Abstract:
A method for producing window components using polymer based, metallurgy based, extruded, injection molded, or wood material is provided. This invention provides a low cost, highly reliable, low defect method of producing window components by machining from a singular piece of material, providing bendable portions, with angled portions adapted to fit together to define a wide range of window shapes and sizes.

Description:
This application is based on Provisional Patent Application Serial No. 60/157,625, which was filed on Oct. 4, 1999, and priority is claimed thereto. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to the manufacture of window systems. More specifically, this invention relates to the manufacture of window systems using polymer based or metallurgy based component parts. 
     2. Description of Related Art 
     A variety of methods and process for the construction of window system assemblies have been proposed. Typically, these prior methods and processes require costly, complex, inconsistent, error and waste prone, susceptible to defects manufacturing steps. Generally, these prior methods and processes require a large number of pieces of equipment and skilled craftsmen. For general background, the reader is directed to the following United States Patent Nos., each of which is hereby incorporated by reference in its entirety for the material contained therein: U.S. Pat. Nos. 4,327,142, 4,407,100, 4,460,737, 5,155,956, 5,491,940, 5,540,019, 5,555,684, 5,585,155, 5,603,585, 5,620,648, 5,622,017, and 5,799,453. The reference to this related U.S. Patent documents is not an admission of prior art, as the inventor&#39;s date of invention may predate the date of filing and/or publication of these references. 
     SUMMARY OF THE INVENTION 
     It is desirable to provide a method and process of the manufacture window systems, which makes use of singular advanced components of a polymer based or metallurgy based window system, that minimizes complexity, cost, product inconsistencies, defects, while producing a universal window system using largely automated procedures and advanced materials. 
     Therefore, it is a general object of this invention to provide a method and process for the construction of universal window systems, using advanced components of a polymer based or a metallurgy based product. 
     It is a further object of this invention to provide a method and process for the construction of universal window systems that reduces labor costs. 
     It is a still further object of this invention to provide a method and process for the construction of universal window systems that reduces the defects of the window system products. 
     Another object of this invention is to provide a method and process for the construction of universal window systems that makes use of automation techniques to improve product quality. 
     A further object of this invention is to provide a method and process for the construction of universal window systems that produces window components in a singular form. 
     A still further object of this invention is to provide a method and process for the construction of universal window systems that works with extruded, injected, or other composite derived materials. 
    
    
     These and other objects of this invention will be readily apparent to those or ordinary skill in the art upon review of the following drawings, detailed description and claims. In the preferred embodiment of this invention, the method and process of this invention are described as follows. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In order to show the manner that the above recited and other advantages and objects of the invention are obtained, a more particular description of the preferred embodiment of this invention, which is illustrated in the appended drawings, is described as follows. The reader should understand that the drawings depict only a present preferred and best mode embodiment of this invention, and are not to be considered as limiting in scope. A brief description of the drawings is as follows: 
     FIG. 1 a  is a window component profile, manufactured using the process of this invention. 
     FIG. 1 b  is an alternative window component profile, manufactured using the process of this invention. 
     FIG. 2 a  is a window component profile in the rotational stage of the process of this invention. 
     FIG. 2 b  is an alternative window component profile in the rotational stage of the process of this invention. 
     FIG. 3 a  is a completed window component in the final stage ready for installation. 
     FIG. 3 b  is an alternative completed window component in the final stage ready for installation. 
     FIG. 4 is a process flow diagram of the preferred method of this invention. 
     Reference will now be made in detail to the present preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 a  shows a window component profile, manufactured using the process of this invention. This preferred embodiment of the window component has three generally elongate sections  101   a ,  101   b ,  101   c  and two half sections  102   a ,  102   b , each connected  113   a ,  113   b ,  113   c ,  113   d  to an adjacent section. In alternative embodiments, when it is desired to have windows with non-rectangular shapes, the number of sections can be increased or reduced. For example, a triangular shaped window may have only two long sections and two half sections. In another example, an octagonal shaped window may have seven long sections and two half sections. The connections  113   a ,  113   b ,  113   c ,  113   d  are flexible permitting a bend at the connection  113   a ,  113   b ,  113   c ,  113   d . The preferred elongate sections  101   a ,  101   b ,  101   c  and half sections  102   a ,  102   b  are preferably made of a composite material, molded, cut, milled, routed or otherwise shaped in to the desired generally decorative shape. While the sections  101   a ,  101   b ,  101   c  are shown, in this embodiment, as being of generally the same length, in alternative embodiments, the sections  101   a ,  101   b ,  101   c  may have different lengths as appropriate to the desired window shape. Each section  101   a ,  101   b ,  101   c  is provided with two diagonal cut sloped portions (respectively  105 ,  106 ;  107 ,  108 ; and  109 ,  110 ). These diagonal cut sloped portions  105 ,  106 ,  107 ,  108 ,  109 ,  110  are shown having an angle of 45 degrees, however, in alternative embodiments this angle may be either increased or decreased as necessary in order to facilitate the joining of two adjacent diagonal sloped portions, to thereby produce a window component having the desired shape. The ends  103  and  112  are, in this embodiment, at approximately 90 degrees from the base  100  of the window portions, thereby facilitating the joining of the ends  103 ,  112 , as shown in FIG. 3 a.    
     FIG. 1 b  shows an alternative window component profile, manufactured using the process of this invention. This second preferred embodiment of the window component has four generally elongate sections  114   a ,  114   b ,  114   c ,  114   d  each connected  116   a ,  116   b ,  116   c  to an adjacent section. In alternative embodiments, when it is desired to have windows with non-rectangular shapes, the number of sections can be increased or reduced. For example, a triangular shaped window may have only three long sections. In another example, an octagonal shaped window may have eight long sections. The connections  116   a ,  116   b ,  116   c  are flexible permitting a bend at the connection  116   a ,  116   b ,  116   c . The preferred elongate sections  114   a ,  114   b ,  114   c ,  114   d  are preferably made of a composite material, molded, cut, milled, routed or otherwise shaped in to the desired generally decorative shape. While the sections  114   a ,  114   b ,  114   c ,  114   d  are shown, in this embodiment, as being of generally the same length, in alternative embodiments the sections  114   a ,  114   b ,  114   c ,  114   d  may have different lengths, as appropriate for the desired window shape. Each section  114   a ,  114   b ,  114   c ,  114   d  is provided with two diagonal cut sloped portions (respectively  115   a ,  115   b ;  115   c ,  115   d ;  115   e ,  115   f ;  115   g ,  115   h ). These diagonal cut sloped portions  115   a ,  115   b ,  115   c ,  115   d ,  115   e ,  115   f ,  115   g ,  115   h  are shown having an angle of 45 degrees, however, in alternative embodiments this angle may be either increased or decreased as necessary in order to facilitate the joining of two adjacent diagonal sloped portions, to thereby produce a window component having the desired shape. The joining of the ends  117 ,  118  are as shown in FIG. 3 b  to form the complete window component. 
     FIG. 2 a  shows a window component profile in the rotational stage of the process of this invention. This view shows the window component of FIG. 1 a , with the diagonal sloped portions  106 ,  107  and  108 ,  109  brought into contact and joined to form corners  201 ,  202  and thereby the bottom  205  of the window component. 
     FIG. 2 b  shows an alternative window component profile in the rotational stage of the process of this invention. This view shows the window component of FIG. 1 b , with the diagonal sloped portions  15   b ,  115   c  and  115   d ,  115   e  brought into contact and joined to form corners  203 ,  204  and thereby the bottom  206  of the window component. 
     FIG. 3 a  shows a completed window component in the final stage ready for installation of the window component of FIG. 1 a . Ends  103  and  112  are connected forming a joint  301  at the top  309  of the window component. Diagonal sloped portions  104 ,  105  and  110 ,  111  are brought into contact and joined to form corners  302  and  303  and to define an interior  307  suitable for holding and retaining glass or other similar transparent or semi-transparent material. The joints  301 ,  311 ,  312 ,  313 ,  314  are typically and preferably made using adhesive, although alternatives such as bolts, screws, pins, clips and the like can be substituted without departing from the concept of this invention. 
     FIG. 3 b  shows a completed window component in the final stage ready for installation of the window component of FIG. 1 b . Ends  117  and  118  are connected forming a joint  315  of the diagonal sloped portions  115   a ,  115   h , thereby forming a corner  304 . Diagonal sloped portions  115   f ,  115   g  are brought into contact and joined to form corner  305  and to define an interior  308  suitable for holding and retaining glass or other similar transparent or semi-transparent material. The joints  315 ,  316 ,  317 ,  318  are typically and preferably made using adhesive, although alternatives such as bolts, screws, pins, clips and the like can be substituted without departing from the concept of this invention. 
     FIG. 4 shows a process flow diagram of the preferred method of this invention. Initially, the material is fed  400  into the assembly process. Next, the material is straight cut  401  preferably by a saw or mill machine. The cut material is set  402  for Lifter or Balance Holding punch, preferably on a drill or router machine. The material is then punched  403  for the lifter clip, also preferably on a drill or router machine. Weep punching  404  is next performed on the material, again typically using a punch, drill or router machine. These punching steps are used to provide ventilation and drainage points in the window component. Miscellaneous processing  405  is performed to remove loose material and/or rough edges. A first three-way cut  405  is made, to produce diagonal portions, preferably using a cutter, grinder, or corner set. A second three-way cut  406  is made, to produce additional diagonal portions, also preferably using a cutter, grinder or corner set. A second weep punch  408  is made to further provide additional drainage and ventilation, preferably using a drill or router machine. A polymer compound is applied  409  to the joint regions thereby providing durable, flexible corners. Identification markings are applied  410  to permit control and tracking of window components. The assembly or window component is rotated with the corner and/or end portions joined together using adhesive, screws, bolts, clips, pins or the like forming the complete window component ready for the insertion of the transparent medium and for installation in the building structure. 
     The described embodiments of this invention are to be considered in all respects only as illustrative and not as restrictive. Although specific steps and window system components are illustrated and described, the invention is not to be limited thereto. The scope of this invention is, therefore, indicated by the claims. All changes, which come within the meaning and range of equivalency of, the claims are to be embraced as being within their scope.