The invention will appear more clearly from the following detailed description when taken in connection with the accompanying drawings, showing by way of examples a preferred embodiments of the inventive ideas wherein like numerals refer to like parts throughout.
In the drawings forming part of this application:
FIG. 1 is a perspective and sectional view through a thermally insulated and connected inner and an outer metal window frame construction illustrating the first step of the invention, portions of the frame members being broken away.
FIG. 2 is a view similar to FIG. 1 but showing the poured-in thermal connector and the web connecting the frame members as cut.
FIG. 3 is a perspective and sectional view through an outer and an inner metal window frame illustrating a further embodiment of the invention.
FIG. 4 is a view similar to FIG. 3 but showing a reinforcing member imbedded in the poured-in thermal connector and the web connecting the frame members as cut.
Referring to the drawings in detail, the window frame construction A, in the initial extrusion of which is an inner and outer frame extruded from a single piece of aluminum, includes the inner frame 10 which includes the base portion 12. The outer edge of the base portion 12 terminates in the right angular wall 14 which terminates in the right angular flange portion 16. The other end of the base portion 12 terminates in the right angular inner wall 18 which in turn terminates in the right angular flange portion 20 initially part of the base 22 of the outer frame 24.
Extending from the base 22 and spaced from and parallel to the wall 18 is the flange 26 which terminates in the right angular lip 28 underlying the flange portion 20 and spaced therefrom. The base portion 22 terminates in the flange portion 30 which terminates in the right angular lip 32.
The numeral 34 designates an extension of the flange 30 from the base portion 22, and the extension 34 terminates in the right angular flange portion 36 forming part of the base 22 and overlying the flange portion 16. The flange portion 36 is spaced from the flange 16 thereby forming an opening O between the inner frame 10 and the outer frame 24.
In making up the thermally insulated frame construction A the inner surfaces of the above described member are coated with a bond preventor or inhibitor such as a fine talcum powder P through the opening O between the flange 36 and the flange 16 or the surfaces may be coated with a thin vinyl. Then a liquid resinous adhesive such as an epoxy resin R is deposited into the cavities between the frame members 10 and 24 through the opening O to fill the same and allowed to "set" whereby the cavities are completely filled with the resinous adhesive as illustrated in FIG. 2.
A saw or milled cut S is made in the flange portion 20 where it joins with the base 22 indicated by broken lines in FIG. 1 and the actual cut in FIG. 2 as S thereby producing two separate insulated frame members 10 and 24 with no contact of one frame member with the other the same being separated but interfitting and isulated one from the other by the epoxy filler connector R in the form of the thermal connector C, FIG. 2. With expansion and contraction of outer frame member 24 relative to the inner frame 10 due to temperature changes frame 24 moves relative to the frame 10. If the epoxy alone was used without the powder P and due to its stong adherence of the epoxy to the frame, warpage of and fracture of the epoxy connector and warpage of the frame members would occur. However, with the powder P a sliding movement between the frame parts and the epoxy connector is allowed upon expansion and contraction of the metal frame parts whereby warping of the frame members and fracture of the epoxy connector does not occur. Should there by any failure of the connector R the frames cannot come apart due to the overlap between the flanges 16 and 32 and the flanges 20 and 34.
Relative to FIGS. 3 and 4 there is illustrated thermally insulated and connected frame construction similar to that of FIGS. 1 and 2 but with an inter-locking member that adds structural integrity to the connector connecting the frame members. The window frame construction B includes the inner frame member 42 connected to the outer frame member 44 by the web portion 46 defined between the broken lines 48 and 50, FIG. 3. The outer frame 42 includes the side wall 52 terminating at one edge in the base portion 54 which terminates in the right angular flange 56 spaced from and parallely disposed to the wall portion 52. The other edge of the wall 52 terminates in the right angular top wall portion 58 which in turn terminates in the right angular flange 60 spaced from the sidewall 52 with the edge thereof spaced from the edge of flange 56.
The inner frame 44 includes the side wall 62 terminating at one edge in the base portion 64 which terminates in the right angular flange 66 spaced from and parallely disposed to the wall portion 62. The other edge of the wall 62 terminates in the right angular top wall portion 67 which in turn terminates in the right angular flange 68. Both top wall portion 58 and top wall portion 67 each extend as at 58A and 64A, respectively, which form parts of conventional inner and outer window frames. Further provided is the structurally reinforcing member M which includes the flat base portion 59 formed at one end with the right angle T flange 61 and at the other end with the right angle T flange 63. The widths of the T portions 61 and 63 are greater than the widths of the slots between flanges 56 and 60 and 66 and 68. As a result the member M adds structural integrity to the connector Ca, FIG. 4, and it prevents separation of the frame members if the connector Ca fails.
In constructing the thermally insulated frame construction B the member M is inserted and held within each of the frames 42 and 44 and it does not contact any of the frame parts. Then the inner surfaces of the above described frame members and reinforcing member M have deposited thereon a bond preventor or inhibitor such as talcum powder Pa through the opening Oa between the edge of the flanges 60 and 68 or the surface may be coated with a thin vinyl. Next a liquid resinous adhesive such as an epoxy resin Ra is deposited into the cavities between the frame members 42 and 44 through opening Oa and allowed to "set" whereby the cavities are completely filled as illustrated in FIG. 4 and the member M held in position. A saw or milled cut 68 is made at the web portion 46 between broken lines 46 and 48 thereby producing two frame members 42 and 44 connected and insulated by the epoxy filler Ra in the form of thermal connector Ca, FIG. 4. With the powder Pa a sliding movement between the frame parts, the reinforcing member M and the connector Ca is allowed whereby fracture of the connector Ca and warpage of the frame parts does not occur.