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:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is based on copending U.S. patent application Ser. No. 09/679,220, filed on Oct. 3, 2000, which in turn 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 INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    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.  
           [0004]    2. Description of Related Art  
           [0005]    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. 2,037,611, 2,047,835, 2;21 9,594, 2,781,111, 2,952,342, 3,074,772, 3,087,207, 3,287,041, 3,305,998, 3,315,431, 3,327,766, 3,348,353, 3,376,670, 3,484,126, 3,802,105, 3,854,248, 4,269,255, 4,327,142, 4,407,100, 4,460,737, 4,597,232, 4,941,288, 5,155,956, 5,1 89,841, 5,491,940, 5,540,019, 5,555,684, 5,585,1 55, 5,603,585, 5,620,648, 5,622,01 7, 5,799,453, 5,901,509, 6,047,514 and 6,073,412. 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 INVENTION  
         [0006]    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.  
           [0007]    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.  
           [0008]    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.  
           [0009]    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.  
           [0010]    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.  
           [0011]    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.  
           [0012]    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.  
           [0013]    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 DRAWINGS  
       [0014]    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.  
         [0015]    [0015]FIG. 1 b  is an alternative window component profile, manufactured using the process of this invention.  
         [0016]    [0016]FIG. 2 a  is a window component profile in the rotational stage of the process of this invention.  
         [0017]    [0017]FIG. 2 b  is an alternative window component profile in the rotational stage of the process of this invention.  
         [0018]    [0018]FIG. 3 a  is a completed window component in the final stage ready for installation.  
         [0019]    [0019]FIG. 3 b  is an alternative completed window component in the final stage ready for installation.  
         [0020]    [0020]FIG. 4 is a process flow diagram of the preferred method of this invention.  
         [0021]    [0021]FIG. 5 is a detailed flow chart of the present, typically although not necessarily automated, process of this invention. 
     
    
       [0022]    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  
       [0023]    [0023]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.    
         [0024]    [0024]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.  
         [0025]    [0025]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.  
         [0026]    [0026]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  115   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.  
         [0027]    [0027]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.  
         [0028]    [0028]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.  
         [0029]    [0029]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, or notch,  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.  
         [0030]    [0030]FIG. 5 shows a detailed flow chart of the present, typically although not necessarily automated, process of this invention. This present embodiment of the invention may employ automation techniques and technology to improve the quality and consistency of the manufacturing process while simultaneously reducing labor and material costs. Although the steps of the process shown in this FIG. 5 accommodate automation technology, the reader should understand that in alternative envisioned embodiments, the steps can be performed in a manual fashion. Data profiles are received  501  by a control processor. A typical control processor is a programmable computer, although alternative processors, such as single purpose electronic devices could be substituted without departing from the concept of this invention. The data profiles include information related to the desired window shape, size, texture, color, frame material (also referred to herein as construction material), glass or other medium type and/or other features typically specified in the construction of window frames. Frame window materials are typically selected from but are not necessarily limited to composites, plastic, metal, and wood reinforced with a foldable back portion. Textures include patterns, roughness and the like in the surface of the construction material. Window shapes supported by this invention include square, rectangular, triangular, octagonal, and other polygonal shapes, circular, oval and other curved shapes. Moreover, the window shapes may be either an irregular or normal polygon, and includes trapeziums, half rounds, and ellipses. The data profile also typically includes dimensional information, such as height, width and thickness of desired frame(s). This dimensional information may be input, or received by the processor in various units, including either English units (inches, feet, yards) and/or metric units (centimeters, meters). The data profile also includes information concerning the type and size of desired transparent, or semi-transparent, material. Typically, this material is glass, although plastic, acrylic, composite or other generally transparent, window compatible material can be substituted without departing from the concept of this invention. Also, typically described in the data profile is the frame material, color and texture used and desired, as well as such other window-type features, such as single pane windows, double pane windows, horizontal sliders, single or double hung sliders, patio doors, shaped windows, picture windows, and other types of windows known in the art.  
         [0031]    The control processor, which may be a distributed processor in communication with a processor receiving the data, a separate processor computing, and a still other processor controlling the manufacturing equipment and perhaps a further processor tracking the process of the window components through the process of this invention, computes  502  the cutting and notching of the received material. This computation step  502  preferably includes calculating the length of window frame components (which will be produced from the received material), calculates and/or selects the positioning of the notches within each window frame component, as well as the angle of the sloped or “notch” portion as well as the distance between notches. In general, for a regularly shaped square or rectangular window, the notch angles would be 45 degrees and the number of elongated sections would be four, while for an octagon the notch angles would be 22.5 degrees and the number of elongated sections would be eight. In order to provide certain curved window shapes the notch angles may also be non-linear. The notch angles are selectable generally from 0 degrees to 180 degrees to provide for a selection of a generally continuous set of window shapes. The number of notch angles is also selectable, with four angles in each notch being typical. The data treatment calculation may include tolerance ranges from 0.000 inches to 0.500 inches to account for potential stretching of various construction materials. Construction materials are received  503 . Typically, these construction materials are received in a single piece form and often have a nail fin provided on the outer surface area. A cutter is provided to perform the cutting operation for cutting the received construction materials to the required length of the window frame component and to create the notches defining the sections (also referred to as elongated sections) of the window component. Typically, this cutter is a mill, router, saw, compression metal cutter, high-pressure water jet cutter, heat or torch cutter, and the like. A wide variety of construction materials may be used with this invention, including, but not necessarily limited to vinyl, plastic, polymers, wood, metal, fiberglass and/or other composite materials. Once the construction materials are received  503 , the processor activates  504  the cutter using the notching sequences previously calculated to perform the cutting and notching sequences on the construction material to produce a linear physical profile. In the present embodiment this activation  504  is a batch computation process. In the present embodiment, a mill cuts  505  the construction material to length and cuts the angled notches in the construction material to define the sections. In one present embodiment the angled notches are made sequentially, in other embodiments multiple angled notches are made simultaneously or at least with several cutters operating independent from each other. In one embodiment of the process movement of the construction material is done automatically, while in other embodiments, a person may be required or prompted to move the material as required to position for angled notching. In some embodiments, the angled notches define sections of equal length, in other embodiments; the angled notches define sections of unequal length. Typically, a three-way notch or cut is provided to produce the diagonal partial cut-through notches of the present embodiment. Drilling or punching  506  operations may then be performed to introduce openings in the construction material for drainage, air filtration, placement of hardware, routing of conduit and/or dimpling. A composite material may then be applied  507  to the surface of the construction material to improve flexibility, durability and weather proofing of the resulting frame. The selected composite material applied is selected to be appropriate to the construction material, and is typically a polymer compound with high temperature tolerance and moisture resistance. An adhesive material, typically a chemical or polymer adhesive, is applied  508  to the angled notch portions to assist in the adhesion of the after folded corners. After the typically batch system has completed cutting operations  505 , the construction material is folded  509  to form one or more corners from the ends of the individual sections. During and/or after the folding step  509  additional adhesive may be injected to provide a seal in the folded corners. After folding  509 , the construction material takes on the shape of the desired window shape, such as a square, rectangle or other selected shape identified in the received  501  data, and an interior adapted to hold in place the selected transparent medium. The selected transparent medium is typically glass, although alternatives including plastic, acrylic and other similar transparent or semi-transparent materials can be substituted without departing from the concept of this invention. In an alternative embodiment, the construction material is folded  509  after each angled notch cutting operation  505 , so that with each fold, the appearance of the material increasingly resembles the desired shape and selected data profile. A second typically polymer composite, typically adhesive, material is injected  510  in each corner thereby affixing the construction material in the desired shape. This second polymer composite also enhances the seal in the corners and may be used to retain the transparent medium in place in the interior of the frame component. After folding the section ends, including the ends (see  103  arid  112  of FIG. 1 a ) of the component and the angled notches (cumulatively now corners) are fixed  511  in place, typically through the injection of the second polymer, through the use of the adhesive of step  508  or alternatively by the use of metal joining or metallurgical process (such as welding and the like) or mechanical fastener devices (such as screws, brackets, bolts and the like). Composite material is typically applied  512  to the exterior portions of the construction material to provide a desired finish to the frame component. Throughout the process of this invention, the components are presently tracked  513  for inventory and quality control purposes. In some embodiments, the tracking  513  may be facilitated by identification marking of the window components, construction materials and/or sections for automatic or manual detection.  
         [0032]    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.