Spacer frame for an insulating unit having strenghtened sidewalls to resist torsional twist

Abstract

A spacer stock has a pair of outer legs joined by a base to provide the spacer stock with a generally U-shaped cross section. The outer legs are formed e.g. each leg has a pair of members having a hairpin cross section to reduce the degree of torsional twist of the spacer stock and/or spacer frame with the legs preferably only connected by the base having only one thermal conducting path e.g. through the base from one leg to the other leg. The spacer stock may be shaped or sections of spacer stock joined to provide a spacer frame. The spacer frame may be used to fabricate a multi-sheet glazing unit e.g. by securing a sheet to each of the outer legs with moisture impervious adhesive or sealant.

1. An elongated spacer stock used in the manufacture of a spacer frame to separate sheets of an insulating unit, the spacer stock comprising:
 an elongated base;   a first elongated leg having a first member and a second member joined together to have a generally U-shaped cross section;   a second elongated leg having a first member and a second member joined together to have a generally U-shaped cross section; wherein   the first and second legs are spaced from and out of contact with one another and joined to the base to provide a generally U-shaped cross section with open end of the U formed by the first and second legs and base in a first direction, the U shape of the first leg open in a second direction, and the U-shape of second leg open in the second direction with the first and second directions opposite to one another, and the first and second legs spaced from and out of contact with one another.   
     
     
       2. The spacer stock of  claim 1  wherein the first member of the first and second legs is joined to the second member of the first and second legs by a radiused portion. 
     
     
       3. The spacer stock of  claim 2  wherein the first and second members of the first and second legs are spaced from one another. 
     
     
       4. The spacer stock of  claim 3  wherein the end of the second member of the first and second legs is radiused. 
     
     
       5. The spacer stock of  claim 4  wherein the radiused end of the second member of the first and second legs contacts surface of the base between the first and second legs. 
     
     
       6. The An elongated spacer stock of  claim 4  used in the manufacture of a spacer frame to separate sheets of an insulating unit, the spacer stock comprising:
 an elongated base; 
 a first elongated leg having a first member and a second member joined together to have a generally U-shaped cross section; 
 a second elongated leg having a first member and a second member joined together to have a generally U-shaped cross section; 
 wherein the first members of the first and second legs are joined to the base to provide the spacer stock with a generally U-shaped cross section, wherein an open end of the U formed by the first and second legs and the base is open in a first direction, the U-shaped cross section of the first leg open in a second direction, and the U-shaped cross section of the second leg open in the second direction with the first and second directions opposite to one another; 
 wherein the first and second legs are spaced from and out of contact with one another; 
 wherein the first and second members of the first leg are spaced from and out of contact with one another; the first and second members of the second leg are spaced from and out of contact with one another; the second member of the first and the second legs are spaced from one another, and the first and second legs are connected to one another only by the base to provide only one thermal conducting path from the first leg to the second leg, and 
 wherein the end of the second member of the first and second legs is radiused, and the radiused end of the second member members of the first and second member legs are spaced from the inner surface of the elongated base between the first and second legs. 
 
     
     
       7. The spacer stock of  claim 1  wherein the first and second members of each of the first and second legs are in contact with one another. 
     
     
       8. An elongated spacer stock used in the manufacture of a spacer frame to separate sheets of an insulating unit, the spacer stock comprising:
 a base:   a first leg connected to the base; and   a second leg connected to the base and spaced from the first leg, wherein the legs and the base are connected to provide a generally U-shaped cross-section, wherein the first and second legs have a thickness greater than the thickness of the base to reduce torsional twist of the spacer stock.   
     
     
       9. The An elongated spacer stock of  claim 1  used in the manufacture of a spacer frame to separate sheets of an insulating unit, wherein the spacer stock has comprises:
 a continuous elongated base; 
 a first elongated leg having a first member and a second member joined together to have a generally U-shaped cross section; 
 a second elongated leg having a first member and a second member joined together to have a generally U-shaped cross section; 
 wherein the first members of the first and second legs are joined to the base to provide the spacer stock with a generally U-shaped cross section with an open end of the U formed by the first and second legs and the base open in a first direction, the U-shaped cross section of the first leg open in a second direction, and the U-shaped cross section of the second leg open in the second direction with the first and second directions opposite to one another; 
 wherein the first and second legs are spaced from and out of contact with one another, and 
 wherein the first and second members of the first leg are spaced from and out of contact with one another; the first and second members of the second leg are spaced from and out of contact with one another; the second member of the first and the second legs are spaced from one another; the first and second legs are connected to one another only by the base to provide only one thermal conducting path from the first leg to the second leg, and portions of the second member of the first and second legs are removed at positions along the spacer stock that form corners when the spacer stock is bent into a the spacer frame. 
 
     
     
       10. The spacer stock of  claim 9  wherein the first member of the first and second legs at corners has weaking have crease lines arranged to have a generally “V” shape. 
     
     
       11. The spacer stock of  claim 9  wherein the first member of the first and the second legs has a cut out portion at the positions along the spacer stock that form corners when the spacer stock is bent into a the spacer frame. 
     
     
       12. The An elongated spacer stock of  claim 1  used in the manufacture of a spacer frame to separate sheets of an insulating unit, the spacer stock comprising:
 an elongated base, wherein the base has a “T” shaped cross section extending; 
 a first elongated leg having a first member and a second member joined together to have a generally U-shaped cross section; 
 a second elongated leg having a first member and a second member joined together to have a generally U-shaped cross section; 
 wherein the first members of the first and second legs are joined to the base to provide the spacer stock with a generally U-shaped cross section with an open end of the U formed by the first and second legs and the base open in a first direction, the U-shaped cross section of the first leg open in a second direction, and the U-shaped cross section of the second leg open in the second direction with the first and second directions opposite to one another; 
 wherein the first and the second legs are spaced from and out of contact with one another; 
 wherein the first and second members of the first leg are spaced from and out of contact with one another; the first and second members of the second leg are spaced from and out of contact with one another; the second member of the first and the second legs are spaced from one another, and the first and second legs are connected to one another only by the base to provide only one thermal conducting path from the first leg to the second leg, and 
 wherein the “T” shaped cross section of the base extends upwardly between the first and second legs, and is spaced from and out of contact with the first and second legs. 
 
     
     
       13. A closed spacer frame for separating sheets of an insulating unit, the closed spacer frame comprising:
 a base defining perimeter of the closed spacer frame; 
 a first leg connected to the base, the first leg defining a side of the spacer frame and having a first member and a second member joined together to have a generally U-shaped cross section wherein the first member and the second member of the first leg are spaced from one another; 
 a second leg connected to the base, the second leg defining an opposite side of the spacer frame and having a first member and a second member joined together to have a generally U-shaped cross section wherein the first member and the second member of the second leg are spaced from one another; wherein 
 the first and second legs are spaced from and out of contact with one another and connected to the base to provide the spacer frame with a generally U-shaped cross section with an open end of the U-shaped cross section of the spacer frame facing in a first direction and opening of U the U-shaped cross section of the first and second legs facing in a second direction opposite to the first direction to reduce torsional twist, and the first and second legs are connected to one another only by the base to provide only one thermal conducting path from the first leg to the second leg. 
 
     
     
       14. The closed spacer stock frame of  claim 13  wherein the first member of the first and second legs is joined to the second member of the first and second legs by a radiused portion. 
     
     
       15. The closed spacer stock frame of  claim 14  wherein the first and second legs each include:
 athe first member of the first and the second legs joined to athe second member of the first and the second legs, respectively to have a generally hairpin configuration with the first member of the first and the second legs joined to the base. 
 
     
     
       16. The closed spacer stock frame of  claim 15  wherein:
 the end of the second member of the first and second legs is radiused, and 
 the radiused end of the second member of the first and second legs is out of contact with the base. 
 
     
     
       17. The closed spacer frame of  claim 13  wherein the spacer frame has corners and the base is continuous around the corners of the spacer frame. 
     
     
       18. The closed spacer frame of  claim 17  wherein the portions of the outer first and second legs are bent toward one another over the base. 
     
     
       19. The closed spacer frame of  claim 18  wherein portions of the second member of the first and second legs are removed at the corners and the portions of the first and second legs bent toward one another over the base are portions of the first member are bent over the base of the first and second legs. 
     
     
       20. The closed spacer frame of  claim 16  wherein a bead of moisture pervious material having a desiccant is deposited on the surface of the base between the first and second legs defined as inner surface of the base, and the bead having portions between the radiused end of the second member of the first and second legs and the inner surface of the base. 
     
     
       21. An insulating unit comprising:
 a pair of sheets;   a spacer frame between the pair of sheets, and the spacer frame comprising:
 a base; 
 a first leg 
 a second leg; wherein 
 the first and second legs are spaced from and out of contact with one another and joined to the base to provide the spacer frame in cross section with a generally U-shaped cross section with the open end of the U facing a first direction and the first and second legs each including a first U-shaped member having two ends, one end attached to the base and the remaining end joined by a radiused portion to the second member such that the members form a generally U-shaped cross-sectional configuration with the opening of the U facing a second direction opposite to the first direction to reduce torsional twist, and 
   means for securing the sheets to the spacer frame.   
     
     
       22. The insulating unit of  claim 21  wherein the securing means include a moisture impervious sealant securing the sheets to the first and second legs of spacer frame. 
     
     
       23. The insulating unit of  claim 20  further including a bead of a moisture pervious material having a desiccant mounted on surface of the base between the first and second legs. 
     
     
       24. The insulating unit of  claim 21  wherein the first and second legs each include:
 a first member joined to a second member to have a generally hairpin configuration with the first member joined to the base and the second member having an end positioned relative to the base. 
 
     
     
       25. The insulating unit of  claim 24  wherein the first member is joined to the second member by a radiused portion. 
     
     
       26. The An insulating unit of  claim 25  comprising:
 a pair of sheets; 
 a spacer frame between the pair of sheets, the spacer frame comprising:
 a base; 
 a first leg 
 a second leg; 
 wherein the first and second legs are spaced from and out of contact with one another and joined to the base to provide the spacer frame in cross section with a generally U-shaped cross section with an open end of the U-shaped cross section facing a first direction and the first and second legs each including a first member having two ends, one end attached to the base and the remaining end joined by a radiused portion to a second member such that the second member has an end positioned relative to the base and the first and the second members form a generally U-shaped cross-sectional configuration with an opening of the U-shaped cross-sectional configuration facing a second direction opposite to the first direction to reduce torsional twist, and the first and second legs are connected to one another only by the base to provide only one thermal conducting path from the first leg to the second leg, and 
 wherein: the first and second members are spaced from one another to provide the first and second legs with a hairpin cross sectional configuration; the end of the second member is radiused, and the radiused end is spaced from and out of contact with the base, and 
 means for securing the sheets to the spacer frame. 
 
 
     
     
       27. The insulating unit of  claim 26  wherein the spacer frame has corners and the base is continuous around the corners. 
     
     
       28. The insulating unit of  claim 23  wherein the bead is between the ends of the second member and the inner surface of the base. 
     
     
       29. The insulating unit of  claim 28  wherein the bead is a moisture pervious adhesive. 
     
     
       30. The insulating unit of  claim 29  wherein the unit has a low thermal conducting edge. 
     
     
       31. The insulating unit of  claim 29  further including a sheet mounted between the legs within the frame. 
     
     
       32. A method of making and using a spacer stock comprising the steps of:
 providing a strip of bendable material and   shaping the strip to provide an elongated piece of spacer stock having a base, a first leg and a second leg, the base and legs joined to provide the spacer stock with a generally U-shaped cross section with the U open in a first direction and the first and second legs spaced from one another and out of contact with one another, and the legs each having a first member joined to a second member to have a U-shaped cross section with the opening of the U in a second direction opposite to the first direction to reduce torsional twist of the spacer stock.   
     
     
       33. The A method set forth in  claim 32  further including of making and using a spacer stock comprising the steps of:
 providing a strip of bendable material; 
 shaping the strip to provide an elongated piece of spacer stock having a base, a first leg and a second leg, the base and legs joined to provide the spacer stock with a generally U-shaped cross section with the U-shaped cross section open in a first direction and the first and second legs spaced from one another and out of contact with one another, and the legs each having a first member joined to and spaced from a second member to have a U-shaped cross section with an opening of the U-shaped cross section of the first and second legs open in a second direction opposite to the first direction to reduce torsional twist of the spacer stock and the first and second legs connected to one another only by the base to provide only one thermal conducting path from the first leg to the second leg; 
 identifying corner positions on the elongated piece of spacer stock; 
 removing portions of the second member of the first and second legs at the corner positions, and 
 bending the spacer stock at the corner positions to provide a spacer frame. 
 
     
     
       34. The method as set forth in  claim 33  further including the step of:
 securing a sheet to outer surface of each of the legs to provide an insulating unit.