SEALED UNIT AND SPACER WITH STABILIZED ELONGATE STRIP
A sealed unit includes at least two sheets of material separated by a spacer. In one example, a spacer includes an elongate strip having a first longitudinal edge and a second longitudinal edge and defines a plane extending between at least portions of the first and second longitudinal edges. The spacer also includes at least a first stabilizer connected to the elongate strip adjacent the first longitudinal edge. The first stabilizer has a first surface arranged substantially perpendicular to the plane. The first surface is adapted to support the elongate strip against a first sheet of material. Some embodiments include a second stabilizer adapted to support the elongate strip against the second sheet of material.
1 . A spacer comprising:
an elongate strip having a first longitudinal edge and a second longitudinal edge and defining a plane extending between at least portions of the first and second longitudinal edges; and
a first stabilizer connected to the elongate strip adjacent the first longitudinal edge, the first stabilizer having a first surface arranged substantially perpendicular to the plane, the first surface adapted to support the elongate strip against a first sheet of material.
2 . The spacer of claim 1 , further comprising a second stabilizer connected to the elongate strip adjacent the second longitudinal edge, the first stabilizer having a second surface arranged substantially perpendicular to the plane, the second surface adapted to support the elongate strip against a second sheet of material, wherein the spacer is adapted to maintain a space between the first and second sheets when arranged therebetween.
3 . The spacer of claim 2 , wherein the elongate strip has an undulating shape.
4 . The spacer of claim 3 , wherein the undulating shape is regular and repeating.
5 . The spacer of claim 2 , wherein the elongate strip includes an external surface and an internal surface.
6 . The spacer of claim 5 , wherein the first stabilizer includes an external portion connected to the external surface and an internal portion connected to an internal surface.
7 . The spacer of claim 6 , wherein the first and second stabilizers are plastic.
8 . The spacer of claim 2 , wherein the first and second stabilizers include a plurality of stabilizers, each stabilizer being separated from an adjacent stabilizer by a space.
9 . The spacer of claim 1 , wherein the first surface includes a trough, the trough arranged and configured to support at least one bead of sealant thereon.
10 . The spacer of claim 1 , wherein the spacer further comprises a desiccant connected to an interior surface of the elongate strip.
11 . A method of making a spacer, the method comprising:
forming an undulating shape in a first elongate strip, the undulating shape having a regular and repeating pattern, wherein the first elongate strip has a first longitudinal edge and a second longitudinal edge; and
forming a first stabilizer on the elongate strip adjacent the first longitudinal edge.
12 . The method of claim 11 , further comprising forming a second stabilizer on the elongate strip adjacent the second longitudinal edge.
13 . The method of claim 12 , wherein forming further comprises extruding.
14 . The method of claim 13 , wherein the first and second stabilizers are made of plastic.
15 . The method of claim 11 , wherein forming the first and second stabilizers further comprises:
pre-forming the first and second stabilizers; and
connecting the first and second stabilizers to the elongate strip after pre-forming.
16 . The method of claim 15 , wherein connecting comprises adhering the pre-formed first and second stabilizers using an adhesive.
17 . A sealed unit comprising:
a first sheet having a first surface;
a second sheet having a second surface;
a spacer arranged between the first and second sheets to maintain a gap between the first and second sheets, the spacer comprising:
an elongate strip having a first edge and a second edge;
a first stabilizer connected to the elongate strip adjacent the first edge of the elongate strip, the first stabilizer including a first sealant trough; and
a second stabilizer connected to the elongate strip adjacent the second edge of the elongate strip, the first stabilizer including a second sealant trough;
a first sealant bead arranged in the first sealant trough and connecting the spacer to the first sheet; and
a second sealant bead arranged in the second sealant trough and connecting the spacer to the second sheet.
18 . The sealed unit of claim 17 , wherein the elongate strip has an undulating shape.
19 . The sealed unit of claim 18 , wherein the undulating shape has a period in a range from about 0.005 inches to about 0.1 inches and an amplitude from about 0.005 inches to about 0.1 inches.
20 . The sealed unit of claim 17 , further comprising a desiccant connected to an interior surface of the elongate strip.
21 . The sealed unit of claim 17 , further comprising secondary sealant beads arranged adjacent the first and second sealant beads.
22 . The sealed unit of claim 17 , wherein the elongate strip has a material thickness in a range from about 0.0001 inches to about 0.010 inches.
23 . The sealed unit of claim 17 , wherein the elongate strip has a material thickness in a range from about 0.0001 inches to about 0.005 inches.
24 . The sealed unit of claim 17 , wherein the elongate strip has a material thickness in a range from about 0.0003 inches to about 0.004 inches.
25 . The sealed unit of claim 17 , wherein the first and second stabilizers are plastic.