Novel muntin bar assemblies

Abstract

A muntin bar assembly, for example, included in an insulating glass unit, includes at least one weld joint joining a muntin bar keeper to a spacer; the keeper holds a muntin bar in a fixed relation with the spacer. A method for preparing the assembly includes steps of welding the keeper to the spacer and attaching the muntin bar to the keeper. The keeper may include a base, which accommodates welding of the keeper to the spacer, and at least one engaging element extending out from the base to hold the muntin bar.

1 . A muntin bar assembly, comprising: 
 a spacer including a surface;    a muntin bar;    at least one muntin bar keeper joined to the spacer and holding the muntin bar in a fixed relation with the spacer; and    at least one weld joint formed between the at least one keeper and the spacer surface.    
   
   
       2 . The assembly of  claim 1 , wherein the at least one muntin bar keeper comprises: 
 a base extending alongside the spacer surface; and    at least one engaging element extending out from the base and holding the muntin bar; and    wherein the at least one weld joint is formed between the base and the spacer surface.    
   
   
       3 . The assembly of  claim 2 , wherein the base of the at least one keeper is free of any spacer-engaging protrusions.  
   
   
       4 . The assembly of  claim 2 , wherein the at least one weld joint is offset from the at least one engaging element.  
   
   
       5 . The assembly of  claim 2 , wherein the muntin bar includes a perimeter wall forming a lumen and the at least one engaging element of the at least one keeper is press fitted within the lumen.  
   
   
       6 . The assembly of  claim 2 , wherein the at least one engaging element includes opposing legs.  
   
   
       7 . The assembly of  claim 6 , wherein the base includes a tab extending laterally from the legs and the at least one weld joint is formed between the tab and the spacer surface  
   
   
       8 . The assembly of  claim 2 , wherein the at least one engaging element includes two engaging elements spaced apart from one another, and the base extends therebetween.  
   
   
       9 . The assembly of  claim 8 , wherein the at least one weld joint is disposed between the two engaging elements.  
   
   
       10 . The assembly of  claim 1 , wherein the muntin bar includes a perimeter wall extending around a substantial portion of the at least one keeper to effectively hide the keeper.  
   
   
       11 . The assembly of  claim 1 , wherein the at least one keeper holds the muntin bar in the fixed relation without penetrating through the surface of the spacer.  
   
   
       12 . A method for preparing a muntin bar assembly, the method comprising: 
 welding at least one muntin bar keeper to a spacer; and    attaching a muntin bar to the at least one keeper.    
   
   
       13 . The method of  claim 12 , further comprising cutting the spacer to length prior to welding.  
   
   
       14 . The method of  claim 12 , further comprising cutting the spacer to length subsequent to welding.  
   
   
       15 . The method of  claim 12 , further comprising bending the spacer into a spacer frame prior to welding.  
   
   
       16 . The method of  claim 12 , further comprising bending the spacer into a spacer frame subsequent to welding.  
   
   
       17 . The method of  claim 12 , further comprising separating the at least one keeper from a cohesive group of keepers to place the at least one keeper for welding.  
   
   
       18 . The method of  claim 17 , wherein the cohesive group is formed in a coil and separating the at least one keeper comprises unrolling a length of the cohesive group.  
   
   
       19 . The method of  claim 17 , wherein separating the at least one keeper comprises shearing along a common base of the cohesive group of keepers.  
   
   
       20 . The method of  claim 12 , wherein the at least one keeper comprises a first keeper and a second keeper, and welding comprises welding the first keeper to the spacer at a first location and welding the second keeper to the spacer at a second location, the second location being spaced apart from the first location along a length of the spacer.  
   
   
       21 . The method of  claim 20 , wherein welding of the first and second keepers is simultaneous.  
   
   
       22 . The method of  claim 20 , wherein welding of the first and second keepers is sequential.  
   
   
       23 . The method of  claim 12 , wherein welding comprises resistance welding.  
   
   
       24 . The method of  claim 12 , wherein welding comprises welding a first part of the keeper to a first location on the spacer and welding a second part of the keeper to a second location on the spacer.  
   
   
       25 . The method of  claim 24 , wherein welding the first and second parts is simultaneous.  
   
   
       26 . The method of  claim 24 , where welding the first and second parts is sequential.  
   
   
       27 . The method of  claim 12 , wherein attaching the muntin bar comprises press fitting the muntin bar over an engaging element of the keeper.  
   
   
       28 . A component for holding a muntin bar in a fixed relation with a spacer within an insulating glass assembly, the component comprising: 
 at least one engaging element to hold the muntin bar; and    a base supporting the engaging element and including an area being offset from the engaging element to accommodate welding of the base to a surface of the spacer;    wherein the base is free of any spacer-engaging protrusions.    
   
   
       29 . The component of  claim 28 , wherein the at least one engaging element comprises opposing legs.  
   
   
       30 . The component of  claim 28 , wherein the at least one engaging element comprises two engaging elements spaced apart from one another, and the area of the base is disposed between the two engaging elements.  
   
   
       31 . The component of  claim 28 , wherein the base has dimensions less than or equal to dimensions defining a profile of the muntin bar, so that the base is effectively hidden by the muntin bar when the muntin bar is held by the at least one engaging element.  
   
   
       32 . The component of  claim 28 , wherein the area of the base includes a weld projection.  
   
   
       33 . A component for holding a muntin bar in a fixed relation with a spacer within an insulating glass assembly, the component comprising: 
 at least one engaging element to hold the muntin bar; and    a base supporting the engaging element and including a weld projection.    
   
   
       34 . The component of  claim 33 , wherein the weld projection is offset from the at least one engaging element.  
   
   
       35 . The component of  claim 33 , wherein the at least one engaging element comprises opposing legs.  
   
   
       36 . The component of  claim 33 , wherein the at least one engaging element comprises two engaging elements spaced apart from one another, and the weld projection is disposed between the two engaging elements.  
   
   
       37 . The component of  claim 33 , wherein the base has dimensions less than or equal to dimensions defining a profile of the muntin bar so that the base is effectively hidden by the muntin bar when the muntin bar is held by the at least one engaging element.  
   
   
       38 . An insulating glass assembly, comprising: 
 a pair of glass panes;    a spacer separating the glass panes from one another and including a surface disposed therebetween;    a muntin bar disposed between the glass panes;    at least one muntin bar keeper holding the muntin bar in a fixed relation with the spacer; and    at least one weld joint formed between the at least one keeper and the spacer surface.    
   
   
       39 . The assembly of  claim 38 , wherein the at least one muntin bar keeper comprises: 
 a base extending alongside the spacer surface; and    at least one engaging element extending out from the base and holding the muntin bar; and    wherein the at least one weld joint is formed between the base and the spacer surface.    
   
   
       40 . The assembly of  claim 39 , wherein the base of the at least one keeper is free of any spacer-engaging protrusions.  
   
   
       41 . The assembly of  claim 39 , wherein the at least one weld joint is offset from the at least one engaging element.  
   
   
       42 . The assembly of  claim 39 , wherein the muntin bar includes a perimeter wall forming a lumen and the at least one engaging element of the at least one keeper is press fitted within the lumen.  
   
   
       43 . The assembly of  claim 39 , wherein the at least one engaging element includes opposing legs.  
   
   
       44 . The assembly of  claim 43 , wherein the base includes a tab extending laterally from the legs and the at least one weld joint is formed between the tab and the spacer surface  
   
   
       45 . The assembly of  claim 39 , wherein the at least one engaging element includes two engaging elements spaced apart from one another, and the base extends therebetween.  
   
   
       46 . The assembly of  claim 45 , wherein the at least one weld joint is disposed between the two engaging elements.  
   
   
       47 . The assembly of  claim 38 , wherein the muntin bar includes a perimeter wall extending around a substantial portion of the at least one keeper to effectively hide the keeper.  
   
   
       48 . The assembly of  claim 38 , wherein the at least one keeper holds the muntin bar in the fixed relation without penetrating through the surface of the spacer.