Muntin assembly and method of manufacture

A method of forming a muntin grid, the method comprising the steps of:

• pre-notching a flat strip to form a first and second pre-notched strips;
• roll forming the first and second pre-notched strips to from a first and second muntin bars defining first and second notches, respectively, the first and second muntin bars defining a contoured shape comprising first and second lateral sections coupled together and spaced by a raised central section;
• inserting a lateral member of a clip into the first notch and coupling the clip to the first muntin bar, the clip having centrally linked lateral and longitudinal members, the lateral member extending along a lateral axis, the longitudinal member extending along a longitudinal axis, the lateral member supporting first and second lateral arms and the longitudinal member supporting first and second longitudinal arms the first and second lateral arms extend along a third axis in a first direction and the first and second longitudinal arms extend along the third axis in a second direction, the first direction opposite the second direction and the longitudinal, lateral and third axis are perpendicular to each other, the longitudinal member coupled to a second boss spaced and directly opposed to a first boss supported by the lateral member, the second boss and the first boss extend away from each other along the third axis;
• and
• inserting the longitudinal member into the second notch to couple the first muntin bar to the second muntin bar, wherein the first boss is in contact with a first internal surface of the first muntin bar, and the second boss is in contact with a first internal surface of the second muntin bar when the first muntin bar is coupled to the second muntin bar by the clip.

A muntin grid comprising:

• a clip comprising:
• centrally linked lateral and longitudinal members, the lateral member extending along a lateral axis, the longitudinal member extending along a longitudinal axis;
• first and second lateral arms supported by the lateral member and first and second longitudinal arms supported by the longitudinal member, the first and second lateral arms extend along an arm axis in a first direction and the first and second longitudinal arms extend along the arm axis in a second direction, the first direction opposite the second direction and the longitudinal, lateral and arm axes are perpendicular to each other;
• and
• a second boss coupled to the longitudinal member, the second boss spaced and directly opposed to a first boss supported by the lateral member, the second boss and the first boss extend away from each other along a third axis;
• and
• a first muntin bar defining a contoured shape comprising first and second lateral sections coupled together and spaced by a raised central section, a first notch defined in the first muntin bar, the clip frictionally retained in the first notch, wherein the first boss and the first and second lateral arms are in contact with internal surfaces of the first muntin bar;
• and
• a second muntin bar defining a contoured shape comprising first and second lateral sections coupled together and spaced by a raised central section, a second notch defined in the second muntin bar, the clip frictionally retained in the second notch, wherein the second boss and the first and second longitudinal arms are in contact with internal surfaces of the second muntin bar, the clip being frictionally retained in the first and second notches couples the first and second muntin bars together.