joint formed between the at least one keeper and the spacer surface.
2. The assembly of claim 1, wherein the at least one muntin bar keeper comprises:
- a base extending alongside the spacer surface; and
- at least one engaging element extending out from the base and holding the muntin bar; and
- wherein the at least one weld joint is formed between the base and the spacer surface.
3. The assembly of claim 2, wherein the base of the at least one keeper is free of any spacer-engaging protrusions.
4. The assembly of claim 2, wherein the at least one weld joint is offset from the at least one engaging element.
5. The assembly of claim 2, wherein the muntin bar includes a perimeter wall forming a lumen and the at least one engaging element of the at least one keeper is press fitted within the lumen.
6. The assembly of claim 2, wherein the at least one engaging element includes opposing legs.
7. The assembly of claim 6, wherein the base includes a tab extending laterally from the legs and the at least one weld joint is formed between the tab and the spacer surface
8. The assembly of claim 2, wherein the at least one engaging element includes two engaging elements spaced apart from one another, and the base extends therebetween.
9. The assembly of claim 8, wherein the at least one weld joint is disposed between the two engaging elements.
10. The assembly of claim 1, wherein the muntin bar includes a perimeter wall extending around a substantial portion of the at least one keeper to effectively hide the keeper.
11. The assembly of claim 1, wherein the at least one keeper holds the muntin bar in the fixed relation without penetrating through the surface of the spacer.
12. A method for preparing a muntin bar assembly, the method comprising:
- welding at least one muntin bar keeper to a spacer; and
- attaching a muntin bar to the at least one keeper.
13. The method of claim 12, further comprising cutting the spacer to length prior to welding.
14. The method of claim 12, further comprising cutting the spacer to length subsequent to welding.
15. The method of claim 12, further comprising bending the spacer into a spacer frame prior to welding.
16. The method of claim 12, further comprising bending the spacer into a spacer frame subsequent to welding.
17. The method of claim 12, further comprising separating the at least one keeper from a cohesive group of keepers to place the at least one keeper for welding.
18. The method of claim 17, wherein the cohesive group is formed in a coil and separating the at least one keeper comprises unrolling a length of the cohesive group.
19. The method of claim 17, wherein separating the at least one keeper comprises shearing along a common base of the cohesive group of keepers.
20. The method of claim 12, wherein the at least one keeper comprises a first keeper and a second keeper, and welding comprises welding the first keeper to the spacer at a first location and welding the second keeper to the spacer at a second location, the second location being spaced apart from the first location along a length of the spacer.
21. The method of claim 20, wherein welding of the first and second keepers is simultaneous.
22. The method of claim 20, wherein welding of the first and second keepers is sequential.
23. The method of claim 12, wherein welding comprises resistance welding.
24. The method of claim 12, wherein welding comprises welding a first part of the keeper to a first location on the spacer and welding a second part of the keeper to a second location on the spacer.
25. The method of claim 24, wherein welding the first and second parts is simultaneous.
26. The method of claim 24, where welding the first and second parts is sequential.
27. The method of claim 12, wherein attaching the muntin bar comprises press fitting the muntin bar over an engaging element of the keeper.
28. A component for holding a muntin bar in a fixed relation with a spacer within an insulating glass assembly, the component comprising:
- at least one engaging element to hold the muntin bar; and
- a base supporting the engaging element and including an area being offset from the engaging element to accommodate welding of the base to a surface of the spacer;
- wherein the base is free of any spacer-engaging protrusions.
29. The component of claim 28, wherein the at least one engaging element comprises opposing legs.
30. The component of claim 28, wherein the at least one engaging element comprises two engaging elements spaced apart from one another, and the area of the base is disposed between the two engaging elements.
31. The component of claim 28, wherein the base has dimensions less than or equal to dimensions defining a profile of the muntin bar, so that the base is effectively hidden by the muntin bar when the muntin bar is held by the at least one engaging element.
32. The component of claim 28, wherein the area of the base includes a weld projection.
33. A component for holding a muntin bar in a fixed relation with a spacer within an insulating glass assembly, the component comprising:
- at least one engaging element to hold the muntin bar; and
- a base supporting the engaging element and including a weld projection.
34. The component of claim 33, wherein the weld projection is offset from the at least one engaging element.
35. The component of claim 33, wherein the at least one engaging element comprises opposing legs.
36. The component of claim 33, wherein the at least one engaging element comprises two engaging elements spaced apart from one another, and the weld projection is disposed between the two engaging elements.
37. The component of claim 33, wherein the base has dimensions less than or equal to dimensions defining a profile of the muntin bar so that the base is effectively hidden by the muntin bar when the muntin bar is held by the at least one engaging element.
38. An insulating glass assembly, comprising:
- a pair of glass panes;
- a spacer separating the glass panes from one another and including a surface disposed therebetween;
- a muntin bar disposed between the glass panes;
- at least one muntin bar keeper holding the muntin bar in a fixed relation with the spacer; and
- at least one weld joint formed between the at least one keeper and the spacer surface.
39. The assembly of claim 38, wherein the at least one muntin bar keeper comprises:
- a base extending alongside the spacer surface; and
- at least one engaging element extending out from the base and holding the muntin bar; and
- wherein the at least one weld joint is formed between the base and the spacer surface.
40. The assembly of claim 39, wherein the base of the at least one keeper is free of any spacer-engaging protrusions.
41. The assembly of claim 39, wherein the at least one weld joint is offset from the at least one engaging element.
42. The assembly of claim 39, wherein the muntin bar includes a perimeter wall forming a lumen and the at least one engaging element of the at least one keeper is press fitted within the lumen.
43. The assembly of claim 39, wherein the at least one engaging element includes opposing legs.
44. The assembly of claim 43, wherein the base includes a tab extending laterally from the legs and the at least one weld joint is formed between the tab and the spacer surface
45. The assembly of claim 39, wherein the at least one engaging element includes two engaging elements spaced apart from one another, and the base extends therebetween.
46. The assembly of claim 45, wherein the at least one weld joint is disposed between the two engaging elements.
47. The assembly of claim 38, wherein the muntin bar includes a perimeter wall extending around a substantial portion of the at least one keeper to effectively hide the keeper.
48. The assembly of claim 38, wherein the at least one keeper holds the muntin bar in the fixed relation without penetrating through the surface of the spacer.
Type: Application
Filed: Dec 12, 2006
Publication Date: Jul 12, 2007
Inventors: Benjamin Zurn (Roseville, MN), Curt Queck (Fontanelle, IA), Daniel Stava (Elkhorn, NE)
Application Number: 11/609,502
International Classification: E04C 3/30 (20060101);