Composite fenestration assembly

A composite fenestration assembly having one or more sub-assemblies including at least one glazing border constructed of a first material and a rigid overlay providing a structural framework for the glazing border while maintaining narrow sight lines and providing an architecturally pleasing exterior appearance.

BACKGROUND

1. Field of the Disclosure

The disclosure relates broadly to fenestrations, their manufacture, and their assembly, and more specifically, to composite fenestrations incorporating at least two different materials including one of a ferrous based material.

Metal framed windows go back to medieval times long before steel working was an available technology. The metal frames were constructed by metalworkers or blacksmiths from wrought iron, an iron alloy with a low carbon content. These simple metal frames were glazed with either stained glass or clear leaded lights. Where flat sections of wrought iron were used to make up a frame, the leaded light was fixed to the frame with wire secured with lead solder and, later on, a copper rivet was used instead of the wire. The light was further weatherproofed at its junction with the frame using a putty mixture of whiting and linseed oil. The metal frame was then secured to the building. Given the expense of such wrought iron windows and the lack of widespread skill to make them, such windows were mostly incorporated into ecclesiastical buildings and homes of those who could afford them. Wrought iron windows eventually fell out of favor with the rich and fashionable, who adopted timber frames instead, since timber could be carved more ornately and was more readily available. However, religious buildings and those requiring better security retained the metal window look. In addition, the metal frame windows offered a more secure entry point than traditional wooden windows as well as a certain aesthetic.

In the 1800s, all steel window frames were introduced as the Industrial Revolution brought about major advances in hot rolled steel permitting the mass production of steel framed windows. The Industrial Revolution further allowed for window production to take place in a controlled environment allowing for a wider choice of designs and styles. These all steel window frames were typically constructed of flat stock with a channel for receiving a pane of glass and provided an architecturally pleasing exterior appearance due the relatively thin elevational profile and expansive sight lines. These fire-resistant metal frames and sashes became the standard for factories and commercial buildings, as well as for larger residential and university buildings, institutions, prisons, and workhouses. In the first half of the 1900s, the profiles of the metal frame windows continued to expand in number. However, most metal frame windows were typically relatively flat with an exterior nib cooperating with an interior bead to secure a pane of glass to the metal frame. Over time, however, such construction resulted in poor thermal effectivity and were also eventually abandoned in favor of wood framed windows, especially in the single-family residential market. However, the architecturally pleasing aspect of such windows remained desired.

In 1955, hot-dip galvanizing was introduced enhancing the durability and appearance of the steel windows. The popularity of such windows lasted until about the 1970s. However, there has been a recent resurge in the popularity of steel windows given their thinner sight lines allowing for a greater viewing window, their durability, and vintage architectural look.

Steel windows suffer from a few drawbacks, however. The first is that steel is relatively inefficient as an insulator allowing the temperature gradient to transition from the exterior to the interior of the building. As one solution to obtain a more desirable thermal profile, all steel frames may be broken, severed, or split with a non-conductive or lower conductive material inserted between the exterior and interior halves of the frame. While this approach led to a more thermally acceptable solution, there is a cost for the additional manufacturing required to split the metal frames, inserting the insulating material, and then reassembling the frames. In addition, such thermal break window frames tended to stray away from the thin profile of the original windows by introducing thicker window frames in order to accommodate the added insulating material. The cold interior appearance of an all steel frame window is also not generally viewed as desirable compared to a wood or vinyl frame either.

As an early alternative to metal framed windows, the earliest American windows were wood casement windows, hinged at the sides. By the early 1800s, sliding single- and double-hung windows had come into popular use. As opposed to all steel windows, all wooden windows were often used in residential and commercial building practices. Such windows had a vastly improved thermal performance compared to all metal frames. Wood may also be chosen to match the interior of the building, either the flooring, furniture, or walls and generally has a more pleasing warm interior appearance. Wood, however, suffers from significant maintenance issues an requires frequent painting which often involved stripping off the old paint, priming, and then repainting the wooden portions of the window due to the exposure to the outside elements. Such task could be particularly cumbersome if the window were divided into a number of panes such as when muntins were introduced into the window structure. In addition to painting, often the wood was susceptible to rot and had to be replaced. For this reason, following the end of World War II with the increased availability, lower price, and non-corroding properties of aluminum, cladding was introduced into the window market supplanting wood windows as the primary choice of homeowners in the latter part of the 20thcentury, especially given its promise of minimal maintenance. The clad windows were developed to provide a more environmental resistant material on the exterior of the window to extend the life of the window while reducing the maintenance associated with a wood window structure. In other words, the cladding protected the wood from the elements. The dual material windows with clad exterior and wood interior were known as composite windows.

In many cases, the selected cladding material is aluminum, although vinyl. PVC, and fiberglass were also used. Such aluminum cladding took the form of roll-form (coiled or pop can) aluminum or more intricate extruded aluminum. Roll-form aluminum is rolled against the wooden frame components, such as the sash, and positioned directly against the wood. This cladding is easy to install yet fails to perform in respects to durability and water protection as this approach imparts a narrow gap between the aluminum and the sash, that, over time, allows water to seep in and rot the wood, due to minimal air circulation.

As an alternative to roll-form or pop can aluminum, extruded aluminum was introduced. This type of cladding is much thicker, lasts longer and guarantees little to no water damage over time. Extruded aluminum, in contrast to the thin roll-form aluminum, is about the thickness of a quarter and applied at somewhat of a distance from the sash. Both the sash and the frame may be constructed of extruded aluminum, allowing water to pool at the bottom and flow out. Also, because of the intended space between the sash and the cladding, air can easily ventilate that area and prevent the wood from becoming fully saturated. Overall, aluminum-clad windows offer the traditional look of wood while protecting the wood window from harsh weather and damage from insects and decay. In addition, retaining wood as part of the window structure helps keep the cold or heat out to maintain a consistent temperature within the home as wood is a non-conductive material.

In addition, replacing, retrofitting, or upgrading original wood or steel windows with cheaper materials such as aluminum cladding can significantly impact building appearance. Aluminum, for example, is much weaker than steel, requiring bulkier frame profiles that reduce the viewing area and can destroy the delicate look afforded by multi-pane steel windows. Likewise, vinyl may discolor and warp over time, making it a far less durable material over the long term than the original wood. In addition, the aluminum cladding is often extruded into a complicated shape which when placed over the wood counterpart create large air gaps between the wood and the aluminum cladding that often leads to condensation issues.

One solution offered to reduce the bulkier frame profiles introduced by extruded aluminum may be found in U.S. Pat. No. 9,725,946 to Vassilev et al. In the Vassilev patent, the aluminum cladding includes a C-shaped cladding member that snaps onto a wooden frame member and is retained by a groove in both the wooden frame member and an opposing L-shaped member using a clamping action. In order to perform this snap on function and attach the aluminum cladding to the wooden frame member using a mechanical process, the aluminum cladding must be flexible enough to slide over the wooden frame and into the retaining grooves. In addition, the aluminum cladding member incorporates a stiffening rib that creates a gap between the exterior facing surface of the wooden frame member and interior surface of the aluminum cladding. While the rib is relatively short and assists in narrowing the cross-sectional profile of the window structure, nonetheless a gap is introduced, and the aluminum cladding only touches the wooden frame member where the ribs project from the main body of the aluminum cladding. Such gap creates an air pocket and is often used to allow condensation due to thermal differences that forms between the aluminum cladding and the wooden frame member to collect and then drip out through an opening in the bottom of the cladding to assist in keeping moisture away from the wooden frame member. As the wood frame provides the structural element and the aluminum only the decorative and weatherproofing element, a gap is also necessary to allow the wood room to expand and contract.

In addition, the aluminum cladding discussed in Vassilev is not a self-supporting structure. The cladding members are merely butted up against one another and may be caulked at the seams. The aluminum cladding, while protecting the exterior surface of wooden frame members from the elements is primarily decorative and provides no structural integrity. Instead, the joined together wooden frame members provide the structural element in this construction. Also, as readily seen in FIG. 2 of the Vassilev patent, the cladding projects well above the lowermost extent of the glass thereby reducing the sightline through the glass portion of the window.

Given the foregoing drawbacks of an all metal frame, an all wood frame, an aluminum clad frame, and all vinyl frame, there exists a need for a composite fenestration assembly that takes advantage of a combination of the insulating qualities of a non-ferrous material such as wood and the strength of a ferrous-based material such as steel while presenting both pleasing interior and exterior profiles and thin profiles with narrow sight lines to overcome the drawbacks of prior fenestration constructions.

BRIEF SUMMARY

In accordance with this disclosure, a composite fenestration assembly constructed of at least two different materials may be in the form of a glazing border constructed of a non-ferrous material and defining at least one glazing opening, the glazing border including a glazing support surface facing toward the glazing opening and an exposed surface facing the exterior of the structure when positioned within the rough opening while an overlay constructed of a rigid ferrous material provides the structural framework to support the glazing border and defines an interior facing surface slipped onto the glazing border to cover at least a portion of the exposed surface of the glazing border in an abutting relationship with the glazing opening forming a combined glazing border and inner overlay assembly.

In another implementation, an outer frame and outer overlay may be combined in a similar manner to the glazing border and inner overlay assembly and may be employed to provide a support structure between the rough framing of a structure and the glazing border and inner overlay assembly.

In yet another implementation, a first leg of at least one overlay projects in a different direction than a second leg of the same overlay with the first leg interposed between a glazing assembly and the glazing support surface of a glazing border.

In yet another implementation, the border may be constructed of a non-ferrous material such as wood and the overlay constructed of a ferrous material such as steel.

Another implementation may incorporate an overlay without hooks or catches on an interior surface.

Another implementation may include an overlay with an interior surface that directly abuts, with or without an intermediate adhesive layer, an exposed surface of a corresponding border without any air gaps therebetween.

In at least one implementation, the thermal coefficient of the border is lower than the thermal coefficient of the overlay with no thermal break therebetween.

Another implementation may incorporate a glazing stop of a third material.

In yet another implementation, the original sight lines of a glazing secured within the glazing border are not reduced by the overlay.

Methods for constructing and assembling dual material fenestrations are also disclosed herein.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Exemplary Composite Fenestration Assembly (Outward Swing Casement Window): Referring initially toFIGS. 1A-6, a first exemplary embodiment of a composite fenestration assembly, generally designated100, may be provided for installation in a rough opening102of a structure104and dividing an interior106from an exterior108while allowing light to pass therethrough. Such structure104may be any structure wherein a fenestration unit may be installed. For example, the composite fenestrations assemblies are most commonly used in residential and commercial buildings in both the interior and exterior regions. However, vehicles, aircraft, and nautical craft may also employ portals and other openings that may accommodate a composite fenestration assembly as described herein.

As defined in this disclosure, although the term fenestration was originally used as an architectural term for the arrangement of windows, doors and other glazed areas in a wall, the term has evolved to become a standard industry term for windows, doors, skylights, and other glazed openings in a structure. A glazed opening is an opening that includes a glass panel, such as a door or window. The glazed opening may include a movable component. For example, an inswing or outswing window may include a movable glass panel surrounded by a sash. The opening may alternatively be fixed and non-openable; for example, a fixed light or picture window. In this disclosure, the term fenestration shall also apply to both the openings in the structure, whether framed or not, and the windows, doors, and skylights set within such openings. In this initial example, the composite fenestration assembly100will be described in terms of a rectangular outward swinging casement window installed in a building104(FIGS. 1B-1C) as just one example.

The Inner Support Structure Sub-Assembly: With continued reference toFIGS. 1A-6, the composite fenestration assembly100may be entirely made up of or include one or more sub-assemblies. In this exemplary embodiment, the composite fenestration assembly includes at least an inner glazing support structure sub-assembly, generally designated110. The inner sub-assembly110, also referred to as the protected sash in this example, generally comprises two primary components, a glazing border, generally designated112, and also referred to as the sash or movable portion of the composite fenestration assembly100, and an inner overlay, generally designated114, providing the rigid structural framework for the glazing border112and constructed to protect the glazing border from the exterior elements while also providing a pleasing metal frame fenestration exterior appearance. It will be appreciated that this construction is the opposite of a dual material conventional window such as a wood frame window with aluminum cladding wherein the wooden frame provides the structural framework and the non-structural aluminum cladding is merely a decorative outer surface providing a weather resistant cover for the otherwise exposed exterior wood surface.

As shown in more detail inFIGS. 2-6, the glazing border112in this example includes a number of non-ferrous based material components or members including a laterally projecting bottom rail116(FIG. 3), an opposing laterally projecting top rail118(FIG. 4), and a pair of opposing left and right stiles120(FIG. 5),122(FIG. 6), respectively, spanning the gap between the bottom and top rails. In this exemplary embodiment, the border is preferably constructed of wood or a wood-based material, composite, or laminate, chosen for its superior thermal insulation characteristics, although vinyl, fiberglass, or other suitable non-ferrous based material may also be used. As shown inFIGS. 1A and 2, the sash components116,118,120, and122are joined together using conventional window construction techniques and define a glazing opening124therebetween.

As best shown inFIGS. 3-6, the glazing border members116,118,120,122include an interior facing surface126a-d, an outward facing surface128a-d, an exterior facing surface130a-d, and a glazing opening facing surface132a-d, respectively. The interior facing surfaces126a-dpresent a decorative surface that is responsible for presenting the preferred interior view when the composite fenestration assembly100is mounted within the rough opening102(FIGS. 1B-1C). In this example, the decorative surface is merely the interior surface of the wooden border. It could also be a veneer added to the interior surface or decorative inlay. In this exemplary embodiment, the interior surface is generally planar and projecting parallel with a vertical plane passing through the rough opening in the building structure. However, the interior surface may incorporate other decorative profiles as well such as commonly used in window framing.

With continued reference toFIGS. 3-6, the outward facing surfaces128a-dof the glazing border members116,118,120,122face the corresponding inwardly facing surfaces232a-dof the outer frame sub-assembly210(FIG. 2) discussed below and generally provide a set of one or more surfaces for mounting, positioning, or abutting the inner sub-assembly110(FIG. 2) to the outer sub-assembly210or may present a gap to be filled with a weatherproofing component. The exterior facing surfaces130a-d, also referred to as the exposed surfaces since such surfaces would otherwise normally be exposed to the elements when the composite fenestration assembly is mounted within the rough opening without some sort of protective covering, present a generally planar surface paralleling the corresponding interior facing surfaces126a-d. The glazing opening facing surfaces132a-dface inwardly toward the glazing opening124(FIGS. 1A and 2) and are generally divided into two sections. The first section is the interior stop section134a-dand the second adjacent section136a-dforms a glazing support section and projects partially beneath the interior stop section and extends toward the exposed surfaces130a-d. Curved shoulders138a-dprovide a transition surface from the corresponding glazing opening facing surfaces132a-dand the exposed surfaces130a-d. In this exemplary embodiment, the glazing opening facing surface132a-dis recessed from the outer extent140a-dof the glazing assembly, generally designated142, within a recessed region137a-d(FIGS. 2-6). The recessed regions may be completely filled with corresponding members of the overlay114as described below and as shown inFIGS. 3-6or partially filled. In other words, the first legs168a-dof the inner overlay may be interposed between the outer extent140a-dof the glazing assembly and the corresponding glazing opening facing surfaces132a-d, partially interposed, or not interposed at all. If interposed, such first legs provide a rigid support for the glazing assembly and likely reduce the impact of movement on the glazing assembly in the form of contraction or expansion by the non-ferrous border. Such construction extends to other embodiments discussed herein as well. The recessed regions137a-dmay be introduced into the wood glazing border members116,118,120,122as a single or series of relief cuts, rabbets, rebates, notches, grooves, step cuts, or otherwise machined during the assembly process. Such relief cut is preferable to accommodate the thickness of the overlay114described below.

With continued reference toFIGS. 2-6, the glazing assembly142in this example is a dual pane window with an inner pane144and an outer pane146separated by a spacer148a-dand bounded by a silicone molded seal150a-d. The space between the panes may be vacuum, or filled with air, Argon, or other gas. The interior stop sections134a-dincludes an interior stop152a-dintegral with or secured against the respective interior stop section to provide an interior inhibitor against the glazing moving inwardly to the interior of the structure when mounted within the rough opening102(FIGS. 1B-1C) relative to the glazing border112.

Referring still toFIGS. 2-6, the inner overlay114or protective sash overlay includes a number of ferrous-based material components or members including a laterally projecting bottom rail160, an opposing laterally projecting top rail162, and a pair of opposing left and right stiles164,166, respectively spanning the gap between the top and bottom rails. The inner overlay members160,162,164, and166generally correspond to their respective glazing border counterparts116,118,120, and122, respectively. In this exemplary embodiment, the overlay is preferably constructed of ferrous-based material such as angle iron, chosen for its superior structural strength, although other suitable ferrous-based materials may be used. Angle iron may also be referred to as steel angle. The protective sash overlay components160,162,164, and166are joined together by welding the adjacent components together at their respective corners to define a structurally integral framework for the glazing border with an opening167that generally aligns with glazing opening124when the inner overlay214and glazing border212are brought together. The overlay components may be mitered, straight cut, or abutted together with other suitable joints.

As shown inFIGS. 3-6, the inner overlay members160,162,164, and166include a first leg168a-dand a second leg170a-dprojecting at a right angle to the first leg. The first leg includes a glazing opening facing surface172a-dwhile the second leg includes an exterior facing surface174a-d. Opposing these surfaces172a-dand174a-dare interior overlay surfaces176a-dthat complement at least a portion of the respective glazing opening facing surfaces132a-d, the transition shoulders138a-d, and at least a portion of the exposed surfaces130a-dof the respective border components116,118,120, and122of the glazing border112such that each overlay member160,162,164, and166may be placed in a close abutting relationship with its corresponding border component116,118,120, and122.

In this first exemplary embodiment, the first leg168a-dof the inner overlay components160,162,164, and166extends between the glazing assembly142and the glazing opening facing surfaces132a-dof the glazing border112. This provides a firm mounting surface for securing the glazing assembly142. However, this is not meant to be limiting and the first leg may extend a shorter distance across the glazing opening facing surface132a-dand/or without extending between the glazing assembly and the glazing opening facing surface. It will also be appreciated that the glazing opening surfaces172a-ddo not extend into the glazing opening124so as not to interfere with the sightlines, defined by a plane155a-dpassing through the innermost extents153a-dand183a-dof the corresponding inner stops152a-dand outer stops182a-d, respectively, through the glazing assembly142. In this exemplary embodiment the first legs168a-dare disposed between the silicone seal150a-dand the glazing opening facing surfaces132a-dwithin the recessed regions137a-d.

With continued reference toFIGS. 3-6, the second legs170a-dof the inner overlay114(FIG. 2) extend at a right angle from the corresponding first legs168a-dand further extend away from the glazing assembly142to cover the entire collective exposed surfaces130a-dof the glazing border112in each view as shown inFIGS. 3-6. In the sill view (FIG. 3), the second leg170aextends past an outermost edge178aof the glazing border and into the gap180between the inner sub-assembly110and the outer sub-assembly210. In the head view (FIG. 4), in the jamb detail—hinge side view (FIG. 5), and jamb detail—off hinge side view (FIG. 6), the second legs170b-dterminate at a position flush with their respective outer facing surface178b-dof the glazing border112. This overlay114construction is unlike the aluminum cladding solutions that include a metallic protective section projecting toward the glazing and result in covering up or obscuring a portion of the glazing thus reducing the overall sight lines and viewing area of the glazing.

The inner overlay114is typically constructed to match the corresponding inner perimeter region made up of the interior facing glazing opening surface132a-dand exposed surface130a-d, and the transition138a-dtherebetween to maintain the sight lines through the glazing panes144,146as large as possible, typically preserving the original sightlines even after the overlay is assembled to the glazing border, while still providing the structural framework for the glazing border112.

In addition to the interior stop152a-d, an exterior stop182a-dmay be employed to secure the glazing assembly142in place from the exterior. The exterior stop may be integral with the overlay or secured thereto. This exterior stop may be constructed of a ferrous-based material as with the overlay or, alternatively, aluminum, or other suitable weather resistant material and finished to match or stand out from the exterior surface174a-dof the inner overlay114.

With reference toFIGS. 2-6, the glazing border112may be slip fit into the inner overlay114resulting in the interior surfaces176a-dof the first and second legs168a-d,170a-d, respectively, of the inner overlay directly abutting and covering at least a portion of and preferably all of the exposed surfaces130a-dof the glazing border112and the transition shoulder138a-das well as at least a portion and preferably all of the glazing opening facing surface132a-d. The resulting overlap between the inner overlay and glazing border is something resembling a handshake connection or joint. In other words, any portion of the glazing border112that may be exposed to the elements when the inner sub-assembly110is secured to the building structure104(FIGS. 1B-1C) through a connection to the outer sub-assembly210and within the rough opening102is preferably covered by the overlay114. Alternatively, the rigid inner overlay114may be slip fit over the glazing border112without any need to flex the first and second legs168a-dand170a-d, respectively. Such precision lit is generally obtained using precision wood machining equipment and precision metal working equipment. In this exemplary embodiment, no air gaps exist between these inner overlay and glazing border surfaces. As the inner overlay114provides the structural integrity of the inner sub-assembly110, the non-ferrous based material such as wood may be constructed with less thickness than a conventional wooden window if desired thereby reducing the amount of expansion and contraction and overall thickness of the inner sub-assembly110and thus the composite fenestration assembly100.

To secure the inner overlay114to the glazing border112, a layer of structural adhesive or sealant184(FIG. 7) suitable for bonding a ferrous based material to a non-ferrous based material may be employed to bond the two components together. The bonding components may be suitably prepared prior to applying the adhesive. In some instances, a series of grooves186a-cas, for example, shown inFIG. 3, may be introduced into the glazing opening facing surface132a-dto provide an overflow reservoir for the adhesive for a better bonding event. Alternatively, grooves may be introduced into the interior surface of the inner overlay or in both the ferrous and non-ferrous based materials. Such structural adhesive preferably alleviates the need for mechanical fasteners but such fasteners such as screws, bolts, and nails may be used as well or as an alternative to the adhesive. The structural adhesive and rigidity of the inner overlay114also ensures minimal wood movement. Reducing the wood movement aids in also reducing the likelihood of cracking the glazing. With the protective inner overlay114affixed to the glazing border112, the structural integrity of the inner overlay allows for the inner sub-assembly110to be secured by fastening just the inner overlay to the outer sub-assembly210. In other words, no mounting or fastening hardware need penetrate the glazing border in order to secure the inner sub-assembly110to the outer sub-assembly, although this is not meant to be limiting and hardware may project into or through the glazing border112as well as, for example, shown by hinge, generally designated194, inFIG. 5.

It will be appreciated that the inner overlay114in this exemplary embodiment does not incorporate any opposing or mirroring interior surfaces in that no portion of the interior surfaces176a-dfor a particular inner overlay member160,162,164,166of the inner overlay114directly face across from one another as shown inFIGS. 3-6. This is generally achieved by employing a second leg170a-dthat projects from the first leg168a-dat an angle ranging from ninety degrees up through two hundred and seventy degrees, and preferably at a right angle up through an obtuse angle. This overlay construction is therefore unlike the clamping style claddings in other windows in which two or more surfaces face directly across from one another to form a C-shape or channel to enable clamping on the wooden frame component. Moreover, the interior surfaces176a-dof the inner overlay114are smooth with a generally planar interior surfaces of the first legs168a-dand a generally planar interior surfaces of the second legs170a-dwith curved transitions138a-dtherebetween. No catches or hooks are needed on the interior surfaces176a-dor anywhere on the overlay members160,162,164, and164to secure the overlay114to the glazing border112as a structural adhesive is all that is necessary. No other mechanical fasteners are needed but may be used if desired.

The Outer Support Structure Sub-Assembly (Outer Frame): Referring now toFIG. 2, in addition to the inner support structure sub-assembly110, an outer support structure sub-assembly or outer sub-assembly, generally designated210, may be provided. The construction of the outer support structure sub-assembly is similar in many instances to the glazing support structure sub-assembly110. However, the two sub-assemblies110,210serve different functions. The inner support structure sub-assembly110primarily serves to define one or more glazing openings124and support one or more glazings or windowpanes144,146within and then be connected in some manner, either fixed to or moveable relative to the outer support structure sub-assembly210. The outer support structure sub-assembly210, on the other hand, is constructed to serve as the connection between the building structure104and the inner support structure sub-assembly110. In this disclosure, the outer support structure sub-assembly is also referred to as the frame that is connected to the rough framing of the rough opening. The inner support structure sub-assembly110is often referred to as the sash, transom, awning, casement, portrait, or fixed panel, depending on the type of fenestration.

Referring still toFIG. 2. The outer sub-assembly210comprises two primary components, an outer border212or frame and an outer overlay214providing the structural framework for the outer border. It will be appreciated that this is the opposite of a dual material conventional window such as a wood frame window with aluminum cladding wherein the wooden frame provides the structural framework and the non-structural aluminum cladding is merely a decorative outer surface providing a weather resistant cover for the otherwise exposed exterior wood surface.

As shown inFIG. 2, the outer border212, also referred to as the frame in this example, includes a number of non-ferrous based material components or members including a laterally projecting sill216, an opposing laterally projecting head218, and a pair of opposing left and right jambs220,222respectively spanning the gap between the top head and the bottom sill. In this exemplary embodiment, the border is preferably constructed of wood or a wood-based material, chosen for its superior thermal insulation characteristics. The frame components216,218,220, and222may be joined together using conventional window construction techniques and define an inner sub-assembly opening224therebetween.

As shown inFIGS. 3-6, each frame member216,218,220, and222includes a set of interior facing surfaces226a-d, outward facing surfaces228a-d, exterior facing surfaces230a-d, and also inner sub-assembly opening facing surfaces232a-dthat coincide with the glazing opening facing surfaces132a-dof the glazing border. Like its counterpart in the glazing border112, the interior facing surface226a-dis a decorative surface that is responsible for presenting the preferred interior view when the outer sub-assembly210is mounted within the rough opening102. In this example, the decorative surface is merely the interior surface of the wooden frame. It could also be a veneer added to the interior surface or decorative inlay. In this exemplary embodiment, the interior surface226a-dis generally planar and projecting parallel with a vertical plane passing through the rough opening102(FIGS. 1B-1C) in the building structure104. However, the interior surface may incorporate other decorative profiles as well such as commonly used in window framing.

With continued reference toFIGS. 3-6, the outward facing surfaces228a-dface the rough framing surrounding the rough opening102(FIGS. 1B-1C) of the structure104and generally provides a surface for mounting the frame212to the rough framing using conventional window mounting techniques, such as, for example, nail fins, clips, or brackets. The exterior facing surfaces230a-dof each frame member216,218,220, and222, respectively, also referred to as the exposed frame surface since such surface would otherwise be exposed to the elements when the outer sub-assembly210is mounted within the rough opening, form a generally planar surface paralleling the respective interior surfaces226a-d. The inner sub-assembly opening facing surfaces232a-dface inwardly toward the inner sub-assembly opening224and are generally divided into two sections. The first section is the interior block section234a-dand the second adjacent mounting hardware section236a-dprojects outwardly from the interior block section and extends toward the exposed surface230a-d. A set of curved shoulders238a-dprovides a set of transition surfaces between the inner sub-assembly opening facing surfaces232a-dand the exposed surfaces230a-d. In this exemplary embodiment, the inner sub-assembly opening facing surface232a-dwithin the mounting section236a-dincludes a recessed region237a-d. The recessed region may be introduced in a manner using the same or similar process for the glazing border112above. Such recessed region preferably accommodates the thickness of the outer overlay214described below. The interior block sections234a-dinclude a slot239a-dfor receiving a weatherproofing seal or strip241a-dthat extends between the inner and outer sub-assemblies110and210.

Referring now toFIGS. 2-6, the outer overlay214or frame protector includes a number of ferrous-based material components or members including a laterally projecting sill260, an opposing laterally projecting head262, and a pair of opposing left and right jambs264,266, respectively spanning the gap between the sill and head. The outer overlay members260,262,264, and266generally correspond to their respective outer frame counterparts216,218,220, and222, respectively. In this exemplary embodiment, the outer overlay214is also preferably constructed of ferrous-based material such as angle iron, chosen for its superior structural strength. The outer overlay components260,262,264, and266are joined together by welding the adjacent components together at their respective corners to define a structurally integral framework for the frame with an outer overlay opening267that generally aligns with frame opening224when the outer overlay214and outer frame212are brought together. The outer overlay components260,262,264, and266may be mitered, straight cut, or abutted together with other suitable joints.

As shown inFIGS. 2-6, each outer overlay member260,262,264, and266includes first leg268a-dand a second leg270a-dprojecting at a right angle to the first leg. The first leg includes an inner sub-assembly facing surface272a-dwhile the second leg includes an exterior facing surface274a-d. Opposing these surfaces272a-dand274a-dare interior outer overlay surfaces276a-dthat complement1908at least a portion of the inner sub-assembly opening facing surface232a-d, the transition shoulder238a-d, and at least a portion of the exposed surface230a-dof the respective outer frame members216,218,220, and222of the outer frame212such that each outer overlay member260,262,264, and266may be placed in a close abutting relationship with its corresponding outer frame component216,218,220, and222.

In this exemplary embodiment, the first leg268a-dof the outer overlay214extends parallel to the outward facing surface128a-dof the glazing border112stopping short of the first block section234a-d. The inner sub-assembly facing surfaces272a-dof the first legs268a-dof the outer overlay214are also parallel to their corresponding glazing opening facing surfaces172a-dof the first legs168a-dof the inner overlay114in this example, although this is not meant to be limiting. In this exemplary embodiment, the first legs268a-dof the outer overlay extend toward the first block section to match the depth of the innermost projection of the first leg168a-dof the inner overlay as shownFIGS. 3-6. However, this is not meant to be limiting and the first leg may extend more or less than this distance. The second leg270a-dof the outer overlay extends at a right angle from the first leg and covers the entire exposed surface230a-dof the outer frame212in each view as shown inFIGS. 3-6except for a return region279a-dwhere another building component such as molding, stucco, or other covering will overlap and protect that portion of the outer frame from the elements.

The outer overlay214is typically constructed to match the corresponding inner perimeter region of the outer frame212made up of at least portions of the interior facing inner sub-assembly opening surface232a-dand exposed surface230a-d, and the transition238a-dwhile also not interfering with the sight lines in the inner sub-assembly110. The outermost surfaces174a-dof the inner overlay114and the outermost surfaces274a-dof the outer overlay are coplanar in this exemplary embodiment, although this is not meant to be limiting and the outermost surfaces of the overlays may be offset to one another.

With reference toFIGS. 2-6, the outer frame212may be slip fit into the outer overlay214resulting in the interior surfaces276a-dof the first and second legs268a-dand270a-d, respectively, of the outer overlay directly abutting and covering at least a portion of and preferably all of the exposed surfaces230a-dof the outer frame212and the transition shoulders238a-dexcept for the return regions279a-d, and at least a portion of the inner sub-assembly opening facing surface232a-d(also referred to as the inner sub-assembly surface). In other words, any portion of the outer frame212that may be exposed to the elements when the outer sub-assembly210is secured to the building structure104(FIGS. 1B-1C) within the rough opening is preferably covered by the outer overlay214. Alternatively, the outer overlay214may be slip fit over the outer frame212without any need to flex the first and second legs268a-dand270a-d, respectively. In this exemplary embodiment, no air gaps exist between these outer overlay and outer frame surfaces. As the outer overlay214provides the structural integrity of the outer sub-assembly210, the non-ferrous based material such as wood may be constructed with less thickness than a conventional wooden window if desired thereby reducing the amount of expansion and contraction and overall thickness of the outer sub-assembly210and thus the composite fenestration assembly100.

To secure the outer overlay214to the outer frame212, a layer of structural adhesive similar to the adhesive184inFIG. 7may be employed to bond the two components together. The bonding components may be suitably prepared prior to applying the adhesive. In some instances, a series of grooves286a-cas for example shown inFIG. 3, may be introduced into the inner sub-assembly facing surface232a-d(also referred to as the inner sub-assembly surface) to provide an overflow reservoir for the adhesive for a better bonding event. Alternatively, grooves may be introduced into the interior surface of the outer overlay214or in both the ferrous and non-ferrous based materials. As with the inner overlay114and glazing border112, such structural adhesive preferably alleviates the need for mechanical fasteners but such fasteners such as screws, bolts, and nails may be used as well or as an alternative to the adhesive. The structural adhesive and rigidity of the outer overlay214also ensures minimal wood movement. With the protective overlay214affixed to the outer frame212, the structural integrity of the overlay allows for the outer sub-assembly210to be secured by fastening just the overlay214to the structure104(FIGS. 1B-1C). In other words, no mounting or fastening hardware need penetrate the outer frame in order to secure the outer sub-assembly210to the outer sub-assembly, although this is not meant to be limiting and hardware may project into or through the outer frame214as well as shown, for example, by nail fin197ainFIG. 4.

As with the inner overlay114above, it will be appreciated that the outer overlay214in this exemplary embodiment does not incorporate any opposing surfaces and is therefore unlike the clamping style claddings in other windows. The interior surfaces276a-dof the outer overlay214are smooth with a generally planar interior surface of the first legs268a-dand a generally planar interior surface of the second legs270a-dwith a curved transition238a-dtherebetween. No catches or hooks are needed on the interior surface276a-dor anywhere on the outer overlay members260,262,264,266to secure the outer overlay214to the outer frame212as a structural adhesive is all that is necessary. No other mechanical fasteners are needed but may be used if desired.

In addition to the inner and outer sub-assemblies110,210, respectively, several other fenestration related components may be incorporated into a final installation within the rough opening102(FIGS. 1B-1C). These include weatherproofing components, installation and mounting hardware, and pane dividing features such as muntins.

Referring now toFIGS. 3-6, several weatherproofing components may be incorporated between the inner sub-assembly110and the outer sub-assembly210. For example, inFIG. 3, a sill side weatherstrip241aincludes a first section engaged in slot239aand a second section filling up a gap190abetween the interior surface126aof the glazing border112and the interior block section234aof the outer frame214. Similarly, inFIG. 4, a head side weatherstrip241bincludes a first section engaged in slot239band a second section filling up a gap190bbetween the interior surface126bof the glazing border112and the interior block section234bof the outer frame214. Also, inFIG. 4is another weatherstripping component243disposed in a gap257between the outward facing surface128bof the inner sub-assembly110and the inner sub-assembly facing surface272bof the first leg268bof the head216of the outer sub-assembly210.

Also, inFIG. 5, a left side jamb weatherstrip241cincludes a first section engaged in slot239cand a second section filling up a gap190cbetween the interior surface126cof the glazing border112and the interior block section234cof the outer frame214. InFIG. 6, a right side jamb weatherstrip241dincludes a first section engaged in slot239dand a second section filling up a gap190dbetween the interior surface126dof the glazing border112and the interior block section234dof the outer frame214. Such weatherstripping inhibits the passage of air between the interior106and exterior108of the structure104when the composition fenestration assembly100is secured within the rough opening102and in a closed configuration (FIGS. 1B-1C). Additional weatherproofing components such as caulking, insulating foam, mohair strips, weatherproof papers, decorative molding, flashing, and the building finish may also contribute to weatherproofing the composite fenestration assembly100and surrounding area and assist in improving the insulation characteristics of the structure in the which the composite fenestration assembly is mounted. The location and securement of such weatherproofing components is well known and within one of ordinary skill in the art.

In addition to the weatherproofing components, various installation hardware may be employed such as locks and latches, operators, cranks, handles, hinges, bolts, rollers, hangers, strike plates, sweeps, nail fins, clips, and brackets, balances, door closer, to name a few. Such hardware may generally be grouped into hardware either fixedly or movably connecting the inner sub-assembly110to the outer sub-assembly210and hardware connecting the outer sub-assembly210to the framing defining the rough opening102. For example, in the sill view ofFIG. 3, a casement window friction stay, generally designated192, defines one connection between the inner sub-assembly110and the outer sub-assembly210. While the upper connection between the friction stay192and the inner sub-assembly is conventional, it will be noted that the first leg268aof the outer overlay214may extend between the bottom of the friction stay and the sill216. In such case, the first leg of the outer overlay may be machined to accommodate fasteners such as screws, bolts, or nails to secure the bottom of the stay to the sill component218. Where the first leg is not interposed between the stay and the sill, connection may be made using conventional techniques. The sill216may be secured to the framing defining the rough opening102(FIGS. 1B-1C) as would be understood by one of ordinary skill in the art.

Turning now toFIG. 4, there is no hardware shown connecting the inner sub-assembly110to the outer sub-assembly210but a nail fin197ais secured to the outward facing surface228bof the head218of the outer sub-assembly210. Such nail fin may be nailed to the framing surrounding the rough opening102as would be understood by one of ordinary skill in the art.

Turning now toFIG. 5, a hinge, generally designated194, with a first leaf195aconnected to the left side jamb220of the outer sub-assembly210and a second leaf195bconnected to the outer facing surface128cof the left stile120. As shown inFIG. 4, the hinge leaves195a-bare connected to their respective fenestration components220,120using fasteners such as screws198a-bor bolts199a-b. Where a first leg168a-dor268a-dof either overlay114,214is disposed within the connection path, the first leg may be modified to accommodate the passthrough of such fasteners such as by drilling a hole. In addition to the hinge194, a nail fin197bwith an L-shaped construction similar to the nail fin197a(FIG. 4) may be used to secure the left side jamb220to the framing defining the rough opening102as would be understood by one of ordinary skill in the art. It will be appreciated that wherever fasteners are used to the hardware to the sub-assemblies110,210or to the structure104, washers or an opposing backing plate constructed of a stronger material than the non-ferrous based material to receive the distal end of the fasteners may be employed to strengthen the connection.

InFIG. 6, the off-hinge side of the composite fenestration assembly100, another nail fin197cmay be used to secure the right side jamb222to the framing defining the rough opening102as well. In addition, a crank handle or latch245(or both) may be provided to facilitate opening and closing the sash or inner sub-assembly110as would be understood by one of ordinary skill in the art.

While the foregoing embodiment of a composite fenestration assembly100has been described as an outward swing casement window, it will be appreciated that other embodiments may be constructed in accordance with this disclosure as, for example, a left handed outswing French door discussed below, among many others.

Exemplary Embodiment of a Composite Fenestration Assembly (Left Handed Outswing French Door): Referring initially toFIGS. 8A-13, a composite fenestration assembly, generally designated300, is provided for installation in a rough opening302of a structure304and dividing an interior306from an exterior308while allowing light to pass therethrough. In this exemplary embodiment, as with the composite fenestration assembly100described above, such structure may be any structure wherein a fenestration unit may be installed, most commonly residential and commercial buildings, although vehicles, aircraft, and nautical craft may employ portals and other openings that would accommodate a composite fenestration assembly as described herein. In this example, the composite fenestration assembly will be described in terms of a rectangular left hand outswing French door installed in a building as another example. It will be appreciated that the door construction shares many similarities with the window construction described above with one of the main exceptions being that a window has a sill while a door has a threshold that requires a different construction as traffic will be crossing over the threshold as explained below.

The Inner Support Structure Sub-Assembly: With continued reference toFIGS. 8A-13, the composite fenestration assembly300may be entirely made up of or include one or more sub-assemblies. In this exemplary embodiment, the composite fenestration assembly includes at least an inner glazing support structure sub-assembly, generally designated310, and in this example, generally forms the door or movable component of the composite fenestration assembly300. The inner sub-assembly or door310comprises two primary components, a glazing border, generally designated312, and an inner overlay, generally designated314, providing the structural framework for the glazing border. It will be appreciated that, like the exemplary window described above, this is the opposite of a dual material conventional window such as a wood frame window with aluminum cladding wherein the wooden frame provides the structural framework and the non-structural aluminum cladding is merely a decorative outer surface providing a weather resistant cover for the otherwise exposed exterior wood surface.

As shown inFIG. 9, the glazing border312includes a number of non-ferrous based material components or members including a laterally projecting bottom rail316, an opposing laterally projecting top rail318, and a pair of opposing left and right stiles320,322, respectively, spanning the gap between the top and bottom rails. In this exemplary embodiment, the border is preferably constructed of wood or a wood-based material, chosen for its superior thermal insulation characteristics. The door components316,318,320, and322are joined together using conventional window construction techniques and define a glazing opening324therebetween. In this exemplary embodiment, the bottom rail may further include a door sweep track439afor receipt of a door sweep441ato assist in weatherproofing the bottom section of the door.

As shown inFIGS. 10-13, each border member316,318,320,322includes a corresponding interior facing surface326a-d, an outward facing surface328a-d, an exterior facing surface330a-d, and a glazing opening facing surface332a-d. The interior facing surfaces326a-dpresent a decorative surface that is responsible for presenting the preferred interior view when the composite fenestration assembly is mounted within the rough opening302(FIGS. 8B-8C). In this example, the decorative surface is merely the interior surface of the wooden border. It could also be a veneer added to the interior surface or decorative inlay. In this exemplary embodiment, the interior surface is generally planar and projecting parallel with a vertical plane passing through the rough opening in the building structure. However, the interior surface may incorporate other decorative profiles as well such as commonly used in door framing.

With continued reference toFIGS. 10-13, the outward facing surface328a-dfaces the inwardly facing surface432a-dof the outer frame sub-assembly410discussed below and generally provides a surface for mounting, positioning, or abutting the inner sub-assembly310to the outer sub-assembly410or may present a gap to be filled with a weatherproofing component. The exterior facing surface330a-dof each member316,318,320,322, also referred to as the exposed surface since such surface would otherwise be exposed to the elements when the composite fenestration assembly is mounted within the rough opening without some sort of protective covering, is a generally planar surface paralleling the interior surface. The glazing opening facing surface332a-dfaces inwardly toward the glazing opening324(FIG. 9) and is generally divided into two sections. The first section is the interior stop section334a-dand the second adjacent section336a-dextends from the interior stop section toward the exposed surface330a-d. In this exemplary embodiment, a right angle shoulder338a(FIG. 10) and a set of curved shoulders338b-d(FIGS. 11-13) provide a transition surface from the corresponding glazing opening facing surface332a-dand the exposed surface330a-d. In this exemplary embodiment, the glazing opening facing surface332a-dincludes at least portion that is recessed from the outer extent340a-dof the glazing assembly, generally designated342, within a recessed region337a-d. The recessed regions may be completely filled with corresponding members of the overlay314as described below and as shown inFIGS. 10-13or partially filled. The recessed regions337a-dmay be introduced into the wood glazing border members316,318,320,322as a single or series of relief cuts, rabbets, rebates, notches, grooves, step cuts, or otherwise machined during the assembly process. Such relief cut is preferable to accommodate the thickness of the overlay described below.

The glazing assembly342in this example is a dual pane window or insulated glass unit (IGU) with an inner pane344and an outer pane346separated by a spacer348a-dand bounded by a silicone molded seal350a-d. The space between the panes may be vacuum, or filled with air, Argon, or other gas. The interior stop sections334a-dincludes an interior stop352a-deither integral with or secured against the respective interior stop section to provide an interior inhibitor against the glazing assembly342moving inwardly to the interior306(FIGS. 8B-8C) of the structure304when mounted within the rough opening302relative to the glazing border312.

Referring now toFIGS. 9-13, the inner overlay314includes a number of ferrous-based material components or members including a laterally projecting bottom rail360, an opposing laterally projecting top rail362, and a pair of opposing left and right stiles364,366, respectively spanning the gap between the top and bottom rails. The inner overlay members360,362,364, and366generally correspond to their respective glazing border counterparts316,318,320, and322, respectively. In this exemplary embodiment, the overlay is preferably constructed of ferrous-based material such as angle iron, chosen for its superior structural strength, although other suitable ferrous-based materials may be used. The sash components360,362,364, and366are joined together by welding the adjacent components together at their respective corners to define a structurally integral framework for the glazing border with an opening367that generally aligns with glazing opening324when the inner overlay314and glazing border312are brought together. The overlay components may be mitered, straight cut, or abutted together with other suitable joints.

As shown inFIGS. 10-13, each inner overlay member360,362,364, and366includes a corresponding first leg368a-dand a second leg370a-dprojecting at a right angle to the first leg. The first leg includes a glazing opening facing surface372a-dwhile the second leg includes an exterior facing surface374a-d. Opposing these surfaces372a-dand374a-dis an interior overlay surface376a-dthat complements at least a portion of the respective glazing opening facing surface332a-dand the transition shoulder338a-d, as well as at least a portion of the exposed surface330a-dof the respective glazing border components316,318,320, and322of the glazing border312such that each overlay member360,362,364, and366may be placed in a close abutting relationship with its corresponding border component316,318,320, and322. In this exemplary embodiment, the second leg370aof the bottom rail360extends all the way to the outward facing surface328aof the glazing border bottom rail316and then turns inwardly to cover a portion of the outward facing surface328a. The intermediary section of the second leg370amay provide a reinforced kick plate area if desired.

In this exemplary embodiment, the first leg368a-dof each inner overlay component360,362,364, and366extends at least partially between the glazing assembly342and the glazing opening facing surface332a-dof the glazing border312. This provides a firm mounting surface for securing the glazing assembly342. However, this is not meant to be limiting and the first leg may extend a shorter distance across the glazing opening facing surface332a-dwithout extending between the glazing assembly and the glazing opening facing surface. It will also be appreciated that the glazing opening surfaces372a-ddo not extend into the glazing opening324so as not to interfere with the sightlines, defined by a plane355a-dpassing through the innermost extents353a-dand383a-dof the corresponding inner stops352a-dand outer stops382a-d, respectively, through the glazing assembly342. In this exemplary embodiment the first legs368a-dare disposed at least partially between the silicone seal350a-dand the glazing opening facing surfaces332a-dwithin the recessed regions337a-d.

With continued reference toFIGS. 9-13, the second leg370a-dof the inner overlay314extends at a right angle from the corresponding first leg368a-dand covers at least a portion of if not the entire exposed surface330a-dof the glazing border312in each view as shown inFIGS. 8A-CandFIGS. 10-13. However, in the bottom rail view (FIG. 10), the second leg370aextends slightly past an outermost edge378aof the glazing border and into the gap390abetween the inner sub-assembly310and the threshold portion460of the outer sub-assembly410. In the top rail view (FIG. 11), in the jamb detail—hinge side view (FIG. 12), and jamb detail—off hinge side view (FIG. 13), the second leg370b-dterminates at a position flush with the outer facing surface378b-dof the glazing border312.

The inner overlay314is typically constructed to match the corresponding inner perimeter region made up of the interior facing glazing opening surface332a-dand exposed surface330a-dand the transition338a-dtherebetween to maintain the sight lines through the glazing panes344,346as large as possible, typically preserving the original sightlines even after the overlay314is assembled to the glazing border312, while still providing the structural framework for the glazing border312.

In addition to the interior stop352a-d, an exterior stop382a-dmay be employed to secure the glazing assembly342in place from the exterior. The exterior stop may be integral with the overlay or secured thereto. This exterior stop may be constructed of a ferrous-based material as with the overlay or, alternatively, aluminum, or other suitable weather resistant material and finished to match or stand out from the exterior surface374a-dof the inner overlay314.

With reference toFIGS. 9-13, the glazing border312may be slip fit into the inner overlay314resulting in the interior surfaces376a-dof the first and second legs368a-d,370a-d, respectively, of the inner overlay directly abutting and covering at least a portion of and preferably all of the exposed surface330a-dof the glazing border312and the transition shoulder338a-d, as well as at least a portion of and preferably all of the glazing opening facing surface332a-d. In other words, any portion of the glazing border312that may be exposed to the elements when the inner sub-assembly310is secured to the building structure304(FIGS. 8B-8C) through a connection to the outer sub-assembly410and within the rough opening302is preferably covered by the overlay314. Alternatively, the inner overlay314may be slip fit over the glazing border312without any need to flex the first and second legs368a-dand370a-d, respectively. In this exemplary embodiment, no air gaps exist between these overlay and border surfaces. As the inner overlay314provides the structural integrity of the inner sub-assembly310, the non-ferrous based material such as wood may be constructed with less thickness than a conventional wooden door if desired thereby reducing the amount of expansion and contraction and overall thickness of the inner sub-assembly310and thus the composite fenestration assembly300.

To secure the inner overlay314to the glazing border312, a layer of structural adhesive similar to adhesive184inFIG. 7suitable for bonding a ferrous based material to a non-ferrous based material may be employed to bond the two components together. The bonding components may be suitably prepared prior to applying the adhesive. In some instances, a series of grooves386a-cas, for example, shown inFIG. 11, may be introduced into the glazing opening facing surface332a-dto provide an overflow reservoir for the adhesive for a better bonding event. Alternatively, grooves may be introduced into the interior surface of the inner overlay or both the ferrous based and non-ferrous based materials. Such structural adhesive preferably alleviates the need for mechanical fasteners but such fasteners such as screws, bolts, and nails may be used as well or as an alternative to the adhesive. The structural adhesive and rigidity of the inner overlay314also ensures minimal wood movement. With the protective inner overlay314affixed to the glazing border312, the structural integrity of the inner overlay314allows for the inner sub-assembly310to be secured by fastening just the inner overlay to the outer sub-assembly410. In other words, no mounting or fastening hardware need penetrate the glazing border in order to secure the inner sub-assembly310to the outer sub-assembly, although this is not meant to be limiting and hardware may project into or through the glazing border as well as, for example, the hinge394inFIG. 12.

With the exception of the bottom rail overlay member360, it will be appreciated that each inner overlay member362,364,366in this exemplary embodiment does not incorporate any opposing surfaces and is therefore unlike the clamping style claddings in other doors. The interior surfaces376a-dof the inner overlay314are smooth with a generally planar interior surface of the first legs368a-dand a generally planar interior surface of the second legs370a-dwith a sharp right angle shoulder338aor curved shoulder transitions338b-dtherebetween. No catches or hooks are needed on the interior surface376a-dor anywhere on the inner overlay members360,362,364,366to secure the overlay314to the glazing border312as a structural adhesive is all that is necessary. No other mechanical fasteners are needed but may be used if desired and their omission is not meant to be limiting.

The Outer Support Structure Sub-Assembly (Outer Frame): In addition to the inner support structure sub-assembly310, an outer support structure sub-assembly or outer sub-assembly, generally designated410, may be provided. The construction of the outer support structure sub-assembly is similar in many instances to the glazing support structure sub-assembly310. However, the two sub-assemblies310,410serve different functions. The inner support structure sub-assembly310primarily serves to define one or more glazing openings324and support one or more glazings or windowpanes344,346within a door and then be connected in some manner, either fixed to or moveable relative to the outer support structure sub-assembly410. The outer support structure sub-assembly410, on the other hand, is constructed to serve the connection between the building structure304and the inner support structure sub-assembly310. Typically, the outer support structure sub-assembly is referred to as the frame that is connected to the rough framing of the rough opening302(FIGS. 8B-8C). The inner support structure sub-assembly310is often referred to as the door.

Referring back toFIG. 9, the outer sub-assembly410comprises two primary components, an outer border412or frame and an outer overlay414providing the structural framework for the outer border. It will be appreciated that this is the opposite of a dual material conventional window such as a wood frame window with aluminum cladding wherein the wooden frame provides the structural framework and the non-structural aluminum cladding is merely a decorative outer surface providing a weather resistant cover for the otherwise exposed exterior wood surface.

As shown inFIG. 9, the outer border412, also referred to as the door frame in this example, includes a number of non-ferrous based material components or members including a laterally projecting top head jamb418, and a pair of opposing left and right jambs420,422, respectively, spanning the gap between the top and bottom rails. In this exemplary embodiment, the border is preferably constructed of wood or a wood-based material, chosen for its superior thermal insulation characteristics. The frame components418,420, and422may be joined together using conventional door frame construction techniques and define an inner sub-assembly opening624therebetween. It will be appreciated that the door construction is somewhat different than the window construction as a highly trafficked threshold replaces a sill. In other words, there is no wooden counterpart in the bottom of the outer border spanning between the two jambs. Instead, in this door example, sill of the window is replaced by a stringer or flange397dthat connects the bottom edges of the opposing nail fins397b,397cfor receiving a threshold component460described below. The stringer component397dmay be part of the assembled frame412or installed separately.

As shown inFIGS. 11-13, each frame member418,420, and422includes an interior facing surface426b-d, an outward facing surface428b-d, an exterior facing surface430b-d, and an inner sub-assembly opening facing surface432b-dthat coincides with the glazing opening facing surface332b-dof the glazing border312. Like its counterparts in the glazing border312, the interior facing surfaces426b-dof the frame members418,420, and422define a decorative surface that is responsible for presenting the preferred interior view when the outer sub-assembly410is mounted within the rough opening302. In this example, the decorative surface is merely the interior surface of the wooden frame. It could also be a veneer added to the interior surface or decorative inlay. However, the interior surface may incorporate other decorative profiles as well such as commonly used in door framing. In this exemplary embodiment, the interior surfaces426b-dare generally planar and project parallel with a vertical plane passing through the rough opening302in the building structure304.

With continued reference toFIGS. 11-13, the outward facing surfaces428b-dface the rough framing surrounding the rough opening302of the structure304(FIGS. 8B-8C) and generally provides a surface for mounting the door frame412to the rough framing using conventional door mounting techniques. The exterior facing surface430b-dof each frame member418,420, and422, respectively, also referred to as the exposed surface since such surface would otherwise be exposed to the elements when the outer sub-assembly410is mounted within the rough opening, is a generally planar surface paralleling the interior surface426b-d. Such exposed surfaces generally require a weatherproof covering constructed of a non-ferrous based material such as wood commonly used in window and door units. The inner sub-assembly opening facing surfaces432b-dface inwardly toward the inner sub-assembly opening424and are generally divided into two sections. For the top rail and left and right jamb sections, the first section is the interior block section434b-dand the second adjacent mounting hardware section436b-dprojects outwardly from the interior block section and extends toward the exposed surface430b-d. Curved shoulders438b-dprovide a transition surface from the corresponding inner sub-assembly opening facing surface432b-dand the exposed surface430b-d. In this exemplary embodiment, the inner sub-assembly opening facing surface432b-dwithin the mounting section436b-dincludes a recessed region437b-din the top rail, left jamb, right jamb members418,420, and422, respectively. The recessed region may be introduced in a manner using the same or similar process for the glazing borders112,312above. Such relief cut is preferable to accommodate the thickness of the overlay described below. The interior block sections434b-dalso include a slot439b-dfor receiving a weatherproofing seal or strip441b-dthat extends between the inner and outer sub-assemblies310and410.

As shown inFIGS. 9-10, a bottom threshold, generally designed460, may be inserted above the stringer397dand connected thereto as would be familiar to one or ordinary skill in the art.

Referring now toFIGS. 8A-13, the outer overlay414includes a number of ferrous-based material components or members including a laterally projecting threshold460, an opposing laterally projecting head462, and a pair of opposing left and right jambs464,466, respectively spanning the gap between the head and sill. The outer overlay members462,464, and466generally correspond to their respective outer frame counterparts418,420, and422, respectively, with the threshold component460covering the flange397dat the bottom of the assembly when fully assembled. In this exemplary embodiment, the outer overlay414is preferably constructed of ferrous-based material such as angle iron, chosen for its superior structural strength. The outer overlay components460,462,464, and466may be joined together by welding the adjacent components together at their respective corners to define a structurally integral framework for the frame with an outer overlay opening467(FIG. 9) that generally aligns with frame opening424when the outer overlay414and outer frame412are brought together. The outer overlay components460,462,464, and466may be mitered, straight cut, or abutted together with other suitable joints. Alternatively, the threshold460may be constructed of a different material and/or installed separately before or after the head462and jambs464,466are installed.

As shown inFIGS. 11-13, each outer overlay member462,464, and466includes first leg468b-dand a second leg470b-dprojecting at a right angle to the first leg. The first leg includes an inner sub-assembly facing surface472b-dwhile the second leg includes an exterior facing surface474b-d. Opposing these surfaces472b-dand474b-dis an interior outer overlay surface476b-dthat complements at least a portion of the inner sub-assembly opening facing surface432b-dand transition shoulder438b-d, as well as at least a portion of the exposed surface430b-dof the outer frame412. It will be noted that, in this exemplary embodiment, the threshold overlay460construction may be conventional as there no wooden counterpart in the outer frame412.

Like the embodiments above, the first legs468b-dof the outer overlay414extends parallel to the outward facing surface328b-dof the glazing border312stopping short of the first block section434b-d. In this exemplary embodiment, the first legs468b-dextend toward the first block section to match innermost projection of the first legs368b-dof the inner overlay314as shownFIGS. 11-13. However, this is not meant to be limiting and the first leg may extend more or less than this distance. The second legs470b-dof the outer overlay extends at a right angle from the first leg and covers the entire exposed surface430b-dof the outer frame412in each view as shown inFIGS. 11-13except for a return region479b-dwhere another building component such as molding, stucco, or other covering will cover and protect that portion of the outer frame from the elements.

The outer overlay414is typically constructed to match the corresponding inner perimeter region of the outer frame412made up of the interior facing inner sub-assembly opening surface432b-dand exposed surface430b-d, and the transition438b-dwhile not interfering with the sight lines in the inner sub-assembly310.

With reference toFIGS. 9-13, the outer frame412may be slip fit into the outer overlay414resulting in the interior surfaces476b-dof the first and second legs468b-dand470b-d, respectively, of the outer overlay414directly abutting and covering at least a portion of and preferably all of the exposed surfaces430b-dof the outer frame412and the transition shoulders438b-dexcept for the return regions479b-d, and at least a portion of the inner sub-assembly opening facing surfaces432b-d. In other words, the outer overlay414covers any portion of the outer frame412that may be exposed to external elements when the outer sub-assembly410is secured to the building structure304within the rough opening302(FIGS. 8B-8C). Alternatively, the outer overlay414may be slip fit over the outer frame412with any need to flex the first and second legs468b-dand470b-d, respectively. In this exemplary embodiment, no air gaps exist between these outer overlay and outer frame surfaces. As the outer overlay414provides the structural integrity of the outer sub-assembly410, the non-ferrous based material such as wood may be constructed with less thickness than a conventional wooden window if desired thereby reducing the amount of expansion and contraction and overall thickness of the outer sub-assembly410and thus the composite fenestration assembly300.

To secure the outer overlay414to the outer frame412, a layer of structural adhesive similar to the adhesive184inFIG. 7may be employed to bond the two components together. The bonding components may be suitably prepared prior to applying the adhesive. In some instances, a series of grooves486a-cas for example shown inFIG. 11may be introduced into the glazing opening facing surface432b-dto provide an overflow reservoir for the adhesive for a better bonding event. Alternatively, grooves may be introduced into the interior surface of the inner overlay or both. As with the inner overlay314and glazing border312, such structural adhesive preferably alleviates the need for mechanical fasteners but such fasteners such as screws, bolts, and nails may be used as well or as an alternative to the adhesive. The structural adhesive and rigidity of the outer overlay414also ensures minimal wood movement. With the protective overlay414affixed to the outer frame412, the structural integrity of the overlay allows for the outer sub-assembly410to be secured by fastening just the overlay414to the structure304(FIGS. 8B-8C). In other words, no mounting or fastening hardware need penetrate the outer frame in order to secure the outer sub-assembly410to the outer sub-assembly, although this is not meant to be limiting and hardware may project into or through the outer frame414as well as shown, for example, by nail fin397ainFIG. 11.

It will be appreciated that the outer overlay414does not incorporate any opposing interior surfaces and is therefore unlike the clamping style claddings in other windows. The interior surfaces476b-dof the outer overlay414are smooth with a generally planar interior surface of the first legs468b-dand a generally planar interior surface of the second legs470b-dwith curved transition shoulders438b-dtherebetween. No catches or hooks are needed to secure the overlay to the glazing border as a structural adhesive is all that is necessary. No other mechanical fasteners are needed but may be used if desired and their omission is not meant to be limiting.

In addition to the inner and outer sub-assemblies310,410, respectively, several other fenestration related components may be incorporated into a final installation within the rough opening302. These include weatherproofing components, installation and mounting hardware, and pane dividing features such as muntins.

Referring now toFIGS. 10-13, several weatherproofing components may be incorporated between the inner sub-assembly310and the outer sub-assembly410. For example, inFIG. 10, a threshold side weatherstrip or sweep441aincludes a first section engaged in slot or sweep track439aand a second section filling up a gap390abetween the bottom surface328aof the glazing border312and the top surface of the threshold460. Similarly, inFIG. 11, a head side weatherstrip441bincludes a first section engaged in slot439band a second section filling up a gap390bbetween the interior surface326bof the glazing border312and the interior block section434bof the outer frame414. Also, inFIG. 11is another weatherstripping component443disposed in the gap457between the top surface328bof the inner sub-assembly310and the first leg468bof the head418of the outer sub-assembly410.

Also, inFIG. 12, a left side jamb weatherstrip441cincludes a first section engaged in slot439cand a second section filling up a gap390cbetween the interior surface326cof the glazing border312and the interior block section434cof the outer frame414. InFIG. 13, a right side jamb weatherstrip441dincludes a first section engaged in slot439dand a second section filling up a gap390dbetween the interior surface326dof the glazing border312and the interior block section434dof the outer frame414. Such weatherstripping inhibits the passage of air between the interior and exterior of the structure when the composition fenestration assembly300is secured within the rough opening302and in a closed configuration. Additional weatherproofing components such as caulking, insulating foam, mohair strips, weatherproof paper, decorative molding, flashing, and the building finish may also contribute to weatherproofing the composite fenestration assembly and assist in improving the insulation characteristics of the building in the which the composite fenestration assembly is mounted. The location and securement of such weatherproofing components is well known and within one of ordinary skill in the art.

In addition to the weatherproofing components, various door installation hardware such as locks and latches, handles, hinges, bolts, rollers, hangers, strike plates, sweeps, nail fins, clips, and brackets, balances, levers, door closer, to name a few without being limiting. Such hardware may generally be grouped into hardware either fixedly or movably connecting the inner sub-assembly310to the outer sub-assembly410and hardware connecting the outer sub-assembly410to the framing defining the rough opening302. For example, turning now toFIG. 10, there is no hardware connecting the inner sub-assembly310to the outer sub-assembly410. Similarly, inFIG. 11, there no hardware connecting the inner sub-assembly310to the outer sub-assembly410but a nail fin397ais secured to the outward facing surface428bof the head418of the outer sub-assembly410. Such nail fin may be nailed to the framing surrounding the rough opening302as would be understood by one of ordinary skill in the art.

Turning now toFIG. 12a hinge394with a first leaf395aconnected to the left side jamb420of the outer sub-assembly410and a second leaf395bconnected to the outer facing surface328cof the left stile320. As shown inFIG. 12the hinge leaves395a-bare connected to their respective fenestration components320,420using fasteners such as screws398a-bor bolts399a-b. Where a first leg of either overlay314,414is disposed within the connection path, the first leg may be modified to accommodate the passthrough of such fasteners such as drilling a hole. In addition to the hinge394, a nail fin397bwith an L-shaped construction similar to the nail fin397a(FIG. 11) may be used to secure the left side jamb420to the framing defining the rough opening302. In addition, a backing plate (not shown) may be employed at the distal end of the fasteners to provide a stronger connection if desired. InFIG. 13, the off-hinge side of the composite fenestration assembly300, another nail fin397cmay be used to secure the right side jamb422to the framing defining the rough opening102as well.

Turning now toFIG. 14, an exemplary set of decorative interior and exterior muntins, generally designated500a.500b, may be used to divide up the inner and outer glass panes of the glazing assembly to form separates lites (or lights) in the viewing area. It will be appreciated that the construction of the muntins500a.500bis same for the muntins taken from circle Z1of eitherFIG. 1AorFIG. 8A, whether discussing a window or a door. For ease of description, an exemplary embodiment of a set of window muntins500a,500btaken from circle Z1ofFIG. 1Awill now be discussed. The interior and exterior muntins500a.500bform a division between two adjacent glazing assemblies142a,142beach with their own inner and outer glass panes144a,144band146a,146b, respectively. Spacers148a,148bare used to maintain separation between the glass panes while a silicon form150a,150bseals the outer ends of the glazing assemblies. Projecting between the seals is a thin flat dowel or bar551that runs the length of the muntin bar that juts out at opposing ends553a,553bbeyond the outermost surfaces of the glass panes to provide a ledge or post to receive an interior muntin500aand the exterior muntin500b, respectively. Both muntins include a receptacle555a,555bfor receiving the post553a.553b, respectively. The interior muntin is typically constructed of the same material as the glazing border but this is not meant to be limiting. The exterior muntin is typically constructed of aluminum that is metallized to present a similar exterior appearance as the overlays114,214314,414but this is not meant to be limiting. The dowel may be constructed of wood, metal, or fiberglass. It will be appreciated that this configuration results in true divided lites. Alternatively, the muntins may be in the form of a grille that is pressed on top of the corresponding windowpane and secured thereto using an adhesive or a friction fit by snapping the muntins into place. Such muntin construction creates simulated divided lites as the associated windowpane is not truly separated between the muntins. As used herein, grille refers to windowpane dividers or muntins or muntin bars. These may be fitted to the exterior surface of the pane and removable for cleaning. Also, grilles may be fitted inside the sealed insulating glass unit.

Materials: As discussed above, the glazing borders112,312and outer frames212,412are typically constructed of a non-ferrous material such as wood, vinyl, or fiberglass or other suitable material and selected for both a pleasing interior facing surface and preferred thermal insulation qualities.

On the other hand, the inner overlays114,314and outer overlays214,414are preferably constructed of steel, a steel alloy, or angle iron. The overlay material is preferably selected to provide a rigid, self-supporting structure capable of providing the structural framework for the glazing border and outer frame. Self-supporting is defined as being capable of maintaining an upright orientation without collapsing under its own weight or maintaining a horizontal orientation without appreciably bending. This is unlike aluminum cladding which would collapse or bend under its own weight. In addition, the overlays are preferably constructed from solid and unbroken angle iron. It will be appreciated that holes or slots may be included in the overlays where mechanical fasteners are used. The overlay material is also preferably constructed to present a pleasing external architectural appearance, often vintage in appearance to match the appearance of all steel windows. The combination of a wood glazing border and outer frame and steel or angle iron overlays satisfies these preferences. In addition, the thermal insulating characteristics of the metal overlay directly abutting the wood material avoid the need for introducing a thermal break in the overlay or between the overlay and glazing borders and/or outer frames. More specifically, the thermal coefficient Uf (thermal coefficient of the border or frame also referred to as the U-factor or U-value) of the first material used for constructing the glazing borders and the outer frame is much lower than the thermal coefficient Uf of the overlay material. Moreover, the combined thermal coefficient Uf of first and second materials (for example wood and steel/angle iron) is an improvement (lower than) over both a wood frame-aluminum clad window, with or without air gaps between the materials as well as an all metal frame separated by a thermal break and filled with an insulating material.

In general, the U-Factor or U-value measures the rate of heat transfer and informs how well the window insulates. U-factor values generally range from 0.25 to 1.25 and are measured in Btu/h*ft2degrees F. The lower the U-factor, the better the window insulates. U-factor may be divided in Ug for the surface of the glass and Uf for the surface of the casing or frame and Uw being the combination of Ug and Uf representing the total coefficient of heat transmission. In these exemplary embodiments, the primary focus is on Uf for the border, overlay, and combination.

The glazing assemblies142,342may be constructed of conventional glass panes and may incorporate one or more panes with spacers employed in dual or triple pane constructions. The space between the multiple pane sets may either be a vacuum or filled with air or a gas such as Argon.

The exterior stop blocks may be constructed of aluminum or other suitable material that may be finished to resemble the appearance of the exterior face of the overlay. Likewise, the muntins may be constructed of a similar material. Typically, the exterior stop blocks and muntins are constructed separately from the overlays and secured during assembly or installation. The interior stop blocks are typically constructed of the same material as the glazing borders and outer frames and generally machined as part of the constructed process and thus integral with the rest of rest of the glazing borders and outer frames. However, it will be appreciated that the interior stop blocks may be a separate component and secured to the glazing borders and/or outer frames using conventional window and door construction techniques.

Exemplary Assembly and Installation of a Composite Fenestration: Referring nowFIGS. 1A-7 and 15, an exemplary method, generally designated600, of assembling a composite fenestration will now be described with the assumption that the glazing border112and outer frame212are constructed of wood and the inner overlay114and outer overlay214are constructed of angle iron. It will be appreciated that the construction of other embodiments discussed herein involves similar steps. Turning now toFIG. 15, in step602a, the specifications of the rough opening, lighting requirements, and design are obtained either by direct measurement at the job site or from a set of architectural plans or blueprints or other set of criteria from the customer or end user. In this example, the rough opening102(FIGS. 1B-1C) in the structure104is assumed to be plumbed, leveled, and squared. However, the installer will ensure such criteria are met before installing as well as replacing and framing wood prior to installation if needed at step602b. The rough opening is preferably constructed to be larger than the outer sub-assembly210to allow room for shimming, leveling, and plumbing to ensure a pleasing window appearance.

In step604a, the components116,118,120, and122of the glazing border or sash112(FIG. 2) may be precision machined using a CNC machine. Similarly, the components216,218,220, and222of the outer frame212may be precision machined as well at step604b. Other wood border construction methods may be used as well but precision machining is preferred. In step606a, the angle iron components160,162,164, and166or each section of the inner overlay may also be machined by shearing one or both legs to the desired length to match or closely resemble the profile of the perimeter region of the glazing border as discussed above. Likewise, in step806b, the angle iron components260,262,264, and266or each section of the outer overlay214may also be machined by shearing one or both legs to the desired length to match or closely resemble the profile of the perimeter region of the glazing border as discussed above. It will be appreciated that these steps604a,604b,606a,606bmay be accomplished consecutively or simultaneously with the corresponding machinery typically required to machine wood and steel. It will be appreciated that the wood components may be machined to match the profile of the angle irons or, alternatively, the angle irons may be machined to match the profile the profile of the wood components.

In step608a, the glazing border112may be assembled and typically joined using dowels and glue and other suitable fasteners where necessary. The outer frame212may be assembled in a similar manner at step608b. It will be appreciated that, as the overlays provide the structural framework, structural support, or structural integrity for the assemblies given the strength of the ferrous material, it is not necessary to build structural borders and such borders may be made thinner than a conventional wooden frame that provides the structural support of the fenestration if desired.

In step610a, the sash overlay114may be assembled by welding adjacent members160,162,164, and166where they meet to define a structurally integral support structure for the corresponding glazing border112, that is, a structural framework. In step610b, a similar process may be used to assemble the outer overlay members260,262,264, and266together to form a structurally integral support structure for the corresponding outer frame212. The inner and outer overlays114,214may be clamped in place, leveled, and plumbed to ensure a particular fit to meet specifications.

In step612, the surfaces of the overlay components160,162,164,166,260,262,264, and266are finished as desired. For example, angle irons may be hot dipped (galvanized) or metallized. Then, after drying, the angle irons may be colored to add a desired exterior appearance, typically to match architectural specifications or resemble an existing exterior appearance to match existing architecture.

In step614, the inner overlay114may be mounted on a set of sawhorses or other suitable holding jig with the interior facing surface facing up. The outer overlay214may be similarly disposed. At step616, a layer of structural adhesive184(FIG. 7) is applied to the interior surface of the inner overlay114as well as the outer overlay214. Such adhesive prevents a lot of movement between the non-ferrous material and ferrous material once cured. Then, in step618, the glazing border112is slip fit into the inner overlay and then tapped or pressed into the inner overlay114to form an inner sub-assembly110. The inner sub-assembly may then be transported as an integral unit once the adhesive cures. The outer sub-assembly210may be constructed similarly by slip fitting the outer frame212into the outer overlay214and allowing the adhesive to cure.

At step620, decorative elements such as muntins500a.500bshown inFIG. 14may be added. Then, at step622, one more glazings144,146(FIGS. 3-6) with their seals150a-dand spacers148a-dmay be installed followed by the inner and outer stops152a-d,182a-d, respectively. It will be appreciated that the inner stops152a-dmay be machined as part of the border manufacturing process above. With the glazing assembly in place against the inner stops, the outer stops182a-dmay be added and secured to the corresponding overlay.

At step624, weatherstripping components241a-dand243may be added to the inner and outer sub-assemblies110,210as preferred.

For installation purposes, the sub-assemblies may remain separate, transported to the installation site, and then installed there as shown in steps626and628. In such case, the outer sub-assembly210would be secured to the exposed frame of the building104within the rough opening102(FIGS. 1B-1C), the surrounding areas sealed off, and the inner sub-assembly110then affixed to the outer sub-assembly to complete the composite fenestration installation.

Turning now toFIG. 16, another exemplary process, generally designated700, will now be described. In this example, it will be assumed that the specifications and condition of the rough opening and site lighting requirements are known either through an on-site inspection or per plans. Construction and assembly of an exemplary window unit100are used for this description. Starting with step702a, the steel overlay114for the window sash112(or door) is constructed by assembling and welding the four inner steel (angle iron) overlay components160,162,164, and166together at their respective corners. At step702b, a finish or coating may be applied to the inner overlay114. At step704a, the sash components116,118,120, and122selected from a second material are constructed or machined to closely fit their corresponding inner overlay components160,162,164,166, respectively. At this point, it is assumed that the interior surfaces of the sash components have been finished. At step704b, a finish coating may be applied to the exterior surfaces of the sash components116,118,120, and122. At step706a, the outer overlay components260,262,264, and266are assembled together and welded together where the components meet at their respective corners to form the outer overlay214. At step706b, a finish or coating is applied to the outer overlay214. At step708a, the outer frame components216,218,220, and222also selected from a second material are constructed or machined to closely fit their corresponding outer overlay components260,262,264,266, respectively. At this point, it is assumed that the interior surfaces of the outer frame components have been finished. At step708b, a finish or coating may be applied to the outer frame components216,218,220, and222. Although it is preferred to manufacture the ferrous based metal overlays114,214first as these provide a sturdy frame in which to insert the wooden or other second material frame components, this is not meant to be limiting and it will be appreciated that each of the steps702a-b,704a-b,706a-b, and708a-bmay be conducted in parallel or sequentially.

With continued reference toFIG. 16, at step710, the sash112is mated or married to the inner steel overlay114to form an inner sub-assembly110. The sash may be either fully assembled before marrying to the inner steel overlay or married component by component. A layer of adhesive marries the two sections112,114together. If additional fasteners are required, they may be added. At step712, the outer frame212is mated or married to the outer steel overlay214to form an outer sub-assembly210. The outer frame may be either fully assembled before marrying to the outer steel overlay or married component by component. A layer of adhesive marries the two sections212,214together. If additional fasteners are required, they may be added. It will be appreciated that steps710,712may be performed in parallel or sequentially.

With continued reference toFIG. 16, at step714, the inner sub-assembly110may be connected to the outer sub-assembly210. Seals and other weatherstripping components may be added at step716followed by the addition of the mounting flanges197a-caround the periphery of the outer sub-assembly210in step718. The operating hardware such as hinges, latches, crank handles, friction stays, and the like may be added at step720. In step722, the glass unit142may be inserted into the aligned glazing openings124,167and then the inner stops134a-dand outer stops182a-dfollowed by the muntin bars500a,500b(FIG. 14), if used, to form a completed composite fenestration assembly100ready for insertion and connection to the building structure104.

It will be appreciated that such process as shown inFIG. 16may be used for a door or a window construction and assembly with only minor modifications, especially in the sill or threshold areas. One of ordinary skill in the art would understand how to install the door threshold. In addition, the order of the steps is meant to be exemplary and not limiting as, for example, the seals, mounting flanges, hardware, glass, stops, and muntins may be added prior to final assembly of the composite fenestration assembly or in a different order as the manufacturer determines.

While the interior surfaces of the overlays in the embodiments discussed herein generally have no opposing surfaces, it will be appreciated that opposing surfaces may be employed as, for example, the inner overlay member360shown inFIG. 10, However, even with such construction, the overlay member is rigid and may be slip fit onto a corresponding border member without flexing unlike the aluminum cladding constructions that incorporate a clamping construction requiring the flexibility of aluminum to accommodate assembly.

It will further be appreciated that the technical solution provided herein to mate a ferrous based material with a non-ferrous based material to construct, assemble, and install requires the skills of both a woodworker and a metal worker, two very distinct skill and tool sets.

Alternatively, the sub-assemblies110,210or310,410may be assembled together and transported to the installation site. In such case, the outer sub-assembly is secured to the exposed building frame within the rough opening. As the inner sub-assembly is already secured to the outer sub-assembly, the only remaining step is to finish the area surrounding the rough opening to waterproof and close off any openings between the interior and exterior of the building structure.

Regardless of either installation process (pre-assembled sub-assemblies or in situ), the mounting hardware as, for example, hinges, nail fins, and the like may be added to around the peripheries of the inner and outer sub-assemblies110,210, or310,410as required by the site specifications. Operational hardware such as cranks, levers, stays, balances, locks, and the like may also be added, as necessary.

As used throughout this disclosure, glazing is the glass portion of window or door and shall apply to a transparent, opaque, or translucent viewing panel, glass, pane, or the like whereas pane shall refer to a single piece of glass within a window or door. However, it will be appreciated that the panes of glass may be divided into lites or lights, with divided lites or true divided lites (TDLs) being separately framed pieces or panes of glass. Designs simulating the appearance of separately-framed panes are often referred to as simulated divided lites (SDLs). A lite is a piece of glass, typically separately framed. A fixed light of fixed light opening as defined in this disclosure is a window that does not open.

As defined in this disclosure, a sightline is visual feature of a window or door that measures the amount of frame viewable by an observer. For a given sized door or window, a narrower sightline means that more of the glass panel is exposed.

The terms “left”, “right”, “top”. “bottom”, “upper”, “lower”, “vertical”, “horizontal”, “front”, “back”, and “side” are relative terms used throughout the to help the reader understand the figures. Unless otherwise indicated, these do not denote absolute direction or orientation and do not imply a particular preference. Any specific dimensions provided herein are intended to help the reader understand the scale and advantage of the disclosed material. Such dimensions given are typical and the claimed invention is not limited to the recited dimensions.

It will be appreciated that while a rectangular composite fenestration assembly with four sides has been described herein, other shapes may be accommodated simply by altering the shape of the borders and their respective overlays. Circular portals, triangular, square, and irregular, non-geometric shapes are contemplated to fall within this disclosure. Typically, the window borders will be constructed with opposing stiles, head, and sill while door borders constructed of opposing top and bottom rails and opposing stiles, but this is not meant to be limiting and other configurations will occur to one of ordinary skill in the art. Along these lines, the composite fenestration assembly may include a border, frame, or overlay with a gap having a different construction as, for example, the door threshold as described above.

It will further be appreciated that the overlay, border, and frame openings generally align. However, such alignment may be coplanar, parallel, offset, or substantially aligned and does not require an exact matching alignment in the same plane. The opening of one component may be greater or lesser than another. For example, the opening defined by the outer frame is generally greater than the opening of the glazing border from the interior to the exterior, top to the bottom, and left to the right so as to accommodate insertion of the inner sub-assembly. In general, the orientation of the openings defined by the overlays, borders, and/or frame merely cooperate to define a fenestration with a viewing window or pane having one or more sightlines that are preferably not obstructed by the overlays.

It will be appreciated that the composite fenestration assembly may be used in new construction and also to retrofit a building once the prior window assembly is removed and the rough opening prepared. The composite fenestration assembly may be manufactured and assembled in a remote location and transported to the installation or job site for final installation as a completed assembly or may be partially assembled remotely and then fully assembled at the site during final installation.

While the foregoing has been described in terms of an inner sub-assembly and an outer sub-assembly that may cooperate to define a complete composite fenestration assembly, it will be appreciated that the inner sub-assembly alone is within the scope of this disclosure as, for example, a direct-set window in which the inner sub-assembly provides both the glazing and the frame that may be secured directly to the rough opening framing. In addition, the inner sub-assembly may be constructed in a different manner than the outer sub-assembly.