ENCAPSULATED GLAZING STRUCTURE

Technical Field This invention relates to window assemblies and, more particularly, to an encapsulated glazing structure comprising at least one pane of transparent material and a frame molded to encapsulate the peripheral edge portion of the pane.

Background Art

Energy efficient window assemblies have become increasingly more important and necessary. Typically, the requirement for such window assemblies is a function of fuel costs. Heretofore, fuel costs were not regarded as being significant and, therefore, residential and commercial buildings could be designed and constructed with low thermal efficient glazing structures. However, the advent of higher fuel costs dictated glazing structures, as well as other building components, which exhibited higher thermal efficiencies.

Many attempts have been made to develop window frames formed of plastic materials, such as polyesters, polyvinyl chlorides. The structural components of such frames were typically formed by extrusion processes, or injection molding processes and, thence remotely assembled with an appropriate glazing material such as panes of glass and associated hardware.

The plastic materials could contain coloring substances as an integral part thereof, and therefore the resultant glazing structures would have the advantage of requiring less maintenance, in respect of painting, and could be cleaned with minimal effort. Also, the structures were more thermally efficient when compared to similar structures formed of metal framing components due to a reduction in the thermal _t conductivity .

While there were certain advantages which resided in these glazing structures utilizing the plastic

framing components, the cost of fabricating the complete glazing structure was expensive. The expense resulted from increased material and labor costs. However, the marketplace has accepted such increased product cost on the basis that such cost will be recaptured in reduced fuel costs from both heating and cooling standpoints.

The next really major advancement in the field of glazing for residential and commercial buildings was manifested in the development of a glazing component having an integral frame of plastic material completely surrounding the peripheral edges thereof and applied by the reaction injection molding process typically utilizing polyurethane plastic material. This product has been considered to be a major advancement and one that retains all of the benefits of the previous designs and simultaneously overcomes the disadvantages .

The present invention is deemed to be an improvement of the last mentioned structure.

Disclosure of the Invention

An object of the present invention is to produce an encapsulated glazing structure having an in situ molded encapsulating frame formed with a subs antially hollow interior. Another object of the invention is to produce subs antially hollow encapsulating frame molded to the peripheral edge portion of a glazing material, such as glass for example, having an integral sealing member extending laterally outward therefrom to maintain sealing contact with the static portion of an associated opening.

The above object, as well as others, may be typically achieved by an encapsulated glazing structure comprising at least one pane of optically transparent material; and a frame molded to encapsulate the peripheral edge portion of the pane, the frame including a main hollow body portion and a

sealing means coupled thereto and extending outwardly therefrom.

Brief Description of the Drawings In the accompanying drawings:

Figure 1 is a perspective view of an encapsulated glazing structure incorporating the features of the invention with portions broken away to more clearly illustrate portions thereof; Figure 2 is a sectional view of the structure illustrated in Figure 1 taken along line 2-2 thereof;

Figure 3 is a cross - sectional view of a structure similar to that shown in Figure 2 directed to modified form thereof; Figure 4 is a cross -sectional view of a structure similar to that illustrated in Figure 2 and 3 showing another modification of the invention .as applied to a casement type window assembly;

Figure 5 is a cross - sectional view of the structure illustrated in Figure 4 showing the vertically extending side stile elements; and

Figure 6 is a cross - sectional view of the structure illustrated in Figures 4 and 5 showing a latching mechanism molded as an integral part of the lower horizontally extending sill element of the encapsulated frame.

Statement of the Invention

In accordance with the present invention, there is provided an encapsulated glazing structure comprising: a main body of glazing material, and an encapsulating frame molded in situ to the peripheral edge portions of said main body; characterized in that said frame includes a hollow interior body portion defined by a pair of spaced apart substantially parallel walls extending laterally outwardly of said main body of glazing material, and a closure strip formed integrally with the hollow body portion and extending

outwardly therefrom and adapted when folded to close the hollow interior body portion.

Modes for Carrying Out the Invention Referring to Figures 1 and 2 wherein like reference numerals refer to the same parts, there is illustrated an insulated glazing structure including a pair of spaced apart panes or sheets 10 and 12 of glass, for example. The sheets 10 and 12 are typically maintained in spaced relation by an elongate spacer strip 14. The spacer strip 14 is adapted to form a continuous band around the marginal edges of the facing surfaces of the sheets 10 and 12 to effectively form a dead air space 16 between the facing surfaces of the sheets 10 and 12. The entire assembly is framed by a formed frame member 18, typically formed of a polymeric material which is polymerized and cured in situ to encapsulate the marginal peripheral edge portions of the assemblage.

The frame member 18 is formed by a reaction injection molding process. The spacer strip 14 may be any flexible, yet rigid material, such as corrugated aluminum, for example. A desiccant containing material 20 is disposed on the inner surface of the strip 14. The material 20 is formed of an extruded butyl based mastic containing a powdered molecular sieve desiccant dispersed throughout. The combination of mastic and desiccant employed should possess the following properties: the resultant combination should be chemically compatible with the other components of the invention; should have the ability to adhere to the sheet, frame, and spacer strip materials; should function to assist in the formation and maintenance of a hermetic seal; should be stable over a wide range of application conditions; and should have the capacity to prevent condensation formation in the associated hermetically sealed area. A product is presently available commercially from Tremco , Inc. , Cleveland, Ohio, U.S.A. and sold under the trademark "Swiggle Strip".

Projecting laterally outwardly from the marginal edges of the sheets 10 and 12, and forming an integral portion of frame 18, is a hollow box-like portion thereof adapted to extend completely around the edge portions of the sheets 10 and 12. The hollow interior portion 26 of the frame 18 is defined by the inner wall 22 and a spaced apart outer wall 24. The hollow interior portion is further defined by a closure strip 28. One of the longitudinally extending edges of the closure strip 28 is coupled to the outermost edge of the inner wall 22 by a living hinge 30.

Sealing means in the form of longitudinally extending ribs 32 and 34 are formed to extend in laterally opposed directions to the outer surfaces of the inner and outer walls 22 and 24, respectively. The ribs 32 and 34 are typically coextensive with the walls 22 and 24, respectively.

Sealing means in the form of longitudinal ribs 36 are formed to extend outwardly from one surface of the closure strip 28.

The initial step in producing the insulated glazing structure, thus far described, involves the appropriate cleaning of the front and rear surfaces, and peripheral edges of the glass sheets 10 and 12 to prepare the surfaces for adherence with material to be employed for the frame member 18. The next step in producing the structure is the application of a primer coating to the previously cleaned glass surfaces. Satisfactory results can be achieved by initially employing a primer layer of a product such as "Betaseal, Glass Primer 43518 Commercial Grade" commercially available from Essex Chemical Company, Clifton, New Jersey, U.S.A. The glass bond area is initially wiped with the primer to form a layer which functions as a coupling agent. The primer material is a clear moisture- sensitive primer comprising gamma-aminopropyltriethoxysilane , which promotes adhesion between other Betaseal products and glass.

Following the above application of the primer layer, a second primer layer is applied over the first layer. The

second primer layer assists the rapid formation of a hydroly- tically stable bond between the glass and associated frame 18 of polyurethane , for example. The material comprising the second layer is a primer, such as for example, a blackout primer, which functions to prevent ultraviolet degradation of sealants and adhesives, or a primer to be used in conjunction with a frame 18 which may itself be a stable polyurethane. An example of the aforementioned blackout primer is commercially available under the description "Betaseal, Glass Primer 43520 Commercial Grade" from Essex Chemical Company.

Approximately twenty minutes after the superposed primer layers have been applied, the final assemblage may be commenced. This period of time is necessary to allow sufficient reaction and drying of the primers. The precise period of time required is dependent upon the particular primers used. Initially, the glass sheet 10 is placed in a die cavity of an associated mold. The spacer strip unit 14 is disposed, in continuous fashion, around the peripheral marginal edge portion ^' of the glass sheet 10. Then, the glass sheet 12 is disposed in superposed relation over and aligned with the sheet 10. The spacer strip unit 14 functions to space the facing surfaces of the glass sheets 10 and 12 from one another at a predetermined desired distance, as well as cooperate to define a dead air space 16. An associated mold element, having a mold cavity formed therein to cooperate with the aforementioned cavity, is then placed over the lower mold and locked in a closed position. A charge of polyurethane reaction mixture is injected into the mold cavity to form a completely encircling frame member 18. It is often desirable to apply a coating to the outer exposed surface of the frame 18 before the multiple glazed structure is installed in an opening in a building or the like. Such coating can be a urethane based paint, containing any desired decorative color producing component such as pigment, for example. A type of urethane based paint useful for such purpose is one manufactured by PPG Industries, Inc.,

Pittsburgh, Pennsylvania, U.S.A. under the designation Purethane 700 HSE-848, for example. The paint coating is then typically baked at approximately 140° - 150°F. for about 20-30 minutes. It must be understood that in addition to the decorative effect, the layer may function to protect the exposed polyurethane material forming the frame 18 from degradation which would otherwise be caused by exposure to ultraviolet radiation normally present in unfiltered sunlight. In the event the frame 18 is composed of an ultraviolet stable polyurethane material, the outermost layer may not be necessary, however it could be applied for decorative purposes.

The frame 18 of the structure, above described, functions to ensure the desired dead air space 16 between the facing surfaces of the glass sheets 10 and 12 and holds the peripheral edges of the glass sheets 10 and 12 in tightly compressed state against the spacer strip unit 14. Also, the frame 18 may be formed in any desired cross - sectional configuration to accommodate existing window framing members of the double hung variety, as well as any other framing configurations .

In order to impart lateral rigidity to the inner wall 22 and the outer wall 24, a plurality of spaced apart strengthening partition walls 40 may be formed. The walls 40 are designed to extend across the space 26 and thereby provide adequate reinforcement to assist in militating against the inner flexure of the associated walls 22 and 24. The above-described structure produces a frame structure which provides more value added features and cost reductions than can be associated with normal polyurethane window frame structures. More specifically, the improved structure reduces the amount of polymer necessary in forming of the frame,- eliminates the need for utilizing an interior core material about which the polymer is molded, incorporates an integral molding of a weather seal, and as will be explained

in greater detail hereinafter, enables hardware to be molded into the frame .

Figure 3 illustrates an embodiment of the invention similar to that illustrated in Figures 1 and 2. However, the thickness of the inner wall 22, the outer wall 24, and the closure strip 28 is increased to provide greater rigidity. Also, the sealing ribs 36 are of slightly different cross- sectional con iguration.

In Figures 4, 5, and 6 there are shown sections of an encapsulated glazing structure utilizing the features of the present invention in a casement-type window assembly. Figure 4, is a section taken through a header portion of a window opening and the associated upper horizontal frame member and associated glazing material. The header 50 is provided with an associated window opening defining member 56. It must be understood that the member 56 includes associated side stiles illustrated in Figure 5, and a horizontally disposed sill member illustrated _, in Figure 6, which extends In generally parallel spaced relation to the illustrated portion of the member 56.

The encapsulating frame 18 includes generally the same component features as the embodiment illustrated in Figures 1, 2, and 3. More specifically, the sheets of glass 10 and 12 are maintained in spaced relation by an elongate spacer strip 14 to form a dead air space 16 between the facing surfaces thereof. Projecting laterally outwardly for the marginal edges of the glass sheets 10 and 12, and forming an integral portion of the frame 18, Is a hollow box-like portion thereof adopted to extend completely around the edge portions of the glass sheets 10 and 12. The hollow interior of the frame 18 is defined by an inner wall 52, and an outer wall 54. A closure strip 58 is coupled to the outermost edge of the outer wall 54 by a living hinge 60. In the embodiment of the invention illustrated in Figures 4, 5, and 6, the closure strip 58 is adapted to extend coextensively with only the upper horizontally disposed portion of the

frame 18 and is suitably secured to the member 56 and the header 50 by spaced apart threaded fastenings 59, for example. It will be understood that other types of fastening means will likewise be employed to secure the strips 58 to the member 56.

Extending laterally outwardly from the main body of the frame 18 and within the hollow interior are spaced apart sealing ribs 62, the outermost distal ends of which are adapted to be in sealing contact with the inner wall surface of the closure strip 58 when the window assembly is in the closed position. When the window assembly is in a closed position, the terminal ends of the sealing ribs 62 are urged into snug sealing relation with the contacting inner facing surface of the closure strip 58 as illustrated in full lines in Figure 4. The dotted line illustration shows the assembly in an open position with the ends of the ribs 62 is an unflexed position, and showing the hinge 60 in open window assembly supporting position.

Figure 5 is a horizontal section taken through one side stile of the window defining member 56. The vertical elements of the member 56 are typically suitably secured within cooperating building framing members 50' which cooperate with the header 50 illustrated in Figure 4.

The sealing ribs 62 of the encapsulating frame 18 are adapted to be in sealing relation with an inwardly tapered surface 56' of the window defining member 56 such that as the window assembly is swung to a closed position, the terminal end positions of the sealing ribs 62 are placed under greater sealing flexure until the assembly is fully closed, thus establishing a properly sealed assembly.

Figure 6 is a vertical section taken through the horizontally disposed sill of the window defining member 56. The lower horizontal element of the member 56 is typically suitably secured within a building framing member 50" which cooperates with the other framing members 50 and 50' illustrated in Figures 4 and 5 to define a window opening.

Further, Figure 6 illustrates the employment of a latching mechanism which typically includes a vertically adjustable latch 66 slidably received within a latchway 68 formed in a portion 70 of the frame member 18 which extends inwardly from the outer surface of the Inner wall 52. The lowermost terminal end of the latch 66 is adjusted to be received within a slot 72 formed in the sill of the window defining member 56.

It will be seen that the vertically disposed side stile elements and the horizontally disposed lower sill element of the window defining member 56 is provided with a stepped portion at the inner terminus of the inwardly tapered surfaces 56' which functions as a finally sealing surface for the frame 18 of the encapsulated glazing structure to effectively come to rest against in a closed sealing relationship therewith. To ^' facilitate the sealing relationship, the terminal edge portions of the inner wall 52 may be provided with longitudinally extending sealing ribs 53. Manifestly, in order to be completely energy efficient, the sealing ribs 53 should be coextensive with the associated inner walls 52.

Accordingly, when the encapsulated glazing structure is moved to a closed position, ^* the sealing ribs 53 of- the inner walls 52 will contact the stepped portions of the stiles and sill member 56' and the latch 66 will index with the slot 72. Thence, the latch 66 is caused to slide downwardly through the latchway 68 until fully latching the glazing structure in sealing relation with the window defining member 56.

In the event additional rigidity is required between the inner walls 52 and outer walls 54, spaced apart strengthening partition walls 40' are provided. These walls 40' may be formed as an integral portion of the frame 18.

There may be instances increased rigidity and dimensional stability may be required. In order to achieve greater rigidity in the final encapsulated product, reinforcing core elements may be employed. For example, in

certain applications wherein the invention is contemplated for use in structures of substantial length, such as for example, in sliding door structures, it may be desirable to employ horizontally and vertically extending flexure resisting core elements formed of wood, for example.