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FIELD OF THE INVENTION 
       [0001]    The invention relates to the manufacture of thermal break sections for the use in the manufacture of window, door, skylight frame assemblies and other fenestration related assemblies. 
       BACKGROUND OF THE INVENTION 
       [0002]    Elongate metal sections for use in the manufacture of window and door frame assemblies are commonly extruded from aluminum. As is well known, it is often desirable for the interior and exterior parts of the section to be thermally isolated from one another. This thermal isolation prevents the low temperature of the exterior parts being transmitted to the interior parts and resulting in undesirable condensation on the internal surfaces. To this end it is common practice to provide a thermal break by connecting the interior and exterior parts of the section only by means of a nonmetallic connector of low thermal conductivity. 
         [0003]    Following are two examples of methods used for providing such a thermal break. In a first method the section is formed from two separately preformed metal extrusions. These are connected together by preformed rigid non-metallic strips which are designed to interlock with the two metal extrusions respectively. Two non-metallic strips are often provided in spaced relation so as to form, with the metal extrusions, a hollow box section. There is then injected into this hollow box section a settable liquid plastics material, the setting of which forces the non-metallic strips and metal extrusions into rigid fixed relation. 
         [0004]    A second common method of manufacturing a section with a thermal break is by the method known as “pour and cut”. According to this method the section is initially extruded and shaped to define an upwardly facing open channel. The channel is then filled with a settable liquid of low thermal conductivity, usually a plastics resin, which is then allowed to set. The part of the section forming the bottom of the channel is then cut through or debridged longitudinally, usually by a product from Azon USA, Inc. sold under the trademark “Bridgemill HMI”. If necessary, any other parts of the section connecting the interior and exterior parts thereof are also debridged so that the interior and exterior parts remain connected solely by the solidified resin, which thus provides the thermal break. 
       SUMMARY OF THE INVENTION 
       [0005]    According to the invention, an architectural thermal barrier component and method of forming same includes an elongate section incorporating a thermal break, for example for use in the manufacture of window or door frame assemblies. The method comprises forming multiple co-extensive elongate elements, one of which includes a channel portion, aligning the elongate elements with one another, crimping the elements in engagement with one another, filling the channel with a settable liquid of low thermal conductivity, effecting solidification of the settable liquid to form a solidified thermal barrier element, and cutting longitudinally through or debridging any part of the elongate elements that bridges the thermal barrier element. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    The following is a more detailed description of an embodiment of the invention, by way of example, reference being made to the accompanying drawings in which: 
           [0007]      FIG. 1  is a cross-sectional view of two metal extrusions according to the invention. 
           [0008]      FIG. 1A  is an enlarged cross-sectional view of a portion of the two metal extrusions according to  FIG. 1 . 
           [0009]      FIG. 2  is a cross-sectional view of a port of the two metal extrusions of  FIG. 1  in an engaged and unlocked condition. 
           [0010]      FIG. 2A  is an enlarged cross-sectional view of a portion of the two metal extrusions according to  FIG. 2 . 
           [0011]      FIG. 3  is a cross-sectional view of the two metal extrusions of  FIGS. 1-2  in an engaged and locked or crimped condition. 
           [0012]      FIG. 3A  is an enlarged cross-sectional view of a portion of the two metal extrusions according to  FIG. 3 . 
           [0013]      FIG. 4  is a cross-sectional view of the two metal extrusions of  FIGS. 1-3  after a settable resin has been placed. 
           [0014]      FIG. 5  is a cross-sectional view of the two metal extrusions of  FIGS. 1-4  after a portion of one of the metal extrusions has been cut away or debridged. 
           [0015]      FIG. 6  is a cross-sectional view of metal extrusions for use in the method according to a further embodiment of the invention. 
           [0016]      FIG. 7  is a cross-sectional view of the metal extrusions of  FIG. 6  in an engaged and locked condition. 
           [0017]      FIG. 8  is a cross-sectional view of the metal extrusions of  FIGS. 6-7  after a settable resin has been placed and a portion of one of the extrusions has been cut away or debridged. 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    Certain terminology will be used in the following description for convenience and reference only, and will not be limiting. For example, the words “upwardly”, “downwardly”, “rightwardly” and “leftwardly” will refer to directions in the drawings to which reference is made. The words “inwardly” and “outwardly” will refer to directions toward and away from, respectively, the geometric center of the arrangement and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import. 
         [0019]    Referring to  FIG. 1 , an architectural thermal barrier component such as a window or door frame assembly  10  includes exterior and interior architectural elements  15 ,  20  extruded from a heat-conducting material, such aluminum or other metals. The elements  15 ,  20  are configured for assembly and receipt of a material with low thermal conductivity to form a thermal break in the window frame assembly  10 . 
         [0020]    As shown in  FIGS. 1-5 , the exterior element  15  includes a planar portion  25  which has a flat outer surface  30  providing a visible exterior surface of the window frame assembly  10 . A box construction  35  projects from an inner surface  40  of the planar portion  25  and includes an upper side  45  and a lower side  50 . The upper and lower sides  45 ,  50  are joined at an inner end  55  of the box construction  35  by a transverse flange  60 . The upper and lower sides  45 ,  50  taper inwardly toward each other at their inner ends  65 ,  70  so that respective upper and lower recesses  75 ,  80  are formed between the upper and lower sides  45 ,  50  and the transverse flange  60 . The upper side  45  further includes an internal screw channel  85  to aid in assembling the window frame assembly  10 , as is known in the art. 
         [0021]    The interior element  20  includes a planar portion  90  which has a flat outer surface  95  providing a visible interior surface of the window frame assembly  10 . A box construction  100  projects from an inner surface  105  of the planar portion  90  and includes an upper side  110  and a lower side  115 . The upper and lower sides  110 ,  115  are joined at an inner end  120  of the box construction  100  by an inner side  125 . The upper side  110  further includes an internal screw channel  130  to aid in assembling the window frame assembly  10 , as is known in the art. 
         [0022]    The interior element  20  further includes a channel portion  135  extending from the inner side  125  of the box construction  100 . The channel portion  135  includes a channel floor section  140  extending inwardly, generally perpendicular to the inner side  125 , proximate the lower side  115  of the box construction  100 . A left channel side  145  extends upwardly from a left end  150  of the channel floor section  140 . A flange  155  extends from an upper end  160  of the inner side  125 , and a corresponding flange  165  extends from an upper end  170  of the left channel side  145 . Each of the flanges  155 ,  165  includes a depending end portion  175 ,  180  respectively. Projections  185 ,  190  arise from the channel floor section  140 , aligned with the depending end portions  175 ,  180 . Guide notches  192 ,  193  are provided on a lower surface  194  of the channel floor section  140  inwardly of the projections  185 ,  190 . 
         [0023]    Upper and lower projections in the form of hooks  195 ,  200  extend from the left channel side  145 . The upper hook  195  extends leftwardly from the upper end  170  of the left channel side  145 , and includes an inwardly directed barb  205 . The lower hook  200  extends leftwardly from a lower end  210  of the left channel side  145  and includes an inwardly directed barb  215 . 
       Method of Assembly 
       [0024]    As shown in  FIGS. 1 and 1A , the interior and exterior elements  15 ,  20  are positioned ready for, but prior to, assembly. In  FIGS. 2 and 2A , the elements  15 ,  20  have been brought together such that the flange  60  is close against the left channel side  145 . During the initial assembly necessary to reach the condition shown in  FIGS. 2 and 2A , the flange  60  must pass between hooks  195 ,  200  or, more specifically, barbs  205 ,  215 . The flange  60  is, however, wider than the distance between the barbs  205 ,  215 . 
         [0025]    One method of passing the flange  60  between the hooks  195 ,  200  is to move the elements  15 ,  20  laterally into engagement. As the elements  15 ,  20  move together, the hooks  195 ,  200  will contact the flange  60 . As the flange  60  passes between the barbs  205 ,  215 , the hooks  195 ,  200  will flex slightly until the barbs  205 ,  215  clear the flange  60 . As the barbs  205 ,  215  clear the flange  60 , there will be an audible and tactile “click” indicating to an assembler that the elements  15 ,  20  are in the initial assembled position. 
         [0026]    Another method of passing the flange  60  between the hooks  195 ,  200  is to arrange the interior and exterior elements  15 ,  20  substantially end to end, aligning the hooks  195 ,  200  with the recesses  75 ,  80 . The elements  15 ,  20  are then moved longitudinally to a side by side configuration as the hooks  195 ,  200  slide longitudinally into the recesses  75 ,  80 . 
         [0027]    Once assembled by either method, the upper hook  195  is aligned with the upper recess  75  and the lower hook  200  is aligned with the lower recess  80 . The upper and lower hooks  195 ,  200  are splayed slightly outwardly from the recesses  75 ,  80  so that they are not firmly engaged within the recesses  75 ,  80 . However, a sufficient portion of the upper and lower hooks  195 ,  200  are received into the recesses  75 ,  80  to effect a holding together of the exterior element  15  and the interior element  20  to enable the assembler to easily handle the loosely connected together parts during a furtherance of the processing and without the elements  15 ,  20  becoming easily disconnected. Since a two color scheme is to be employed, which color was applied to the exterior elements  15  and the interior elements  20  prior to the implementation of the loose connection therebetween, the thickness of the color coating on the exterior and interior elements  15 ,  20  will not impact or negate the loose connection described above. 
         [0028]    Referring to  FIGS. 3 and 3A , the hooks  195 ,  200  have been locked or crimped into the recesses  75 ,  80 . The interior element  20  is thereby locked onto the exterior element  15  by the hooks  195 ,  200  engaging the recesses  75 ,  80  and specifically the barbs  205 ,  215  engaging a back surface of the flange  60 . This locking or crimping will effect the required fixed locking of the exterior and interior elements  15 ,  20  together so that the elements  15 ,  20  cannot move with respect to one another. This fixed locking will occur independent of the respective thicknesses of the color coating on the exterior and interior elements  15 ,  20 . That is, the crimping will impart a plastic deformation of the material of the color coating so that a metal to metal connection will exist without the material of the color coating coming between the elements  15 ,  20  and negatively impacting the integrity or longevity of the connection. 
         [0029]    Referring to  FIG. 4 , the next step of forming the window or door frame assembly  10  is the application of a thermal barrier material  220 , such as poured polyurethane or other plastic or composite material having a low thermal conductivity. Examples of such materials are the “su” (structural urethane) series of thermal barrier chemicals, produced by Azon USA, Inc. of Kalamazoo, Mich. In order to fill the channel portion  135 , the combined section is fed into a conventional “pour and cut” machine (not shown). The construction and operation of such machines is well known and will not therefore be described in detail. The thermal barrier material  220  is applied to fill the channel portion  135 . As the thermal barrier material  220  cures and solidifies, it is physically engaged by the depending end portions  175 ,  180  of the flanges  155 ,  165  and the projections  185 ,  190  of the channel floor section  140 . 
         [0030]    After the thermal barrier material  220  has cured, a circular saw or other cutting implement (not shown) integral in the “pour and cut” machine is traversed longitudinally of the assembly  10  so as to cut through or debridge the channel floor section  140  between the notches  192 ,  193  and between the projections  185 ,  190 . The mechanical connection between the thermal barrier material  220  and the elements  15 ,  20  is thereby undisturbed as the projections  185 ,  190  remain intact and embedded in the thermal barrier material  220 . The assembly  10  thereby remains mechanically connected, but the “debridging” of the channel floor section  140  creates a thermal break between the exterior and interior elements  15 ,  20 . The only thermal connection between the elements  15 ,  20  is now through the thermal barrier material  220 , which has low thermal conductivity. 
       ALTERNATE EMBODIMENT 
       [0031]    In a further embodiment of the invention, shown in  FIGS. 6-8 , a window frame assembly  230  for including a thermal break includes exterior and interior architectural elements  235 ,  240  and a connecting element  245 . The exterior element  235  is formed in similar fashion to the exterior element  15  of the first embodiment above. The exterior element  235  includes a planar portion  250  which has a flat outer surface  255  providing a visible exterior surface of the window frame assembly  230 . A box construction  260  projects from an inner surface  265  of the planar portion  250  and includes an upper side  270  and a lower side  275 . The upper and lower sides  270 ,  275  are joined at an inner end  280  of the box construction  260  by a transverse flange  285 . The upper and lower sides  270 ,  275  taper inwardly toward each other at their inner ends  290 ,  295  so that respective upper and lower recesses  300 ,  305  are formed between the upper and lower sides  270 ,  275  and the transverse flange  285 . The upper side  270  further includes an internal screw channel  310  to aid in assembling the window frame assembly  230 , as is known in the art. 
         [0032]    The interior element  240  includes a planar portion  315  which has a flat outer surface  320  providing a visible interior surface of the window frame assembly  230 . The remainder of the interior element  240  is formed similar to the exterior element  235 . A box construction  325  projects from an inner surface  330  of the planar portion  315  and includes an upper side  335  and a lower side  340 . The upper and lower sides  335 ,  340  are joined at an inner end  345  of the box construction  325  by a transverse flange  350 . The upper and lower sides  335 ,  340  taper inwardly toward each other at their inner ends  355 ,  360  so that respective upper and lower recesses  365 ,  370  are formed between the upper and lower sides  335 ,  340  and the transverse flange  350 . The upper side  335  further includes an internal screw channel  375  to aid in assembling the window frame assembly  230 , as is known in the art. 
         [0033]    The connecting element  245  includes a channel portion  380 . The channel portion  380  is formed by a channel floor section  385  and a pair of opposing, upright left and right channel walls  390 ,  395 . A flange  400 ,  405  extends inwardly from an upper end  410 ,  415  of each of the channel walls  390 ,  395 . Each of the flanges  400 ,  405  includes a depending end portion  430 ,  435  respectively. Projections  440 ,  445  arise from the channel floor section  385 , aligned with the depending end portions  430 ,  435 . Guide notches  450 ,  455  are provided on a lower surface  460  of the channel floor section  385  inwardly of the projections  440 ,  445 . 
         [0034]    Upper and lower hooks  465 ,  470  extend outwardly from the left channel wall  390 . The upper hook  465  extends outwardly from the upper end  410  of the left channel wall  390 , and includes an inwardly directed barb  475 . The lower hook  470  extends outwardly from a lower end  480  of the left channel wall  390  and includes an inwardly directed barb  485 . In like manner, upper and lower hooks  490 ,  495  extend outwardly from the right channel wall  395 . The upper hook  490  extends outwardly from the upper end  415  of the right channel wall  395 , and includes an inwardly directed barb  500 . The lower hook  495  extends outwardly from a lower end  505  of the right channel wall  395  and includes an inwardly directed barb  510 . 
         [0035]    In much the same fashion as the first embodiment, the window frame assembly  230  is assembled by drawing together the exterior and interior elements  235 ,  240 . In the instant embodiment, however, the connecting element  245  is placed between the exterior and interior elements  235 ,  240  such that the flanges  285 ,  350  are close against the left and right channel walls  390 ,  395  respectively. The audible and tactile “click” will indicate to the assembler that each of the exterior and interior elements  235 ,  240  has engaged the connecting element  245 . The elements  235 ,  240 ,  245  can also be initially assembled by longitudinal sliding, as in the first embodiment. In this arrangement, the upper hook  465  is aligned with the upper recess  300  of the exterior element  235  and the lower hook  470  is aligned with the lower recess  305  of the exterior element  235 . Likewise, the upper hook  490  is aligned with the upper recess  365  of the interior element  240  and the lower hook  495  is aligned with the lower recess  370  of the interior element  240 . 
         [0036]    The upper and lower hooks  465 ,  470 ,  490 ,  495  are, however, splayed slightly outwardly from the recesses  300 ,  305 ,  365 ,  370  so that they are not firmly engaged. As in the above embodiment, the hooks  465 ,  470 ,  490 ,  495  are locked or crimped into the recesses  300 ,  305 ,  365 ,  370  to lock the exterior and interior elements  235 ,  240  onto the connecting element  245 , as shown in  FIG. 7 . 
         [0037]    The next step of forming the window or door frame assembly  230  with thermal break section is the application of a thermal barrier material  515  such as poured polyurethane or other plastic or composite material having a low thermal conductivity. The combined section is fed into a conventional “pour and cut” machine (not shown). The construction and operation of such machines is well known and will not therefore be described in detail. The thermal barrier material  515  is applied to fill the channel portion  380 . As the thermal barrier material  515  cures and solidifies, it is physically engaged by the depending end portions  430 ,  435  of the flanges  400 ,  405  and the projections  440 ,  445  of the channel floor section  385 . 
         [0038]    After the thermal barrier material  515  has cured, a circular saw or other cutting implement (not shown) integral in the “pour and cut” machine is traversed longitudinally of the assembly  230  so as to cut through or debridge the channel floor section  385  between the notches  450 ,  455  and between the projections  440 ,  445 . The mechanical connection between the thermal barrier material  515  and the separated left and right walls  390 ,  395  of the channel portion  380  is thereby undisturbed as the projections  440 ,  445  remain intact and embedded in the thermal barrier material  515 , as shown in  FIG. 8 . The assembly  230  thereby remains mechanically connected, but the “debridging” of the channel floor section  385  creates a thermal break between the exterior and interior elements  235 ,  240 . The only thermal connection between the elements  235 ,  240  is now through the thermal barrier material  515 , which has low thermal conductivity. 
         [0039]    The arrangements described above have the advantage that the elements  15 ,  20 ,  235 ,  240  can be extruded consistently with the required tolerances using conventional extrusion technology. The “pour and cut” apparatus can have a conventional configuration and can be used in the conventional manner when the combined section has been assembled. 
         [0040]    The pre-coloring of the elements may be carried out by any of the commonly used methods. The detailed dimensions of the inter-engaging parts of the elements may be so selected as to allow for the thickness of the colored coating and the lesser hardness of the coating may be employed to compensate for tolerances in the dimensions of the inter-engaging parts. 
         [0041]    While the invention has been described in the specification and illustrated in the drawings with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as defined in the claims. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this invention, but that the invention will include any embodiments falling within the scope of the appended claims.

Summary:
According to the invention, an architectural thermal barrier component and method of forming same includes an elongate section incorporating a thermal break, for example for use in the manufacture of window, door, skylight frame assemblies and other fenestration related assemblies. The method comprises forming multiple co-extensive elongate elements, one of which includes a channel portion, and aligning the elongate elements with one another by snap-fitting the elements together or sliding the elements together longitudinally. After the initial assembly, the method includes crimping the elements in engagement with one another, filling the channel with a settable liquid of low thermal conductivity, effecting solidification of the settable liquid to form a solidified thermal barrier element, and cutting longitudinally through or debridging any part of the elongate elements that bridges the thermal barrier element.