Patent Publication Number: US-10774581-B2

Title: Fenestration assembly

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     This application is a divisional of U.S. application Ser. No. 15/147,161 filed May 5, 2016, now U.S. Pat. No. 10,294,714, which claims the benefit of U.S. Provisional Application No. 62/184,032 filed on Jun. 24, 2015 entitled Fenestration Assembly, both of which are herein incorporated by reference in their entirety. 
    
    
     BACKGROUND 
     The present invention relates generally to the field of fenestration assemblies and more particularly to a fenestration assembly having an arcuate portion. 
     SUMMARY 
     A fenestration assembly includes a frame assembly, and a sash assembly. The frame assembly includes at least one unitary frame member formed from a first sheet of material. The sash assembly including at least one unitary member being formed from a second single sheet of material. 
     A process for forming a fenestration assembly providing a first sheet material and cutting the first sheet material to form a first unitary frame member; providing a second sheet material and cutting the second sheet material to form a second unitary frame member; providing a third sheet of material and cutting the third sheet material to form a first unitary sash member; providing a fourth sheet of material and cutting the fourth sheet material to form a first unitary sash member; routing the first unitary frame member with at least one feature; routing the first unitary sash member with at least one feature; operatively connecting the first unitary frame member to the second unitary frame member to form a frame assembly; and operatively connecting the first unitary sash member to the second unitary sash member to form a frame assembly. 
     In one embodiment a fenestration assembly includes a frame assembly, and a sash assembly. The frame assembly includes at least one each unitary frame member formed from a first sheet of material. The sash assembly includes at least one unitary member is formed from a second single sheet of material. A hinge operatively connects the sash assembly to the frame assembly to move the sash assembly from an open position relative to the frame to a closed position relative to the frame, the hinge is completely hidden when the sash is in the closed position. A weather strip is operatively secured to a groove in the unitary frame member, wherein the groove extends inwardly into the unitary frame member and continuously about an opening, the weather strip is positioned external to a glazing bead operatively coupled to the unitary sash member. A second unitary frame member includes grill integrally formed therein. An arcuate header includes an arcuate groove formed therein that removably receives an arcuate portion of a screen assembly, and at least one biasing member positioned within the groove to provide a biasing force to the screen assembly in an installed position, the header groove has a first depth proximate a center of the arcuate portion and a second depth a distance from the center of the arcuate portion, wherein the first depth is greater than the second depth. An inner sill member operatively connected to the frame assembly, the inner sill member includes a first upwardly extending slope region and a second downwardly extending slope region is separated by an apex, the screen assembly is moved up and over the apex from the first slope region to the second slope region and is held in the frame assembly by a biasing force of the biasing member. A glazing clip operatively secures a glazing assembly adjacent a first outer frame member relative to a second frame member. A screen assembly includes a screen frame and a screen mesh member connected to screen frame with a hook material operatively attached to the screen frame and fitting through a plurality of openings in the periphery of the screen mesh material. The unitary member of the sash assembly includes an outer face and an opposing inner face; a first periphery extends between the outer face and the inner face, and a second periphery spaced radially inwardly from the first periphery and defining an open region, a weep path extends from a second opening in the second periphery to a first opening in the first periphery; wherein the weep path is defined by a path extends from the second opening in the outer face toward the inner face; the path includes a first sloped region terminating in a bottom portion and a second portion extends from the bottom portion toward and terminating at the first opening in the first periphery; wherein water in the weep path remains in the region between the first region and the second region proximate the bottom portion. A second unitary sash member is removably coupled to the first unitary sash member with a hook and loop material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric view of a fenestration assembly. 
         FIG. 2  is an exploded view of the fenestration assembly of  FIG. 1 . 
         FIG. 3  is an exploded view of the sash assembly of  FIG. 1 . 
         FIG. 4  is an exploded view of the frame assembly of  FIG. 1 . 
         FIG. 5  is an isometric view of the screen of  FIG. 1 . 
         FIG. 6  is a cross-sectional view of the screen taken generally along lines − 6 - 6  of  FIG. 1 . 
         FIG. 7A  is an illustration of a method of fabricating components of the fenestration assembly from creating a component from scrap materials. 
         FIG. 7B  is an illustration of a method of assembling the frame and sash assemblies. 
         FIG. 8A  is an illustration of a blank being prepared from three scrap pieces of material. 
         FIG. 8B  is the resultant blank formed from the scraps of  FIG. 8A . 
         FIG. 8C  is an exemplary component of the sash assembly from process  7 A. 
         FIG. 9  is a cross sectional view of the fenestration assembly taken generally along line  9 - 9  of  FIG. 1   
         FIG. 10A  is a partial exploded view of a portion of the sash assembly and glazing clip. 
         FIG. 10B  is a partial isometric view of a glazing being secured to two components of the sash. 
         FIG. 11  is a partial isometric view of the arcuate portion of the frame. 
         FIG. 12  A is a cross sectional view taken generally along line  12 A- 12 A of  FIG. 11 . 
         FIG. 12B  is a cross sectional view taken generally along line  12 B- 12 B of  FIG. 11 . 
         FIG. 13A  is a partial isometric view of the screen being inserted into the frame header in a first position. 
         FIG. 13B  is a partial isometric view of the screen being inserted into the frame header in a second position. 
         FIG. 14A  is a cross sectional view of the screen prior to being inserted into the frame. 
         FIG. 14B  is a partial isometric view of the screen inserted within the frame. 
         FIG. 15A  is a cross-sectional view of the sash assembly with the glazing bead secured to the sash frame member with a fastener. 
         FIG. 15B  is a partial exploded cross-sectional view glazing bead prior to attachment to the sash frame member. 
         FIG. 16  is a partial isometric view of an integral weep path. 
         FIG. 17  is a cross-sectional view of the frame assembly along lines  17 - 17  of  FIG. 1  illustrating the hidden sash hinge in the sash and frame assemblies. 
         FIG. 18A  illustrates a portion of the sash frame and hinge component. 
         FIG. 18B  is a partial isometric view of the sash frame with hinge component installed. 
         FIG. 19  is a view of two fenestration assemblies mulled together. 
         FIG. 20  is a cross section of a weather strip component. 
         FIG. 21  is one embodiment of a screen assembly. 
         FIG. 22  is a partial isometric view of two mulled fenestration assemblies. 
         FIG. 23  is an isometric view of a jamb cover header. 
         FIG. 24  is a partial isometric view of a continuous glazing lip. 
         FIG. 25  is a plan view of a continuous mull frame member. 
         FIG. 26  is a partial cross sectional view of a corner of mulled fenestration assemblies. 
         FIG. 27  is an exploded view of a sash glazing bead assembly. 
         FIG. 28  is an exploded view of a portion of a glazing bead attachment. 
         FIG. 29  is an exploded view of the frame assembly. 
         FIG. 30  is a plan view of mulled fenestration assemblies with a connector. 
         FIG. 31  is an isometric view of mulled fenestration assemblies with a connector. 
         FIG. 32  is a partial cross-section of isometric view of mulled fenestration assemblies. 
         FIG. 33  is an isometric view of a picture window. 
         FIG. 34A  is a cross sectional view of a frame and sash assembly. 
         FIG. 34B  is a cross sectional view of a picture window. 
         FIG. 35  is an isometric view of various screen handles. 
         FIG. 36  is a partial isometric view of a screen with a rabbit groove to secure a screen mesh. 
         FIG. 37  is an exploded view of a sash frame assembly with a screen member having more than one member. 
         FIG. 38  is a close up view of a connector and screen members of  FIG. 37 . 
     
    
    
     DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS 
     Referring to  FIG. 1  and  FIG. 2  a fenestration assembly  100  includes a frame assembly  102  for an architectural element for a door or window in an opening of an architectural structure such as building. In one embodiment a movable element  104  is movably secured to frame  102 . Movable element  104  may be a window sash assembly, a door or other type of fenestration structure. 
     To provide an orientation for discussion, the term outwardly direction will refer to the direction that faces away from the building structure that supports the fenestration assembly with a vector having a direction from the inside of the building structure toward the outside of the building structure. If a user is standing outside of a building and looking at the fenestration assembly the user would see the outwardly surfaces of the fenestration assembly. Similarly, if a person is standing inside of a building structure and looking at the fenestration assembly the user would see the inwardly surfaces of the fenestration assembly. 
     Unless otherwise indicated, the directions used herein reflect the orientation of a user facing the fenestration assembly from the interior of an enclosure or building structure. Inwardly includes the direction away from the window towards the user and the interior of an enclosure. The direction up and down includes the direction away from and toward the direction of gravity respectively. The left and right directions include the directions as viewed by a user facing the window or fenestration assembly from the interior of an enclosure. The term front will include the surfaces facing the interior of the enclosure while the term back will include the surfaces or regions facing away from the interior of the enclosure. 
     In one embodiment fenestration assembly  100  is a window such as a casement window. In one embodiment the casement window includes at least one side of the frame and/or sash having a non-linear geometric shape. The non-linear geometric shape may be an arcuate shape or may be a series of linear portions forming a side or plurality of sides of a non rectangular or square shape. However the fenestration assembly may also be a door or other fenestration assembly known in the art. 
     Fenestration assembly  100  includes a frame assembly  102 , a sash assembly  104  and a screen assembly  106 . In one embodiment sash assembly  104  moves relative to frame assembly  102  via hardware as disclosed herein. 
     Referring to  FIG. 3 , frame assembly  102  includes a first outer frame member  108  operatively secured to a second outer frame member  110  which in turn is operatively secured to a third outer frame member  112 . A weather strip  114  is positioned between the third outer frame member  112  and a fourth inner frame member  116 . Weather strip  114  as described further below is secured to fourth inner frame member  116 . A fifth inner frame member  118  is operatively secured to the fourth inner frame member  116 . 
     Referring to  FIG. 18A  second outer frame member  110  includes a first routed region  120  and a second routed region that operatively receives a first sash hinge component of first sash hinge assembly  310  and a second sash hinge component of a second sash hinge assembly respectively. 
     Referring to  FIG. 4 , sash assembly  104  includes a first outer sash member  124  operatively secured to a second intermediate sash member  126 . In one embodiment a weather strip  128  is positioned between first outer sash member  124  and second intermediate sash member  126 . Referring to  FIG. 9  weather strip  128  is positioned in a groove  334  formed by a routed region in the inner face of first outer sash member  124  and the adjoining outer face of second intermediate sash member  126 . In one embodiment weather strip  128  is continuous about the entire periphery of first outer sash member  124 . Weather strip  128  forms a seal between first outers sash member  124  and frame assembly  102  when sash assembly  104  is in the closed position relative to frame assembly  104 . In one embodiment weather strip  128  is not positioned about a bottom portion of first outer sash member  124 . In one embodiment weather strip  128  is position only about the upper left and right outer periphery of first outer sash member  124 . 
     A third inner sash member  130  is operatively secured to second outer sash member  126 . In one embodiment a glazing bead weather strip  132  is proximate third inner sash member  130  and second intermediate sash member  126  and positioned within a groove  320  in second intermediate sash member  126  (See  FIG. 9 ). A glazing assembly  134  is operatively secured intermediate first outer sash member  124 , second intermediate sash member  126  and third inner sash member  130 . In one embodiment first outer sash member  124  includes a grill  140  extending between a periphery of the first outer sash member  124 . In one embodiment first outer sash member  124  and grill  140  is formed from a single material and formed as a single unitary component. 
     Referring to  FIG. 2 ,  FIG. 5  and  FIG. 6  screen assembly  106  includes a frame member  142  having a pair of handle portions  144  integrally formed with frame member  142 . In one embodiment handle portions  144  and frame member  142  is formed as a unitary member from a single sheet of materials as described below. In one embodiment frame member  142  includes a grill that may match the grill  140  of first outer sash member. In one embodiment the screen grill may be formed from a single sheet of material with frame member  142  and in one embodiment the screen grill may be formed of a single sheet of material with no connection to frame member  142 . Referring to  FIG. 1  screen  106  is located inwardly of sash assembly  104 . Screen assembly  106  includes a mesh screen member  146  as is known in the art that is operatively secured to screen frame  142  by a spline  148  that is positioned within a groove  150  that extends completely about the periphery of screen frame  142 . Screen frame  142  includes an inner face  152  and an opposing outer face  154 . Screen member  146  is adjacent outer face  154  and a terminal end of screen member  146  is positioned within groove  150  captured by spline  148 . An edge  156  extends generally perpendicular to inner face  152  and groove  150  extends into screen frame  142  from an exposed portion of frame member  146  in a direction toward generally perpendicular to edge  156  in a direction parallel to face  152 . Groove  150  extends completely about the edge  150  of screen frame  142  including an upper arcuate portion  158 , a first side  160 , a third portion  162  generally opposite arcuate portion  158  and a second side  164  spaced from and generally parallel to first side  160 . Of course other geometric configurations are also contemplated. Groove  150  also extends about the corners or transitions between arcuate portion  158 , first portion  160 , third portion  162  and second portion  164 . In one embodiment spline  148  extends continuously within groove  150  about the screen frame  142  with only two terminal ends that meet or are proximate one another within groove  150 . In one embodiment arcuate portion  158  is an upper portion and third portion  160  is a bottom portion. Groove  150  in one embodiment is on the exterior edge or outer periphery of the screen frame such that it is not visible by a viewer when the screen is in positioned within the frame assembly as discussed herein. 
     Referring to  FIG. 21  in one embodiment a screen assembly  322  includes a hook type material  324  that is secured to an outer face of screen assembly  322  in a notch located adjacent to the periphery of screen assembly  322 . Screen mesh  326  is operatively secured to the frame of screen assembly  322  by the openings in screen mesh  326  being engaged by the hook material  324 . Hook material  324  in one embodiment is similar to the hook material in the Dual Lock material known in the art or in the hook material of the hook and loop material sold under the tradename Velcro. Hook material  324  includes a plurality of hook type members extending in the outward direction that are small enough to fit between the openings in screen mesh material  326  to operatively secure screen mesh material  326  to frame assembly  322 . In one embodiment the hook type members in the hook material  324  are strong enough to maintain screen mesh material  326  with tension about frame assembly but allow for the removal of screen mesh material  326  for replacement and/or repair.  FIG. 21  is a cross section of screen assembly  322  that is similar to cross section  6 - 6  of  FIG. 5 . 
     Referring to  FIG. 7A  an example method  166  of manufacturing is utilized to fabricate the elements of frame assembly  102  and sash assembly  104 . As shown by block  168  an operator receives an order for a particular fenestration assembly  100  including the frame and sash dimensions having particular shapes. As shown by block  170 , the operator opens a digital file on a computer aided cutting apparatus such as a water jet. The operator then selects sheet stock as illustrated in block  172  having a given thickness for a particular component of the frame or sash and positions the sheet stock on a water jet cutting apparatus as is known in the art. In one embodiment sheet stock may be a wood, wood composite material or other material that includes a phenolic material. In one embodiment a phenolic material is in the form of a sheet having a height, width and thickness dimension that are a great as the height, width and thickness of the finished frame component. 
     Phenolic material includes a composite resin material made from a combination of phenol and aldehyde formed into a rigid planar material. In one embodiment the sheet material used to fabricate the unitary frame and sash members are formed from a medium density overlay panel (MDO) that is a paintable surface made of plywood with a weather-resistant resin overlay bonded to the wood by heat and pressure. The term sheet material as used herein defines a sheet of material with a length and width dimensions that is much greater than the thickness. In one embodiment the length and width dimension are at least 10 times the thickness of the sheet material. 
     Referring to block  174  waterjet software is used to drive a positioning laser and in block  176  the operator utilizing the positioning laser loads the stock sheet material into the numeric controlled waterjet cutting apparatus. Once the sheet material is positioned the water jet cuts a blank or blanks from the sheet material as illustrated in block  178 . 
     Once the blanks are cut by a water jet or other cutting equipment known in the art, the cut blanks are then further processed with a cutter and/or router to fully fabricate particular members of the frame and sash assembly. Referring to block  180  the operator opens the digital CNC (computer numerical control) software for routing and/or cutting the blanks. The blank is then positioned on the CNC routing and/or cutting equipment aided by use of a positioning laser as shown in blocks  182 - 186 . In blocks  184 - 186  the operator loads then secures the blank in the routing and/or cutting equipment. In blocks  188  and  190  the CNC equipment then routes and/or cuts the blank to form the final member for the frame assembly or sash assembly. For example and referring to  FIG. 8C  second intermediate sash member  126  includes a routed region  120  to receive a hinge that operatively and movable connects sash assembly  104  to frame assembly  102 . 
     In one embodiment the ready to assembly component that is formed is a unitary component having features in three dimensions. The process  166  is repeated to form all of the parts required for the assembly of the frame assembly, sash assembly and screen assembly that will form the fenestration assembly. 
     In one embodiment process  166  is repeated to form five separate frame components as noted above. In one embodiment first outer frame member  108  is formed from a 1¼ inch phenolic sheet material; second outer frame member  110  is formed from a 1¼ inch phenolic sheet material; third outer frame member  112  is formed from a ½ inch phenolic sheet material; fourth inner frame member  116  is formed from a 1 inch MDO sheet material and fifth inner frame member  118  is formed from a 1 inch MDO (Medium Density Overlay such as engineered plywood) sheet material. As will be discussed below the frame components are secured together with fasteners such as confirmat screws. In addition to the five frame members noted above it is also possible to fabricate other frame members such as a vertical jamb cover, a jamb header, a sill cover, a jamb extender, an interior mull cover, a screen lineal, a screen handle and other components. 
     Referring to  FIG. 7B  a process  192  illustrates a procedure for forming the frame assembly  102  from the various frame components formed in process  166 . Referring to block  194  an operator stages all of the frame components for assembly. In a block  196  and  198  the operator positions the first outer frame member  108  and applies an adhesive glue to an inside face  200  of the first outer frame member  108 . In block  202  the operator then positions the second outer frame member  110  over the first outer frame member  108  such that the outside face  204  of the second outer frame member  110  is adjacent to the inner face  200  of the first outer frame member  108 . 
     In block  204  the operator spreads an adhesive glue on the outside face  206  of third outer frame member  112  and positions the outside face  206  of the third outer frame member  112  over the second outer frame member  110  as illustrated in block  208 . The operator in block  210  then fastens with screws such as confirmat screws  212  third outer frame member  112  to the second outer member  110 . 
     In block  214  an operator applies an adhesive glue to an inside face  216  of third outer frame member  112  and positions an outside face  218  of the fourth inside frame member  116  over the inside face  216  of third outer frame member  112  is illustrated in block  220 . Referring to block  228  and block  230  an adhesive is applied to an outside face  224  of fifth inside frame member  118  and positioned over the inside face  226  of fourth inside frame member  116 . Fourth inside frame member  116  and fifth inside frame member  118  are operatively further connected with a fastener such as a confirmat screw as illustrated in block  232 . Referring to block  234  and block  236  any extra adhesive glue is removed from the frame assembly and then and ready for painting. 
     Referring to  FIG. 8A  and  FIG. 8B  in one embodiment scrap materials  238 ,  240  and  242  that result from process  166  may be glued together to form a material sheet from which a new blank  244  may be formed as illustrated in  FIG. 8B . Referring to  FIG. 8B  blank  242  which may be formed in process  166  into one of the members forming the frame assembly  102 , sash assembly  104  and screen assembly  106  include portions from scrap materials  238 ,  240  and  242 . In this manner member scrap from process  166  may be utilized to form additional members. In this secondary embodiment member  244  is formed from more than one continuous unitary material. Referring to  FIG. 8B  member  244  is formed from thee different scrap portions  238 ,  240  and  242 . Referring to  FIG. 8B  the connecting lines between portions  238 ,  240  and  242  are spaced from each corner. Each corner being created from only one of portions  238 ,  240  and  242 . Member  244  including a first corner and a second corner defined solely by first portion  238 , a third corner defined solely by second portion  240  and a fourth corner defined solely by portion  242 . 
     Referring to  FIG. 8C  a completed second intermediate sash member  126  is formed with routed hinge regions  120  and  122 ; slits  246  to receive a tab for a glazing clip as described in further detail herein below; recess portions  248  for providing a fastener such as a hook and loop material reclosable fastener like Dual Lock™ to operatively secure third inner sash member  130  to second intermediate sash member  126 ; and other feature for securing lock hardware and other operational hardware for opening and closing sash assembly  104  relative to frame assembly  102 . The hardware includes an operator for opening and closing sash assembly  104  relative to frame assembly  102 ; at least one lock handle assembly including a lock handle and a lock bar assembly. In one embodiment third inner sash member  130  includes a glazing bead portion, wherein third inner sash member  130  is secured to second intermediate sash member  126  solely with a hook and loop material. In this third inner sash member  130  may be removably secured to second intermediate sash member  126  without the use of tools and allowing for easy access to glazing assembly  134 . In one embodiment third inner sash member  130  includes a glazing bead portion, wherein third inner sash member  130  is secured to second intermediate sash member  126  solely with a magnet. In one embodiment third inner sash member  130  includes a glazing bead portion, wherein third inner sash member  130  is secured to second intermediate sash member  126  solely with one or a combination of connectors that do not require tools to remove the third inner sash member from the second intermediate sash member such as a hook and loop material and a magnet. 
     Referring to  FIG. 9 ,  FIG. 10A  and  FIG. 10B  a glazing clip  250  includes a base portion  252 , a tab  254  secured to base portion  252  and extending in a first direction away from a plane defined by base portion  252 . Glazing clip  250  includes a raised wall region  256  extending away from an edge of base portion  252  in a perpendicular direction from the plane defined by base portion  252  in a direction opposite the first direction that tab  254  extends from base portion  252 . A terminal end portion of tab  252  is positioned within slot  246  of second intermediate sash member  126  such that raised wall portion  256  contacts a lower edge of glazing assembly  134 . Since second intermediate sash member  126  has been fastened to first outer sash member  124  glazing clip  250  acts to hold glazing assembly  134  against a glazing lip region  258  while a seal  259  such a silicone seal cures between glazing assembly  134  and glazing lip region  258 . A number of glazing clips  250  are similarly positioned about glazing assembly  134  in respective slots  246  to operatively secure glazing assembly  134  to sash members  124  and  126 . In this manner glazing assembly  134  and sash members  126 ,  128  can be moved from a generally horizontal orientation to a vertical orientation. The horizontal orientation is the defined as the orientation in which the glazing glass members define a plane perpendicular to the direction of gravity and the vertical orientation is perpendicular to the horizontal orientation. Stated another way the vertical orientation is the general orientation of a window would be typically positioned in a side of a structure that a person would look through while standing in the structure and not having to look upward as in a sky light orientation. Referring to  FIG. 24  continuous glazing seal  259  extends about a transition or corner of glazing region  258  of first outer sash member  124 . In this manner there are not disruptions or gaps in the corners since the glazing region provides a continuous flat surface. Thee continuous glazing lip provides an optimum seal to glass. 
     Referring to  FIG. 9 ,  FIG. 13A  and  FIG. 13B  screen assembly  106  is positioned within frame assembly  104  by use of at least one biasing member  260  positioned within a header region  262  of frame assembly  104 . Biasing member  260  in one embodiment is a foam cylindrical member that is positioned within a groove  264  of header region  262 . Arcuate portion  158  of screen assembly  106  is positioned within groove  264  by an operator. As arcuate portion  158  is received within groove  264  a region of arcuate portion  158  contacts the biasing member or members  260  and depresses the biasing member  158  until bottom portion  162  clears an inner sill member  266  that is operatively connected to the frame assembly. In one embodiment inner sill member  266  is connected to frame assembly  104  with a fastener  268  having at least one barbed tab  272  fitting within a groove  270  of inner sill member  266 . 
     Referring to  FIG. 13A  Inner sill member  266  includes a first sloped region  274  having an incline terminating in an apex  278  and a second sloped region  276  extending from apex  278  in a direction away from first sloped region  274  and in a generally opposite direction. Referring to  FIGS. 13A and 13B  as user positions screen assembly  106  within groove  264  such that arcuate portion  158  contacts biasing member  260  and continues to move screen assembly  106  in a direction  278  until portion  162  clears apex  278  of inner sill member  266 . Biasing member  260  is then compressed and provides a force on screen assembly toward inner sill member  266  and forces portion  162  of screen assembly  106  to contact second sloped region  276  of inner sill member  266 . The outer face  154  of screen assembly  106  is in contact with the inner face  226  of fourth inner frame member  116 . To remove screen assembly from frame assembly  104  a user utilizing handles  144  urges frame assembly into groove  264  depressing biasing member  264  and pulling portion  162  up and over apex  278  of inner sill member  266  and then pulling portion  162  in a direction generally opposite to vectors  278  and  280 . In one embodiment biasing member  260  is a foam spring to provide tension/pressure on the top of the screen frame to hold the screen in place in the frame assembly. 
     Referring to  FIG. 11 ,  FIG. 12A  and  FIG. 12B  groove  264  is deeper near the center of the arcuate portion of frame assembly  104  than the sides of arcuate portion of frame assembly  104 . Stated another way the depth of groove  264  at section  12 A- 12 A of frame assembly  104  has a greater longitudinal depth along axis  282  than along axis  284  at section  12 B- 12 B. This differential in depth provides for an easier insertion and removal of arcuate portion  158  of screen assembly  106  within arcuate header of frame assembly  104 . 
     Referring to  FIG. 15A  and  FIG. 15B  third inner sash member  130  that includes the glazing bead is operatively secured to second intermediate sash member  126  with a reclosable fastener  286  Dual Lock™ fastener. Referring to  FIG. 10B  and  FIG. 15B  a first portion of the reclosable fastener  288  is operatively secured within a routed recess region  246  of second intermediate sash frame  126  and a second portion  290  is operatively secured to a corresponding portion of third inner sash member  130 . A user then presses third inner sash member  130  toward second intermediate sash member  126  until the first portion  288  and the second portion  290  of the reclosable fastener engage and secure third inner sash member to second intermediate sash member  126 . Other releasable and reusable fasteners that also do not require the use of a separate tool to operate are also contemplated for example magnets or other hook and loop style materials. 
     Referring to  FIG. 16  a weep path  292  is illustrated for a path for liquid that may enter the sash assembly to be vacated from the fenestration assembly. A path  292  is created by a routed path extending into second intermediate sash member  126 . Path  292  includes a first downwardly extending portion  296  that extends from an upper surface  294  that defines a generally horizontal plane when the fenestration assembly is in an in use position in an vertical wall of a structure. Path  292  includes a bottom portion  298  that is a given vertical distance from upper surface  294  in a direction defined by vector  301  which is the same direction as gravity when the fenestration assembly in in an in use position in a vertical wall of a structure. Path  294  includes a portion  300  which extends from bottom portion  298  in a vector direction  306  generally opposite and perpendicular to the slope defined by the slope defined by path portion  296 . Path portion  300  is in fluid communication with a portion  302  that has a vertical vector distance from region  294  that is less than the given vertical vector distance of bottom portion  298  from region  294 . Path portion  302  has an exit to surface  304  of second intermediate member  126 . In operation water that may enter path  292  from region  294  will flow downwardly along path portion  296  and only exit path  292  at surface  304  when the height of water in path  296  from bottom portion  298  along vector  306  is greater than the distance along vector  306  between exit apex portion  308  and bottom portion  298 . A certain amount of water will remain within path  292 . 
     Weep path  292  is completely routed in second intermediate sash member  126  and therefore does not requires any further drilling of apertures after the formation of intermediate sash member  126  by process  166 . Weep path  292  is closed off in the direction  303  by the inner face of first outer sash member  124 . 
     Referring to  FIG. 17  a cross section of the sash assembly  104  and frame assembly  102  illustrate the hidden nature of hinge assembly  310 . When sash assembly  104  is in a closed position relative to frame assembly  102  no portion of hinge assembly  310  is visible to a person viewing the fenestration assembly  100  from inside the structure or from outside the structure. A first portion of hinge assembly  310  is positioned within routed region  120  and the second portion of the hinge assembly  310  is positioned operatively connected to a routed region of second outer frame member  110 . In one embodiment hinge assembly  310  is a type of concealed hinge. One such concealed hinge is marketed by Simonswork under the tradename Tectus® one product being TE2403D the features of which are known in the art. Other of the sash components may also provide a routed region to receive a portion of the hinge assembly such as the first outer sash member  124 . 
     Referring to  FIG. 19  a first and second fenestration assembly may be mulled together along mating frame portions. In one embodiment the frame is cut and routed in process  166  so that the mating region of the external portions provide a first gap  312  proximate the external portions of the mating assemblies and a second gap  314  having a distance that is greater than the first gap  312 . The second gap  314  allow for mating hardware operatively securing each of the fenestrations assemblies to one another to be placed therein and the first gap  312  provides a narrower gap that eliminates the need for additional hardware. First gap  314  be sufficiently narrow enough to be sealed with a standard silicone sealant or other sealant known in the art. 
     Referring to  FIG. 9  and  FIG. 20  weather strip  114  is positioned within a groove  316  within fourth inner frame member  116  and extending about the entire periphery of fourth inside frame  116 . Weather strip  114  includes a tab portion  318  that is received within groove  316 . Weather strip  114  further includes a body  321  having a flexible extension portion  319  extending therefrom that contacts the inner face of second intermediate sash member  126  forming a seal between the inner face of second intermediate sash member  126  and outer face of fourth inner frame member  116 . Extension portion  319  is deformed from its relaxed orientation illustrated in  FIG. 20  to a sealed position illustrated in  FIG. 9  when sash assembly  104  is in the closed orientation relative to frame assembly  102 . 
     The weep path  292  is positioned external to the location of weather strip  114 . Since groove  316  is routed into fourth inner frame member  116  which is formed from a single sheet of material including the corners of fourth inner frame member  116  there need not be any discontinuity as the weather strip may be formed from a single continuous piece with two terminal ends that may be affixed or proximate one another. 
     Weather strip  128  may be three sided or four sided. Referring to  FIG. 9  weather strip  128  is positioned within a groove  318  in first outer sash member  124  that extends about the entire periphery of first outer sash member  124 . A glazing bead weather strip  132  is positioned within a continuous groove  320  within second intermediate sash member  126  forming a seal between the outer periphery of third sash member  130  and second intermediate sash member  126 . 
     Referring to  FIG. 9  other fenestration assembly  100  includes an outer trim member  330  operatively connected to first outer frame member  108 . An outer sill member  332  is operatively connected to first outer frame member  108 . A plurality of trim jamb extenders may be operatively positioned adjacent fifth inner frame member  118  and a frame fascia cover  336 . Referring to  FIG. 17  a jamb cover  338  is positioned proximate third inner sash member  130  and operatively connected to fifth inner frame member  118 . The outer face of screen assembly  106  contacts a surface of jamb cover  338  to limit movement of screen assembly  106  in the outwardly direction when screen assembly is in the installed in-use position. 
     Referring to  FIG. 9  weather strip  114  is positioned proximate the outer face of fourth frame member  116  such that the third sash member  130 , jamb cover  338 , inner sill  266 , frame fascia members  336  are all within the inner side of weather strip  114 . Stated another way, these members are all completely protected from external weather by weather strip  114 . 
     Referring to  FIG. 22  two frame assemblies  404  and  406  may be mulled together to form a mulled bay/bow window  402 . The forming process  166  may be modified so that the mating portions  408  and  410  of two mulled frame members  404  and  406  respectively have a complimentary angle to form the proper bay/bow mulled windows. Stated another way, the mating portions  408  and  410  have a non-perpendicular angle  416  and  418  to the plane defined by inner face portions  412  and  414  respectively. Such that the planes defined by face portions  412  and  414  are not coplanar when the two frame assemblies  404  and  406  are mulled together. Mating portions  408  and  410  include the mating portions of frame members  108 ,  110 ,  112 ,  116 , and  118 . In one embodiment first outer frame member  108  of a first fenestration assembly is formed to overlap second outer frame member  110  of the second fenestration assembly. In this manner the interface  411  between corresponding frame members  110 ,  112 ,  116  and  118  do not line up with the interface  409  between first outer frame member  108  of the first fenestration assembly and the first outer frame member of the second fenestration assembly. 
     Referring to  FIG. 23  a jamb cover header may be formed from multiple parts  432 ,  434 ,  436 ,  438  and  440 . Each part  432 - 440  are formed separately from a board and then secured together to form a curved jamb cover header having a compound curvature. Stated another way the curved jamb cover has a curvature in the x-y plane and a radius of curvature in the x-z plane. In one embodiment the curved jamb will have curved features in two or more of the x-y plane, x-z plane and y-z planes. 
     Referring to  FIG. 25  and  FIG. 26  it is possible using process  166  to create a mill frame  442  out of single sheet stock to create multiple openings out of one sheet. Since there are no connectors in the continuous mull  442  there are no opportunity for leaks as there are no interface components being connected to form the mull frame. There is no need for a corner connector as corners  448  are formed from the single sheet stock.  FIG. 26  is a cutaway of a corner region of mull frame  443  showing that there is no corner connector reason, so no joint line and no opportunity for leaks of air and/or water. 
     Referring to  FIG. 29  it is possible using the mull connector systems described herein to connect different type of fenestration assemblies. In one embodiment a fenestration formed from phenolic material may be mulled to other fenestration assemblies formed from phenolic material either in the field or factory. In one embodiment a fenestration formed from phenolic materials may be mulled to other fenestration assemblies formed from fiberglass either in the field or factory. In one embodiment a mull frame member such as member  108  may be formed from a continuous one piece of material as outlined herein to cover all of the mulled fenestration assemblies. 
     Referring to  FIG. 30  and  FIG. 31  a connector  466  is inserted in to routed connector regions  468  and  470  in two separate frame assemblies. Routed regions  468  and  470  are formed in each of the members forming the frame to provide a secure and strong mulled assembly of the two separate frame assemblies. In one embodiment a first connector  466  is positioned on one side of the mull assembly and a second connector  467  is positioned on a second side of the mull assembly. In one embodiment a connector (not shown) extends the entire through the entire two frame assemblies rom an inner side to a region proximate the outer side such that first connector  466  and second connector  467  would be continuous and joined by an intermediate portion (not shown) and a unitary connector. 
     Referring to  FIG. 27 , third inner sash member  130  includes an integrally formed grid  450  that is formed as one piece with third inner sash member  130 . The ability to construct grid and third inner sash member  130  sash as one piece ensures alignment with other grids in other sash and/or frame components and allows for simple to complex curved grids. Referring to  FIG. 28  a grid  452  may be formed from a single piece of material and be located between two glazings or sheets of glass. In this manner it is possible to align the patters of grid  140  in first sash member  124 , grid  452  in the glazing and grip  450  of third inner sash member  130 . 
     In one embodiment grids  140  and  450  may include a recessed region to receive a portion of a dual lock or hook and loop connector that is secured to a corresponding hook or loop portion that is adhered directly to the glazing. In this manner the three grids  140 ,  452  and  450  will appear to be formed from a single piece of material and not from three separate grids. Referring to  FIG. 35  a hook and loop connector  494  such as Dual Lock may be used on the outer periphery of screen  106  that is removably connected to a corresponding portion of the hook and loop connector on the frame assembly. The connector  494  may be located in a groove routed in the outer periphery of the frame in a direction toward screen mesh such that only the outermost portion of connector material  494  extends beyond the outer periphery of the frame member of screen  106  and in such a manner that the connector  494  would not be readily visible by a user viewing the screen from the inside or outside of the structure in which the screen was deployed. 
     Referring to  FIG. 32  and  FIG. 33A  and  FIG. 33B  in one embodiment the process  166  may be used to create a picture window  480  with a fixed glazing (no moving sash). As illustrated in  FIG. 33A  and  FIG. 33B  a picture window is created by combining second intermediate sash member  126  and second outer sash member  110  in the movable sash embodiment with a member  482  formed with process  166  and a member  484  as a thermal layer. Similarly fourth inner frame member  116  is modified as shown by member  486  in this manner it is possible to employ the methods as described herein for manufacturing a frame and movable sash can be used to form picture window  480 . Note that member  484  may also be a thermal layer. In one embodiment any of the frame or sash members may be substituted with a material having greater thermal properties than the materials identified above either for the picture window  480  of for frame  102  or sash  104 . 
     Referring to  FIG. 5  and  FIG. 34  handle  144  may have various configurations such as handle  490  having a single recess extending therein and handle  492  having a plurality of openings extending therethrough and routed as part of screen frame  106  such that the handle  144  and outer frame  142  are formed from a single sheet of material with not attachments or additional hardware to connect handles portions  144  to the frame  142 . 
     Referring to  FIG. 37  and  FIG. 38  a screen frame  532  may be formed from more than one member. In one embodiment frame  532  is formed from members  534 ,  536 ,  538 , and  535 . Each of members  534 ,  536 ,  538  and  535  are secured to one an adjacent member with a connector  498 . A spline  530  secures a screen  528  to a channel formed within frame  532 . Spline  530  is a continuous member that extends through a channel  504  in connector  498 . In one embodiment the channel formed within screen  528  is continuous about the frame with each frame member  534 ,  536 ,  538  and  535  having a channel portion. Referring to  FIG. 38  member  538  includes a channel  506  that is operatively connected to channel  526  in member  535  via channel  504  in connector  498 . 
     Each member includes a portion of a connector receptacle  550  that receives a portion of connector  498 . Referring to  FIG. 38  member  538  includes a recessed connector portion  522  and member  535  includes a recessed connector portion  520 . Connector portions  522  and  520  form a connector receptacle  550  that operatively receives connector  498  therein. Connector receptacle  550  includes a first non-linear wall portion  508  and a second non-linear wall portion  516  routed in member  5385  that generally corresponds to a portion of the outer geometry of connector  498 . Similarly, a third non-linear wall portion  510  and a fourth non-linear wall portion  518  routed in member  535  generally corresponds to a portion of the outer geometry of connector  498 . In one embodiment portions  508 ,  516 ,  510  and  518  have a concave shape that form a peak or apex  512  and  514  respectively. Connector  498  includes a recess  500  and  502  that correspond to apex  512  and  514  respectively. Connector  498  includes a base  540  that sits within the bottom of the connector receptacle  550  operatively connecting member  538  and  535  together. In one embodiment no additional tools or connector is required to secure connector  498  within connector receptacle  550  and in one embodiment an additional connector such as a fastener or adhesive is sued to secure a connector  498  within each corresponding connector receptacle  550 . Connector  498  may be used to connect two members that have a common longitudinal axis such as with member  534  and  535 . Connector may also be used to connector two members that do not have a common longitudinal axis such as members  538  and  535 . Members that are connected with connector  498  may have longitudinal axis that are perpendicular to one another or may the connectors may have longitudinal axis that are neither perpendicular nor co-linear. Referring to  FIG. 37  member  534  may be non-linear such as arcuate and be connected to another linear member  536  with a connector  498  by proper routing of the connector receptacle  550  within members  534  and  536 . 
     In one embodiment grooves  506  and  526  extend from an outside face of frame  532  in an inwardly directly that is generally perpendicular to the outside face of frame  532 . However it is also contemplated that grooves  506  and  526  extend from an inside face of frame  532  in an outwardly direction. Using method  166  described above a user forms each of the frame members and routes the connector receptacle regions therein and then assembles the members to one another using connectors  498 . Connector  498  may be pressed fit or friction fit with in connector receptacles  550  without any other fastener or adhesive. A user then places spline  530  within the grooves formed within the individual members as well as within channel  504  within each recess securing screen  528  to frame  532 . Convex arcuate portions  552  and  554  provide a transition for spline  530  and screen within  528  through channel  504  that also aids when the members connected with connector  498  do not have co-linear longitudinal axis. 
     It is important to note that the apparatus and methods as described herein are illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited in the claims. Each of the features described herein may be combined together or used independently with other features described herein in all combinations. One non-limiting example is that screen assemblies  106 ,  322  and the screen assembly incorporating frame  532  may be used interchangeable with the fenestration assembly described herein and with other fenestration assemblies not described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements and vice versa, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present invention as defined in the appended claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the exemplary embodiments without departing from the scope of the present inventions as expressed in the appended claims.