Thermally efficient window frame

Abstract

A spacer frame for use in fabricating a window and a method of fabrication thereof is disclosed. The spacer frame for separating first and second glass lites from each other in window. The spacer frame includes a frame forming a multi-sided form comprising a first outwardly facing surface for supporting a first glass lite that is contiguous with a first intermediate wall portion and a second outwardly facing surface for supporting a second glass lite that is contiguous with a second intermediate wall portion. 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. The spacer frame further includes a film overlaying the intermediate wall portion.

1 . A spacer frame for separating first and second glass lites from each other in an insulating glass unit (IGU) for use in fabricating a window, the spacer frame comprising:
 an elongated frame forming a multi-sided form comprising a first outwardly facing surface and a second outwardly facing surface, the first outwardly facing surface for supporting the first glass lite, the first outwardly facing surface is contiguous with a first intermediate wall portion, and the 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; and   a film for preventing fluid leakage, overlaying the intermediate wall portion.   
     
     
         2 . The spacer frame of  claim 1  wherein the film is applied over the intermediate wall portion on at least one side of the spacer frame. 
     
     
         3 . The spacer frame of  claim 1  wherein:
 the first material comprises a first thermal conductivity; 
 the thermal interruption strip comprises a second thermal conductivity, wherein said second thermal conductivity is less than the first thermal conductivity. 
 
     
     
         4 . The spacer frame of  claim 1  wherein the thermal interruption strip comprises a material that is flexible enough to be wound on a roll. 
     
     
         5 . The spacer frame of  claim 1  wherein the first and second intermediate wall portions comprise complementary intruding and protruding undulations. 
     
     
         6 . The spacer frame of  claim 1  wherein at least a portion of the first and second intermediate wall portions comprise interruptions. 
     
     
         7 . The spacer frame of  claim 6  wherein said interruptions comprise at least one of holes and mesh material. 
     
     
         8 . Thermal stock for use in forming a spacer frame for use in an insulating glass unit (IGU), the thermal stock comprising:
 first and second frame stock portions comprising a first thermal conductivity;   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, said second thermal conductivity is less than the first thermal conductivity; and   wherein an intermediate wall portion comprising the thermal interruption strip is covered by a film material for preventing fluid leakage.   
     
     
         9 . The thermal stock of  claim 8 , wherein the thermal interruption strip comprises a central portion, an upper portion, and a lower portion, said central portion spaces the first and second frame stock portions from each other, said upper portion extend over at least an upper portion of the first and second frame stock portions, and said lower portion extend over at least a lower portion of the first and second frame stock portions. 
     
     
         10 . The thermal stock of  claim 9 , wherein the film is applied over at least one of the upper and lower portions of the thermal interruption strip. 
     
     
         11 . The thermal stock of  claim 10 , wherein the film is in direct contact with at least a portion of the first and second frame stock portion. 
     
     
         12 . A method of forming thermal stock for use in insulating glass units, the method comprising:
 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 the thermal interruption strip comprising a lower thermal conductivity material than the first and second frame stock portions; and   overlaying the thermal interruption strip and at least a portion of the first and second frame stock portions with a film.   
     
     
         13 . The method of  claim 12  wherein the step of laterally linking comprises adhesively bonding the first and second frame stock portions to the thermal interruption strip. 
     
     
         14 . The method of  claim 13  wherein the first and second frame stock portions are elongated, generally planar strips of a first material and wherein the thermal interruption strip includes separate layers having said lower thermal conductivity that are adhesively bonded to a first and second exposed surfaces of the generally planar strips. 
     
     
         15 . The method of  claim 14  wherein the thermal interruption strip comprises three layers wherein a middle layer is adhesively attached to two additional layers that are adhesively bonded to the exposed surfaces of the generally planar strips. 
     
     
         16 . The method of  claim 15  wherein the step of laterally linking comprises extruding the thermal interruption strip into contact with the first and second frame stock portions. 
     
     
         17 . The method of  claim 16  where the thermal interruption strip is extruded at an elevated temperature which hardens after coming in contact with the first and second frame stock portions. 
     
     
         18 . The method of  claim 12  wherein the step of laterally linking comprises molding the thermal interruption strip into contact with the first and second frame stock portions. 
     
     
         19 . The method of  claim 12  additionally comprising roll forming first and second frame stock portions to form a channel subsequent to linking the first and second frame stock portions with the thermal interruption strip and wherein the film is applied subsequent to said bending. 
     
     
         20 . An 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, said 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;   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; and   a vapor barrier 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.   
     
     
         21 . (canceled) 
     
     
         22 . (canceled)