Box spacer with sidewalls.

(54) Title: BOX SEPARATOR WITH SIDE WALLS.

(54) Title: BOX SPACER WITH SIDEWALLS.

(57) Summary

Generally speaking, this description is directed to a window assembly and a window spacer. In a possible configuration and through a non-limiting example, the window assembly includes a first sheet, a second sheet, and a spacer disposed between the first sheet and the second sheet. The spacer includes a first elongated strip, a second elongated strip, and continuous side walls or a plurality of side walls. In some embodiments, the side walls include a first portion that has a first clamping mechanism and a second portion has a second clamping mechanism. The first clamping mechanism is arranged and configured to securely engage with the second clamping mechanism to connect the first portion to the second portion.

(57) Abstract

In general terms, this disclosure is directed to a window assembly and a window spacer. In one possible configuration and by non-l¡m¡t¡ng example, the window assembly ¡ncludes a first sheet, a second sheet, and a spacer arranged between the first sheet and the second sheet. The spacer includes a first elongate strip, a second elongate strip, and continuous sidewalls or a plurality of sidewalls. In some executions the sidewalls include a first portion having a first fastening mechanism and a second portion have a second fastening mechanism. The first fastening mechanism is arranged and configured to securely engage with the second fastening mechanism to connect the first portion with the second portion.

BOX SEPARATOR WITH SIDE WALLS

RELATED REQUESTS

This application was filed on November 13, 2008, as a PCT International Patent application in the name of Infinite Edge Technologies, LLC, a national corporation of the USA, applicant for the designation of all countries except the USA, and Paul Trpkovski, a citizen from the USA, applicant for the US designation only, and claims priority to the US Provisional Patent Application Series No. 60 / 987,681 filed on November 13, 2007, US Provisional Patent Application Series No. 61 / 038,803 filed on March 24, 2008, Provisional Fatente Application in series No. 60 / 049,593, filed on May 01, 2007, and US Provisional Patent Application Series No. 61 / 049,599 filed on May 1, 2008.

BACKGROUND

Windows often include two opposing sheets of glass separated by an air gap. The air gap reduces heat transfer through the window to insulate the interior of a building to which it is attached from external temperature variations. As a result, the energy efficiency of the building is improved, and a more even temperature distribution within the building is achieved.

BRIEF DESCRIPTION OF THE INVENTION

Generally speaking, this description is directed to a window assembly and a window spacer. In a possible configuration and as a non-limiting example, the window assembly includes a first sheet, a second sheet, and a spacer disposed between the first sheet and the second sheet. The spacer includes a first elongated strip, a second elongated strip, and continuous side walls or a plurality of side walls.

One aspect is a separator comprising: a first elongated strip; a second elongated strip; and at least one extruded side wall that couples the first elongated strip to the second elongated strip.

Another aspect is a sealed unit assembly comprising a first transparent material; a second transparent material; and a spacer assembly disposed between the first and second transparent materials, the spacer assembly comprising: a first elongated strip having a first side adjacent to the first material! transparent and a second side adjacent to the second transparent material; a second elongated strip having a first side adjacent to the first transparent material and a second side adjacent to the second transparent material; and at least one side wall connecting the first elongated strip to the second elongated strip.

Still another aspect is a method of making a spacer, the method comprising: arranging at least a portion of a first elongated strip and a second elongated strip in a separate relationship, the first elongated strip including a first surface, and the second elongated strip which includes a second surface; extruding a material through an extrusion die to form at least one side wall; and moving the extrusion die relative to the first and second elongated strips while extruding to apply the material to the first surface of the first elongated strip and to the second surface of the second elongated strip to connect the first and second strips elongated.

A further aspect is a method of making a spacer, the method comprising: forming a first side wall portion into a first elongated strip, the first side wall portion including a protrusion; and forming a second side wall portion on a second elongated strip, the second side wall portion including a notched portion.

Another aspect is a separator comprising: a first elongated strip; a second elongated strip; a first side wall portion having a first clamping mechanism, the first side wall portion attached to the first elongated strip; and a second side wall portion having a second clamping mechanism, the second side wall portion attached to the second elongated strip, wherein the first clamping mechanism is arranged and configured to securely engage the second clamping mechanism to connect the first side wall portion to the second side wall portion.

There is no requirement that the provision include all aspects characterized herein to obtain any advantage in accordance with the present description.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a schematic front view of a window ensam in accordance with the present description.

ble of e a

Figure 2 is a schematic perspective view of the corner section of the window assembly shown in Figure 1

Figure 3 is a schematic cross-sectional view of a portion of the window assembly shown in Figure 1 that includes a first sealant.

Figure 4 is a schematic front view of a portion of another embodiment of the separator;

Figure 5 is a perspective diagram of a separator.

Figure 6 is a schematic cross-sectional view of a portion of the separator shown in Figure 5.

Figure 7 is a side view of a portion of the separator shown in Figure 5.

Figure 8 is a perspective diagram of a separator.

Figure 9 is a schematic cross-sectional view of a portion of the separator shown in Figure 8.

Figure 10 is a side view of a portion of the separator shown in Figure 8.

Figure 11 is a perspective diagram of a separator.

Figure 12 is an exploded assembly perspective diagram of the spacer shown in Figure 11.

Figure 13 is an exploded assembly perspective diagram of the spacer shown in Figure 11.

Figure 14 is a schematic cross-sectional view of a portion of the separator shown in Figure 11.

Figure 15 is a side view of a portion of the separator shown in Figure 11.

Figure 16 a schematic cross sectional view of another embodiment of a window assembly including an intermediate member.

Figure 17 is an exploded assembly perspective diagram of a spacer.

Figure 18 is an exploded perspective assembly diagram of a separator.

Figure 19 is a schematic cross-sectional view of a portion of the separator shown in Figures 17 and 18.

Figure 20 is a side view of a portion of the separator shown in Figures 17 and 18.

Figure 21 is an exploded assembly perspective diagram of a spacer.

Figure 22 is a schematic cross-sectional view of a portion of the separator shown in Figure 21.

Figure 23 is a schematic cross sectional view 5 of a separator.

Figure 24 is a schematic cross sectional view of a separator.

Figure 25 is a schematic cross sectional view of a separator.

Figure 26 is a schematic cross sectional view of a separator.

Figure 27 is a schematic front view of a portion of the spacer shown in Figure 4 arranged in a corner configuration.

DETAILED DESCRIPTION

Various embodiments will be described in detail with reference to the drawings, where like reference numbers represent 20 like parts and assemblies through the various views. Reference to various embodiments does not limit the scope of the claims appended hereto. Additionally, any of the examples indicated in this specification are not intended to be limiting and merely indicate some of the many possible embodiments for the appended claims.

Figures 1 and 2 illustrate a window assembly 100 in accordance with the present description. Figure 1 is a schematic front view of window assembly 100. Figure 2 is a 'schematic perspective view of a corner section of window assembly 100.

Window assembly 100 includes sheet 102, sheet 104, and spacer 106. Sheets 102 and 104 are made of a material that allows at least some light to pass through. Typically, sheets 102 and 104 are made of a transparent material, such as glass, plastic, or other suitable materials. Alternatively, translucent or semi-transparent material is used, such as etched, tinted, or tinted glass or plastic.

The spacer 106 includes the elongated strip 110, the elongated strip 114, and side walls 124 and 126. In some embodiments, the spacer 106 also includes a filler 112. The spacer 106 is disposed between the sheets 102 and 104 to hold the sheets 102 and 104 separated from each other. Typically, spacer 106 is arranged to form a closed loop near the perimeter of sheets 102 and 104. E, spacer 106 is capable of withstanding compressive forces applied to sheets 102 and / or 104 to maintain a desired space between sheets 102 and 104. An interior space 120 within window assembly 100 is defined by the spacer 106 and the sheets 102 and 104.

Elongated strips 110 and 114 are typically long, thin strips of a solid material, such as metal or plastic. An example of a suitable metal is stainless steel. An example of a suitable plastic is a thermoplastic polymer, such as polyethylene terephthalate. A material with low or no permeability is preferred in some embodiments. Some embodiments include a material that has low thermal conductivity.

By themselves, the elongated strips 110 and 114 are typically flexible, including some bending and twisting flexibility. In some embodiments, the bending flexibility allows an assembled spacer 106 to be bent to make non-linear shapes (eg, curved). The bending and twisting flexibility also allows for ease of window fabrication. Such flexibility includes elastic or plastic deformation so that the elongated strips 110 or

114 will not fracture during installation in the window assembly

100. Some embodiments of spacer 106 include elongated strips that do not have substantial flexibility, but are instead substantially rigid. In some embodiments, the elongated strips 110 and 114 are flexible, but the spacer e 106 is substantially rigid. In some embodiments, the elongated strips 110 and 114 act to protect the filler 112 from ultraviolet radiation.

Some embodiments include filler 112 which is disposed between elongated strip 110 and elongated strip 114. In some embodiments, filler 112 is a deformable material. Being deformable can allow spacer 106 to form around the corners of window assembly 100. In some embodiments, filler 112 is a desiccant that acts to remove moisture from interior space 120. Desiccants include molecular filter and type of silica gel. An example of a desiccant is a bead desiccant, such as PHONOSORB® molecular filter beads manufactured by WR Grace & Co. of Columbia, MD. If desired, an adhesive is used to bond the pearl desiccant between the elongated strips 110 and 114.

In other embodiments, filler 112 is a material that provides support to elongated strips 110 and 114 to provide increased structural strength. In business modalities that include filler 112, filler 112 fills the space between elongated strips 110 and 114 to support elongated strips 110 and 114. As a result, spacer 106 not only relies on the strength and stability of elongated strips 110 and 114 to maintain proper spacing between sheets 102 and 104 and prevent curling, bending, or breakage. Furthermore, heat transfer through the elongated strips 110 and 114 is also reduced. In some embodiments, filler 112 is a matrix desiccant material that not only acts to provide structural support between elongated strips 110 and 114, but also removes moisture from interior space 120.

Examples of a filler material include adhesive, foam, putty, resin, silicon rubber, or other materials. Some fillers are desiccants or include a desiccant, such as matrix material. The matrix material includes desiccant and other filler material. Examples of matrix desiccants include those made by WR Grace & Co. and HB Fuller Corporation. In some embodiments, a pearl desiccant is combined with another filler.

In some embodiments, padding 102 is made of a material that provides thermal insulation. Thermal insulation reduces heat transfer through spacer 106 both between sheets 102 and 104, and between interior space 120 and an outer side of spacer 106.

In some embodiments, the elongated strip 110 includes a plurality of aperture 116 (shown in Figure 2). The openings 116 allow gas and moisture to pass through the elongated strip 110. As a result, the moisture located within the interior space 120 is allowed to pass through the elongated strip 110 where it is removed by the desiccant or the filler 112. In another embodiment, openings 116 are used for registration. Even in another embodiment, the openings provide reduced heat transfer. In one example, openings 116 have a diameter in a range of from about 0.005 cm to about 0.127 cm. The openings 116 are made by any suitable method, such as cutting, drilling, drilling, laser forming, or the like.

Spacer 106 may be connected to sheets 102 and 104. In some embodiments, spacer 106 is connected to sheets 102 and 104 by a fastener. An example of a bra is an adhesive sealant, as described in more detail below. In other embodiments, a frame, band, or the like is constructed around the window assembly 100 to support the spacer 106 between the sheets 102 and 104. In some embodiments, spacer 106 is attached to the frame or band by a fastener, such as adhesive. Also in the possible modalities, the spacer 106 is fastened to the frame or to the band before the installation of the sheets 102 and 104.

In some embodiments, the ends of the spacer 106 can be connected with a fastener to form a closed loop.

As such, the spacer 106 and the sheets 102 and 104 together define an interior space 120 of the window assembly 100. The interior space

120 reduces heat transfer through window assembly 100.

When the window assembly 100 is fully assembled, the gas is sealed within the interior space 120. In some embodiments, the gas is air. Other modalities include oxygen, carbon dioxide, nitrogen, or other gases. Still other embodiments include an inert gas, such as helium, neon, or a noble gas such as krypton, argon, and the like. Combinations of these or other gases are used in other embodiments.

Figure 3 is a schematic cross-sectional view of a portion of window assembly 100. In this embodiment, window assembly 100 includes sheet 102, sheet 104, spacer 106, and also includes sealants 302 and 304.

Sheet 102 includes outer surface 310, inner surface 312, and perimeter 314. Sheet 304 includes outer surface 320, inner surface 322, and perimeter 324. In one example, W is the thickness of sheets 102 and 104. .W is typically in a range from about 0.12 cm to about 2.54 cm, and preferably from about 0.2 cm to about 1.2 cm. Other modalities include other dimensions. ¡

The separator 106 is disposed between the inner surface 312 and the inner surface 322. The separator 106 typically / is! ' arranged near perimeters 314 and 324. In one example, D1 is the distance between perimeters 314 and 324 and spacer 106. D1 is typically in a range from about 0 cm to about 5.08 cm, and preferably from about 0.2 cm to about 1.2 cm. However, in other embodiments, spacer 106 is disposed at other locations between sheets 102 and 104.

Spacer 106 maintains a space between sheets 102 and 104. In one example, W1 is the total width of spacer 106 and the distance between sheets 102 and 104. W1 is typically in a range from about 0.2 cm to about 5.08 cm, and preferably from about 0.7 cm to about 2.54 cm. Other modalities include other spaces.

The spacer 106 includes the elongated strip 110, the elongated strip

114, side wall 124, and side wall 126. Elongated strip 110 includes outer surface 330, inner surface 332, edge 334, edge 336, and openings 116. Elongated strip 114 includes outer surface 340, inner surface 342 , edge 344, and edge 346. In some embodiments, the outer surface 330 of the elongated strip

110 it is visible to a person when looking through the window assembly 100. The outer surface 330 of the elongated strip 110 provides a clean and finished appearance to the spacer 106. A benefit of some embodiments of the spacer 106 is that formation is not required. roll to bend the elongated strips 110 and 114. However, other embodiments use roll forming.

In one example, T1 is the total thickness of the spacer 106 from the outer surface 330 to the outer surface 340. T1 is typically in a range from about 0.05 cm to about 2.54 cm, and preferably from about 0.2 cm to about 1.2 cm. T2 is the distance between the elongated strip 110 and the elongated strip 114, and more specifically the distance from the inner surface 332 to the inner surface 342. T2 is also the thickness of the filler material 112. T2 is in a range from about 0.05 cm to about 1.2 cm, and preferably from about 0.12 cm to about 0.38 cm. In some embodiments, the elongated strips 110 and 114 and the filler 112 are not linear, in some examples they have a wavy shape as described below and shown in Figure 4. As a result, spacer 102 does not always have a constant thickness in all modes. As a result, T2 is an average thickness in some modalities. Other modalities include other dimensions.

In this embodiment, a first sealant 302 and 304 is used to connect the spacer 106 to the sheets 102 and 104. In one embodiment, sealant 302 is applied to one edge of the spacer 106, such as at edges 334 and 344, and the edge of filler 112 and then pressed against inner surface 312 of sheet 102. Sealant 304 is also applied to an edge of spacer 106 such as at edges 336 and 346, and a filler edge 112 and are then pressed against the inner surface 322 of sheet 104. In other embodiments, the beads of sealant 302 and 304 are applied to sheets 102 and 104, and spacer 106 is then pressed into the beads.

In some embodiments, Senators 302 and 304 are formed of a material having adhesive properties, so Senators 302 and 304 act to attach spacer 106 to sheets 102 and 104. Typically, sealant 302 and 304 is arranged to support spacer 106 in an orientation normal to interior surfaces 312 and 322 of sheets 102 and 104. The first sealant 302 and 304 also acts to seal the bond formed between the spacer 106 and the sheets 102 and 104 by inhibiting the intrusion of gas or liquid into the interior space 120. Examples of the first sealant 302 and 304 include polyisobutylene (PIB), butyl, GDP curable, silicon or hot melt, acrylic adhesive, acrylic sealant, and other Double Seal Equivalent (DCE) type materials.

The first sealant 302 and 304 is illustrated, as extending out of the edges of the spacer 106, so that the first sealant

302 and 304 contact surfaces 330 and 340 of the elongated strips

110 and 114. Such contact is not required in all modalities. However, the additional contact area between the first sealant 302 and 304 and the spacer 106 can be beneficial. For example, additional contact areas increase bond strength. The increased thickness of Senators 302 and 304 also improves the moisture and gas barrier. However, in some embodiments, the sealants 302 and 304 do not extend beyond the outer surfaces 330 and 340 of the spacer 106.

In some embodiments, the elongated strip portions 114 are connected to the elongated strip 110 without the filler 112 therebetween. For example, a portion of the elongated strip 114 may be connected to the elongated strip 110 with a fastener, such as an adhesive, solder, rivet, or other fastener.

FIG. 4 is a schematic front view of a portion of an illustrative embodiment of spacer 106. Spacer 106 includes elongated strip 110, side wall 124, and elongated strip 114. In this embodiment, elongated strips 110 and 114 have a wavy shape. In some embodiments, the elongates 110 and 114 are formed from a metal band, such as stainless, which is then folded into the corrugated shape. Steel strips of some possible forms of the wavy shape include sine, arc, square, rectangular, triangular, and other desired shapes. Some modalities of other matter is formed, and can be formed by other procedures, such as molding. It should be noted that although Figure 4 shows elongated strips 110 and 110 having similar undulations, it is contemplated that elongated strip 114 may have a wavy shape that is much larger than the wavy shape of elongated strip 110 and vice versa.

Another possible embodiment includes a flat elongated strip combined with any type of corrugated strip. Other combinations and arrangements are also possible.

One of the benefits of the corrugated shape is that it increases the flexibility of the elongated strips 110 and 114, which include bending and twisting flexibility. The corrugated shape resists permanent deformation, such as kinks and fractures. This allows the elongated strips 110 and 114 to be handled more easily during manufacturing without damaging the elongated strips 110 and 114. The corrugated shape also increases the structural stability of the elongated strips 110 and 114 to improve the ability of the separator

106 withstand compression and torsional loads. At 20 modalities of the elongated strips 110 and 114 they are also allowed to extend and contract, which is beneficial, for example, when the spacer 106 is formed around a corner. In some embodiments, the wavy shape reduces the need for notches or other stress relief.

In one example, the elongated strips 110 and 114 may have T7 material thicknesses. T7 is typically in a range from about 0.0002 cm to about 0.025 cm, and preferably from about 0.0007 cm to about 0.010 cm. Such a thin material thickness reduces material costs and reduces thermal conductivity through the elongated strips 110 and 114. The wavy shape of the elongated strips 110 and 114 defines a waveform that has a peak-to-peak amplitude and a peak-to-peak period. The peak-to-peak amplitude is also the total thickness T9 of the elongated strips 110 and

114. T9 is typically in a range from about 0.012 cm to about 0.2 cm, and preferably from about 0.05 cm to about 0.10 cm. P1 is the peak-to-peak period of the wavy elongated strips 110 and 114. P1 is typically in a range from about 0.012 cm to about 0.2 cm, and preferably from about 0.05 cm to about 0.10 cm. As described with reference to Figure 7, larger waveforms are used in other modalities. Even other modalities include other dimensions.

Figures 5-7 illustrate an illustrative embodiment of the separator.

106 wherein the continuous side walls 124 and 126 are disposed at the edges of the elongated strips 110 and 114. Figure 5 is a schematic perspective view of the illustrative spacer 106. The

Figure 6 is a cross sectional view of the separator ilus 25 106 shown in Figure 5. Figure 7 is a schematic ateral rative view of the illustrative separator 106 shown in Figure 5. The separator 106 includes elongated strips 110 and 114 separated by walls. Side walls 124 and 126. In this example, side walls 124 and 126 are continuous along the length of spacer 106.

Side walls 124 and 126 provide a uniform or substantially uniform space between elongated strips 110 and 114.

Some modalities of the separator 106 are made in accordance with the following procedure. The elongated strips 110 and 114 are typically formed first. The elongated strips 110 and 114 are made of a material, such as metal, that forms into a long, thin band (or multiple bands), such as by taping the band from a larger sheet. The thin, long band is then formed to include the wavy shape, if desired. The long thin band can also be punched or drilled to form openings

116 on the elongated strip 110, if desired. This is done, for example, by passing the thin, long strip between a pair of corrugated rollers. The teeth of the roller fold the belt into a wavy shape. Different corrugated shapes in different modalities are possible when using rollers having roughly formed teeth. Illustrative tooth shapes include sinusoidal teeth, triangular teeth, semicircular teeth, square (or rectangular) teeth, teeth formed as saw teeth, or other desired shapes. Elongated strips that have a wavy pattern are used in some embodiments, in which case thin, long bands typically do not require additional information. The elongated strips 110 and 114 may alternatively be formed by other procedures, such as by molding or extrusion.

In some embodiments, the elongated strips 110 and 114 are cut to a desired length while fixed in the long, thin band shape and before forming the wavy shape. In other embodiments, the elongated strips are cut after forming the wavy shape. Another possible embodiment is to form long and substantially continuous spacers 106 which are cut to length after forming the spacer 106 which includes elongated strips 110 and 114 as well as side walls 124 and 126. In some embodiments, spacer 106 is formed to be of sufficient length to span the entire perimeter of a window. In other embodiments, spacer 106 is formed to be of sufficient length for an individual side or portion of a window.

After the elongated strips 110 and 114 are formed, the side walls 124 and 126 are formed between the elongated strips 110 and 114. In one possible embodiment, the elongated strips 110 and 114 pass through a guide that orients the elongated strips 110 and 114 in a parallel arrangement and separated by a desired distance. An extrusion die is arranged near the guide and between the elongated strips 110 and 114. As the elongated strips 110 and 114 pass through the guide, a side wall material is extruded into the space between the elongated strips 110 and 114, as shown in Figure 5. Extrusion typically involves heating the material side wall and use a hydraulic dam to push the side wall material through the extrusion die. In this example, continuous side walls 124 and 126 are formed at each end of elongated strips 110 and 114. The guide presses the extruded side walls 124 and 126 against the interior surfaces of the elongated strips 110 and 114, so that the side walls 124 and 126 conform to the corrugated shape and adhere to the elongated strips 110 and 114.

In another possible embodiment, the side walls 124 and 126 are extruded into the space between the elongated strips 110 and 114, while the elongated strips are kept stationary on a guide or template that acts to maintain proper alignment and space of the elongated strips. 110 and 114 while the side walls 124 and 126 are inserted there. For example, a robotic arm is used to guide an extrusion die along the space between the elongated strips 110 and 114. The robotic arm moves the extrusion die to the position of the extruded side walls 124 and 126 within the elongated strips 110 and 114 that remain stationary during the procedure. In some embodiments, extruded side walls 124 and 126 are formed in separate steps. In other embodiments, extruded side walls 124 and 126 are simultaneously formed, such as when using two extrusion dies.

In another possible embodiment, the side walls 124 and '26 are formed by passing the side wall material through a series of rollers, to roll the side walls into a desired shape. The roll formed side walls are then inserted between the elongated strips 110 and 114. In some embodiments, the side wall material is heated and pressed against the elongated strips 110 and 114 to form and bond the side walls 124 and 126 to the elongated strips 110 and 114. In other embodiments, an adhesive is used to bond the walls sides 124 and 126 to the elongated strips 110 and 114.

In another possible embodiment, the side walls 124 and 126 are formed by molding. After molding, the side walls 124 and 126 are inserted into the space between the elongated strips. In some embodiments, a fastener, such as adhesive, is used to attach the side walls 124 and 126 to the elongated strips 110 and 114. In another possible embodiment, the side wall portions 124 and

126 they are fused and pressed against the elongated strips 110 and 114 to hold the corrugated formed surface.

In some embodiments, the side walls 124 and 126 are rigid. When rigid side walls are coupled with elongated strips 110 and 114, the resulting spacer also becomes rigid because side walls 124 and 126 act to prevent bending of elongated strips 110 and 114. However, other embodiments include walls sides 124 and 126 that are formed of a material that has an elastic flexibility of plastic, so that the spacer 106 is flexible.

Although two side walls are illustrated in this example, other embodiments include one or more side walls (eg 3, 4, 5, etc.). Furthermore, the side walls need not be located on the sides of the spacer 106. For example, one or more additional side walls are included at or approximately the center of the spacer 106 in some embodiments.

Additional features are formed in spacers 106 in some embodiments. An example of an additional feature is a slatted bar hole for mounting a slatted bar. Strip bar benefits can be formed on spacer 106 or elongated strip 116 either during formation of elongated strip 116 or spacer 106, or after formation of spacer 106.

In some embodiments, spacer 106 is connected to one or more sheets 102 and / or 104, as shown in Figure 1.

The spacer 106 can be connected to the sheet 102 during or after the manufacturing processes of the spacer 106 discussed above. One or more senators and / or adhesive materials are used in some embodiments to attach spacer 106 to one or more sheet 102 and / or 104.

Figure 6 is a cross-sectional view of the illustrative spacer 106 shown in Figure 5. Spacer 106 includes an elongated strip 110, elongated strip 114, side wall 124, and ateral wall 126. Elongated strip 110 includes external surface 340 and inner surface 342. Elongated strip 114 includes outer surface 330 and inner surface 332. In the illustrative embodiment shown in Figure 6, the side walls 124 and 126 are aligned with or substantially aligned with the edges of the elongated strips 110 and 114.

Illustrative dimensions are now described with reference to Figure 6 for an illustrative embodiment as shown, but other embodiments include other dimensions. In one example, W1 is the total width of the spacer 106. W1 is typically from about 0.2 cm to about 5.08, preferably from about 0.7 cm to about 2.54 cm. T1 is the total thickness of the spacer from outer surface 330 to outer surface 340. Typical T1 is in a range from about 0.05 cm to about 2.54 cm, and preferably from about cm range, and even from mind to mind

0.2 cm to approximately 1.27 cm. T2 is the distance between the elongated strip 110 and the elongated strip 114, and more specifically the distance from the inner surface 332 to the inner surface 342.

T2 is also the height of the side walls 124 and 126, which maintain the space between the elongated strips 110 and 114. T2 is the range from about 0.05 cm to about 1.27 20 cm, and preferably from about 0.12 cm to about 0.38 cm. In some embodiments, the elongated strips 110 and 114 and the filler 112 are non-linear, thereby having a wavy shape described below. In some of these modalities, T2 is an average thickness. G is the thickness of the side walls 110 and 114. G is typically in a range from about 0.02 cm to about 1.27 cm, and preferably from about 0.2 cm to about 0.7 cm. Other modalities include other dimensions than those discussed in this example.

Figure 7 is a schematic side view of the illustrative spacer 106 shown in Figure 5. The spacer 106 includes

elongated strips 110 and 114 and side wall 124. This side view illustrates the wavy shape of illustrative elongated strips 110 and 114. Additional details regarding the wavy shape are described herein with reference to Figure 4. In this example, the edges of side wall 124 have a wavy shape that mates with the wavy shape of elongated strips 110 and 114.

Figures 8-10 illustrate an illustrative embodiment of the spacer 106 where the continuous side walls are arranged.

124 and 126 at intermediate positions between the edges of the elongated strips 110 and 114. Figure 8 is a schematic perspective view of the illustrative spacer 106. Figure 9 is a cross-sectional view of the illustrative spacer 106 shown in Figure 8. Figure 10 is a schematic side view of the illustrative spacer 106 shown in Figure 8. The spacer 106 includes elongated strips 110 and 114 separated by side walls 124 and 126. In this example, the side walls 124 and 126 are continuous along the length of the gap 106. The side walls 124 and 126 provide a uniform or substantially uniform gap between the elongated strips 110 and 114.

In the illustrative embodiment of the spacer 106, shown in Figures 8-10, the side walls 124 and 126 are adjusted from the edges of the desired strips 110 and 114. The adjustment is illustrated in Figure 9 by the adjustment distance S. In one example, the adjusted distance S is typically in a range from about 0.02 cm to about 1.27 cm, and preferably from about 0.2 cm to about 0.7 cm. Other illustrative dimensions shown in Figure 9 are described in more detail here, such as with reference to Figures 3 and 6.

In some embodiments, the adjustment of the side walls 124 and 126 provides additional structural stability toward the center of the elongated strips 110 and 114, such as to increase the resistance of the space or 106 two that tilt or curl under load. In other embodiments, the trim also provides a space for adhesive, senators, or other materials. For example, a gap is defined between the edges of the elongated strips 110 and 114 and adjacent to the fitted side wall 124. A bead of sealant is applied to this gap in some embodiments. The sheet of clear material is then applied to the bead to connect and seal the edges of spacer 106 to the sheet of clear material. The sealant is also applied to a space formed between the fitted side wall 126 in some embodiments, which is then used to connect and seal the edge of the spacer 106 to another sheet of transparent material.

Figures 11-15 illustrate another illustrative embodiment of the spacer 106 that includes divided side walls. Figure 11 is a schematic perspective view of the illustrative spacer 106 arranged in an assembled configuration. Figure 12 is a schematic perspective view of the illustrative spacer 106 shown in Figure 11 arranged in an unassembled configuration. Figure 13 is another schematic perspective view of the illustrative spacer 106 shown in Figure 11 arranged in an unassembled configuration. Figure 14 is a cross-sectional view of the illustrative spacer 106 shown in

Figure 11 arranged in an assembled configuration. Figure 15 is a side view of the illustrative spacer 106 shown in Figure 11 arranged in an assembled configuration.

Spacer 106 includes elongated strips 110 and 114 and side walls 124 and 126. In some embodiments of the elongated strips

110 they include openings to allow moisture to pass through the elongated strip 110. Filler 112, such as including a desiccant, is included within spacer 106 in some embodiments, but is not shown here. Some modes do not include padding 112.

In this example, the side walls 124 and 126 are located in an intermediate position between the edges of the elongated strips 110 and 114, but in other embodiments, the side walls 124 and 126 are aligned with the edges of the elongated strips 110 and 114.

Spacer 106 also includes side walls 124 'and 126.

Illustrative spacer 106 shown in Figures 11-13 includes non-continuous side walls 124 and 126, which include a plurality of separate side wall portions. However, other modalities include continuous sidewalls without spying. In some embodiments, the space between the side wall portions allows the spacer 106 to utilize the flexibility of the elongated strips 110 and 114 and provides space for the spacer 106 to bend. As a result, spacer 106 can be bent to form a corner (such as a 90 ° corner).

Side wall 124 includes a first portion 801, second portion 803, and an illustrative clamping mechanism. A particular example of a clamping mechanism includes a spindle and a notched portion. However, it is recognized that a variety of other restraint mechanisms are used in other modalities. Some alternate examples of the clamping mechanism are described here. The first portion 801 includes a spindle 802 as part of the clamping mechanism, alternatively referred to as a protrusion, and is connected to the elongated strip 114. The second portion 803 includes a notched portion 804 as a proportion of the clamping mechanism, and is connects to the elongated strip 110. The first and second portions 801 and 803 can engage with each other by using the clamping mechanism to form the side wall 124. In some embodiments, the first and second portions 801 and 803 can also be separated from each other to separate the elongated strip 110 from the elongated strip 114.

Side wall 126 includes a first portion 805 and a second portion 807. First portion 805 includes a spindle 806, alternatively referred to as a boss, and is connected to elongated strip 114. Second portion 807 includes a notched portion 808, and is connected to the elongated strip 110. The first and second portions 805 and 807 can be coupled together to form the side wall 126. In some embodiments, the first and second portions 805 and 807 can also be separated from each other to separate the elongated strip 110 from the elongated strip 114.

During manufacturing, the first portions 801 and 805 are secured to the elongated strip 114 and the second portions 803 and

807 are secured to the elongated strip 110. In some embodiments, the first and second portions 801, 805, 803, and 807 are formed using an extrusion process, which forms the first and second portions 801, 805, 803, and 807 in the respective elongated strips 114 and 110. The first portions 801 and 805 are extruded individually in some embodiments, but are extruded simultaneously in other embodiments. Similarly, second portions 803 and 807 are extruded individually in some embodiments, but are extruded simultaneously in other embodiments.

Instead of directly extruding the elongated strips 110 and 114, some embodiments pre-form the first and second portions 801, 805, 803, and 807 and subsequently adhere to or fasten the elongated strips 114 and 110. Alternatively, a portion of the first and second portions prefabricated in some embodiments and then pressed into the respective elongated strip 114 or 110.

Once the spindles 804 are attached to the elongated strip 110 and the notch portion 802 of the plurality of side walls 124 and 126, the elongated strips 110 and 114 can be secured. In one embodiment, a manufacturer can press the elongated strips 110 and 114 together. In other embodiments, a machine can be used to press the elongated strips 110 and 114 together.

In some embodiments, when spindle 804 is disconnected from side walls 124 and 126, spacer 106 is flexible. Then, once spindle 804 is connected to side walls 124 and 126, spacer 106 locks in place and becomes substantially rigid. In this way, the spacer 106 can be easily manipulated into a desired configuration and once there, it is connected to secure the spacer 106 in the desired configuration.

Illustrative dimensions of spacer 106 are shown in Figure 14. In another example, W1 is the total width of spacer 106 and the distance between sheets 102 and 104. W1 is typically in a range from about 0.2 cm to about 5.08 cm, and preferably from about 0.7 cm to about 2.54 cm. In one example, T1 is the total thickness of spacer 106 from outer surface 330 to outer surface 340. T1 is typically in a range from about 0.05 cm to about 2.54 cm, and preferably from about 0.2 cm to about 1.27 cm. T2 is the distance between the wing strip 110 and the elongated strip 114, and more specifically the distance to riga from others the inner surface 332 to the inner surface 342. In other words, T2 is the height of the side walls 124 and 126. T2 it is in a range from about 0.05 cm to about

1.27 cm, and preferably from about 0.12 cm to about 0.38 cm. In some embodiments, the elongates 110 and 114 are not linear, such as having an undulation described below. Therefore, in some of even strips it forms these modalities, T2 is an average thickness. G is the thickness of the side walls 124 and 126. G is typically in a range from about 0.02 cm to about 1.27 cm, and preferably from about 0.2 cm to about 0.7 cm. Other modalities include dimensions.

In Figure 14, the side walls 124 and 126 to each other are adjusted from the edges of the elongated strips 110 and 114. The adjusted distance S, typically is in a range from about 0.02 cm to about 1.27 cm, and preferably from about 0.2 cm to about 0.7 cm. However, other embodiments include side walls 124 and 126 that are aligned or substantially aligned with the edges of the elongated strips 110 and 114.

Some embodiments of spacer 106 include side walls 124 and 126 that are divided into the first and second portions. As shown in Figure 14, the first portions 801 and 805 can have a height M and the second portions 803 and 807 have a height N. The height N does not include the height of the spindle 806, as shown in Figure 13. The sum of M and N is equal to height T1.

Figure 15 shows a side view of the spacer 106 shown in Figure 11 including a non-continuous side wall 124, including a plurality of spaced apart ateral wall portions 1502 and 1504. Additional side wall portions are not visible in Figure 15 Y is the space between the adjacent lateral wall portions, such as the ateral wall portion

1502 and the side wall portion 1504. The space Y is typically in a range from about 0.002 cm to about 1.27 cm and preferably from about 0.02 cm to about 0.12 cm. J is the width of the side wall portions 1502 and 1504. The width J is typically in a range from about 0.02 cm to about 2.54 cm, and preferably from about 0.12 cm to about 0.7 cm.

Figure 16 is a schematic cross-sectional view of another possible embodiment of window assembly 100. Window assembly 100 includes sheet 102, sheet 104, and illustrative spacer 106. Spacer 106 includes elongated strip 110, elongated strip 114 , side walls 124 and 126, the first sealant 302 and 304, and second sealant 402 and 404. In this embodiment, the spacer 106 further includes the opening of the bra 1002, bra 1004, and intermediate member 1006. In some embodiments, separator 106 includes fillers 112.

Some embodiments include an intermediate member 106 that is connected to the spacer 106. In one embodiment, the intermediate member 1006 is a sheet of glass or plastic, which is included to form a three panel window. In another embodiment, the intermediate member is a film or plate. For example, intermediate member 1006 is a film or plate of material that absorbs at least some of the solar ultraviolet radiation as it passes through window 100, thereby heating interior space 120. In another embodiment, the member Intermediate 1006 reflects ultraviolet radiation, thereby cooling the upper space 120 and preventing some or all of the ultraviolet radiation from passing through the window. In some modalities, the intermediary member

1006 divide interior space into two or more regions. My intermediary embro 1006 is a Myiar movie in some forms. In other embodiments, the intermediate member 1006 is a slatted. Intermediate member 1006 acts, in modalities, to provide additional support to the separate. A benefit of some modalities is that the vision of the mi barra gunas r 106.

Intermediate embro 1006 does not require additional 106 spacers or sealants.

The connection of the intermediate member 1006 to the separator 106 can be carried out in several ways. One is to drill or cut openings 1002 in elongated strip 110 of spacer 106 at the desired location (s). In some embodiments, openings 1002 are arranged as grooves and the like. A fastener 1002 is then inserted into the opening and the elongated strip 110 connected. An example of a fastener is a screw. Another example is a bolt. Openings 1002 are not required in all modes. In some embodiments, bra 1004 is an adhesive that does not require openings 1002. Other embodiments include a bra 1004 and an adhesive. Some fasteners 1004 are also arranged to connect to an intermediate member 1006 ', to connect the intermediate member 1006 to the spacer 106. An example of fastener 1004 is a barbell strip fastener.

Figures 17-20 illustrate another illustrative embodiment of spacer 106. Figure 17 is a perspective view of illustrative spacer 106 arranged in an unassembled configuration. Figure 18 is another perspective view of the illustrative spacer 106 shown in Figure 17 arranged in an unassembled configuration. FIG. 19 is a cross-sectional view of the illustrative spacer 106 shown in FIG. 17 arranged in an unassembled configuration. Figure 20 is a side view of the illustrative spacer 106 shown in Figure 17 arranged in an unassembled configuration.

The separator 106 includes elongated strips 110 and 114 and side walls 124 and 126. In some embodiments, the elongated strip 110 includes opening 116, to allow moisture to pass through the elongated strip 110. In this embodiment, the separator 106 includes Non-continuous side walls 124 and 126, including a plurality of side wall portions. Side walls 124 and 126 provide a uniform or substantially uniform space between elongated strips 110 and 114.

In this example, each portion of the side walls 124 and

126 Includes a retaining mechanism that includes a pair of hooks

1702 and 1704. Hooks 1702 and 1704 are configured so that hook 1702 can engage with hook 1704. When disengaged, the first portions 801 and 805 can be separated from the second portions 803 and 807. Hooks 1702 and 1704 are rare. they are configured to engage by arranging the first and second portions 801 and 803 and the first and second portions 807 as shown in Figure 17, and then pressing them

805 and together (such as by applying force to elongated strips 110 and 114) to cause hooks 1702 and 1704 to close together. In some modalities, the hooks 1702 and 1704 are closed by using a closing mechanism. Similarly, a locking mechanism can also be used to disengage hooks 1702 and 1704 in some embodiments.

Figure 19 is a cross sectional view of the separator

106 shown in Figure 17. In Figure 19 the side walls

124 and 126 are adjusted from the edges of the elongated sheets 110 and 114, which have an adjusted distance S. In other embodiments, the side walls 124 and 126 are aligned with the edges of the elongated strips 110 and 114. Q is the height of the first portions 801 and 805. P is the height of the second portions 803 and 807.

Figure 20 is a side view of illustrative spacer 106 shown in Figure 17. Spacer 106 includes side wall portion 2002 and side wall portion 2004. Additional side wall portions are not visible in Figure 20. AND is the distance in a space between the adjacent side wall portions 2002 and 2004. J is the width of the side wall portions 2002 and 2004. Examples of Y, and J are discussed here. It should be noted that although Figures 17-20 show the side walls

124 and 126 as being segmented into a plurality of side wall portions, some embodiments include continuous side walls. In other modes, in some modes, Y equals zero.

The elongated strips 110 and 114 can be made from various materials including, but not limited to, metals, plastics, and ceramics. In addition, elongated strips 110 and 114 can be manufactured through various methods including, but not limited to, roll forming, extrusion, molding, stamping, or a combination of these.

Figures 21-22 illustrate another illustrative embodiment of the spacer 106. Figure 21 is a schematic perspective view of the illustrative spacer 106. Figure 22 is a schematic cross-sectional view of the illustrative spacer shown in

Figure 21. As discussed above, spacer 106 includes elongated strips 110, elongated strip 114, side wall 124, and side wall 126. Side walls 124 and 126 include first portions 801 and 803 and second portions 805 and 807.

In this embodiment, the elongated strip 110, the first portion 803, and the second portion 805 form a continuous piece. The elongated strip

114, the first portion 801, the second portion 807 also form a continuous piece. In other embodiments, the elongated strips 110 and 114 are formed separately from the side walls 124 and 126. For example, the elongated strips 110 and 114 are formed first, such as by folding long, thin strips of material into a corrugated shape. The side walls 110 and 114 are then formed by extruding the side walls into the elongated strips 110 and 114. Alternatively, a fastener, such as adhesive, is used to connect the side walls 124 and 126 for the elongated strips 110 and 114.

The first portions 801 and 803 of the side walls 124 and 126 include a depressed region 2102 at one end. The second portions 805 and 807 include a protrusion 21oL. The protrusions 2104 are configured to engage with the depressed regions 2102 to connect the first portions 25 803 with the second portions 805 and 807.

801 and

As described above, the side walls 124 and 126 are located along the edges of the elongated strips 110 and 114 in some embodiments, and are adjusted by a distance S from the edges of the elongated strips in other embodiments. Furthermore, the spacer 106 shown in Figures 21 and 22 may have dimensions W1 *, T2, and G similar to those described above with respect to Figure 14. Other embodiments include other dimensions.

In some modalities, as shown in Figures 21 and

22, the first portions 2102 of the elongated strips 110 and 114 include depressed regions 2102 in the form of grooves. The second portions 2104 of the elongated strips 110 and 114 include protrusions 2104 in the form of tabs 2106. The depressed regions 2102 are formed to fit with the protrusions 2104 to form an assembled spacer 106. In some embodiments, the depressed regions 2102 have a slightly smaller width than the protrusions 2104 so that when the protrusions 2104 are pressed into the gaps 2102, the friction holds the pieces together. In other embodiments, protrusions 2206 and 2208 have pins 2210 (shown in Figure 22) that engage receiver 2212 to hold elongated strips 110 and 114 together.

In some embodiments, a locking mechanism is used to connect the first portion 2102 to the second portion 2104.

In some embodiments, the closure is also used to disconnect the first portion 2102 from the second portion 2104.

The elongated strips 110 and 114 are made of possible materials including, but not limited to, metals, plastics, and ceramics. Furthermore, elongated strips 110 and 114 are manufactured through various possible methods including, but not limited to, casting, and extrusion.

Figure 23 illustrates another illustrative embodiment of spacer 106. Figure 23 is a cross sectional view of spacer 106 including elongated strip 110, elongated strip 114, ateral wall

112, and side wall 126. Side walls 124 and 126 include first portions 2302 and second portions 2304. Side walls 124 and 126.

The first portions 2302 of the side walls 124 and 126 include the depressed portions 2306. The second portions

2304 side walls 124 and 126 include protrusions

2308. In this example, depressed portions 2306 are in the form of grooves. The protrusions 2308 are in the form of tabs. The protrusions 2308 are configured to engage the depressed portion 2306. Some embodiments are configured to fit together. Once connected, spacer 106 remains connected due to friction or an additional fastener, such as adhesive or sealant.

In this embodiment, the elongated strip 110 and the second portions 2304 are formed from a continuous piece of material.

Similarly, the elongated strip 114 and the first portions 2302 are formed from a continuous piece of material. In some embodiments, separator 106 is formed of long, thin strips of material that are bent, such as by roll forming, in the configuration shown. Other modalities are made by procedures such as extrusion or casting.

Figure 24 illustrates another embodiment of an illustrative spacer 106. Figure 24 is a cross sectional view of spacer 106 including elongated strip 110, elongated strip 114, side wall 124, and side wall 126. Side walls 124 and 126 include the first 2402 portions and the second 2404 portions.

The first portions 2402 of the side walls 124 and 126 include depressed portions 2406. The second portions 2404 of the side walls 124 and 126 include protrusions 2408. In this example, the depressed portions 2406 are in the form of grooves extending longitudinally to along one end of first portions 2402. Protrusions 2408 are in the form of tongues that extend longitudinally along second portions 2404. The protrusions 2408 are configured to mate with the depressed portions 2406.

Some modes are configured to fit together. Once connected, separator 106 remains connected due to friction. In another embodiment, an additional fastener, such as adhesive or sealant, is used to connect the first and second portions of the spacer 106.

In this embodiment, the elongated strip 110 and the first portions 2402 are formed from a continuous piece of material. Similarly, the elongated strip 114 and the second portions 2302 are formed from a continuous piece of material. In some embodiments, separator 106 is formed of long, thin strips of material that are folded, such as by roll forming, in the configuration shown. Other modalities are made by procedures such as extrusion or casting.

Figure 25 is a cross-sectional view of another illustrative spacer 106 including elongated strip 110, elongated strip 114, side wall 124, and side wall 126. In this embodiment, side walls 124 and 126 include first portions 2502 and the second portions 2504. The first portion

2502 includes depressed region 2506. The second portion

2504 includes depressed region 2508. In some embodiments, depressed region 2508 is in the form of a slot. In some embodiments, protrusion 2506 is in the form of a tongue. Other embodiments include a plurality of grooves and a plurality of tabs. Other possible embodiments include a plurality of teeth and a plurality of separate depressions configured to receive the teeth there.

The elongated strips 110 and 114 can be made of materials that include, but are not limited to, metals and plastics. In addition, the elongated strips 110 and 114 may be manufactured through methods that include, but are not limited to, roll forming, bending, and extrusion. The first portions 2502 include the protrusions 2506 that are directly formed on the elongated strip 114 in some embodiments. Second portions 2504 are made, for example, by extruding a material in elongated strip 110. Depressed region 2508 is formed in some ways through the extrusion process. In other embodiments, depressed region 2508 is formed by cutting, drilling, routing, or grinding a groove on one face at one end of second portion 2504. Second portion 2504 is made of a mater such as metal, plastic, ceramics, or combinations of such materials. In some embodiments, first portion 2504 is attached to elongated sheet 110 by one or more fastening methods, such as thermal bonding, ultrasonic welding, adhesive, or the use of another fastener.

Figure 26 is a cross-sectional view of another illustrative spacer 106 including elongated strip 110, elongated strip 114, side wall 124, and side wall 126. In this embodiment, elongated strip 114 includes depressed regions 2602 in the form of parallel grooves. Side walls 124 and 126 include protrusions 2604 that extend outside the ends of side walls 124 and 126. In this embodiment, protrusions 2604 are in the form of tabs. Protrusions 2604 are configured to engage depressed regions 2602.

Figure 27 is a front view of an illustrative spacer

106 and an illustrative corner 2702. Some embodiments of spacer 106 are not flexible. In such embodiments, spacer 106 can be connected to a corner fastener, such as a corner wrench 2702.

Spacer 106 includes an elongated strip 110, side wall

502, and elongated strip 114. In this embodiment, the elongated strips 110 and 114 have a wavy shape. As shown, the corner wrench 2702 is used to form the corner. Some embodiments of spacer 106 may be arranged to form a corner without corner key 2702. In these embodiments, side wall 502 is made of a material that is capable of bending and flexing without twisting or breaking.

The elongated strips 110 and 114 include a wavy shape. As a result, the elongated strips 110 and 114 are arranged to expand and compress as necessary. In embodiments employing continuous side walls 124 and 126, to achieve the bending flexibility necessary to form curves, continuous side walls 124 and 126 can be constructed of a flexible material that allows spacer 106 to bend. In other embodiments that employ continuous side walls 124 and 126, the material used to make continuous side walls 124 and 126 can be heated to soften material J which consequently makes it collapsible. Even in other embodiments that employ continuous side walls 124 and 126, curves can be formed as long as the material is in a collapsible form. The material can then be allowed to settle and / or cure to form a semi-flexible lip or corner. Even in other embodiments employing continuous side walls 124 and 126, curves can be formed by cutting the continuous strips of spacer 106 to form the corners. For example, a continuous strip of spacer 106 can be cut along the 45 ° angles to form the joined corners at right angles.

In embodiments employing the plurality of side walls 124 and 126, to achieve the bending flexibility necessary to form corners, portions J and the plurality of side walls 124 and 126 can be removed to form a corner. For example, in Figure 11, portions of side wall 124 (124a and 124b, and 124c) and side wall 126 (removed portions not shown) can be removed from elongated strip 114. With portions 124a, 124b, and 124c removed, elongated strip 114 can be folded to form a corner. Once the elongated strip 114 is bent, the elongated strip 110 can be secured through spindle 804. In one embodiment, spindle 804 may have protrusions that contact notch 802 so that spindle 804 does not move within notch 802 which consequently forms a corner with edges. In other embodiments, spindle 804 can be allowed to move within notch 802 so that spacer 106 can be bent to form a corner or other nonlinear shape.

Although the present description refers to window assemblies and window dividers, some modalities are used for other purposes. For example, another possible embodiment in accordance with the present description is a separator for a sealed unit.

The various embodiments described above are provided by way of illustration only and should not be construed to limit the claims appended hereto.

Those skilled in the art will readily recognize the few modifications and changes that can be made without following the illustrative modalities and the applications illustrated and described herein, and without departing from the intended scope of the following claims.