Metal working – Method of mechanical manufacture – Obtaining plural product pieces from unitary workpiece
Reexamination Certificate
1999-08-31
2001-07-17
Hughes, S. Thomas (Department: 3726)
Metal working
Method of mechanical manufacture
Obtaining plural product pieces from unitary workpiece
C029S412000, C052S098000, C052S745150, C052S204620, C052S749100, C049S341000
Reexamination Certificate
active
06260251
ABSTRACT:
FIELD OF THE INVENTION
The present invention is directed to a method for constructing a window and more particularly to a efficient method for constructing a window by combining the manufacture and/or assembly of certain window components.
BACKGROUND OF THE INVENTION
A typical window includes at least a frame and a sash. The frame is mounted into a wall or other structural component, and forms the outer perimeter of the window. The sash fits within the frame, and holds the glazing, such as glass. The frame and sash are frequently each composed of four separate linear members that are joined at the corners to form a rectangle. Often the linear members are initially hollow. For venting windows, at least a portion of the sash is movable with respect to the frame. For non-venting or stationary windows, the sash will not be movable.
During manufacturing, a single length of a sash profile, for example, may be manufactured at once, and then cut into the individual linear sash members to form the sash. Extrusion methods may be used to form the single lengths. Then the individual linear sash members are joined to form the rectangular shape of the sash. A similar process may be used to form the frame.
If two separate components, such as a frame and a sash, are used in a window, then two separate lengths of profile must be produced and two separate cutting and assembly processes must be undertaken to make the individual components of the window. For a typical window including a sash and a frame with a perimeter of about 14 feet, the conventional approach requires about 28 feet of various linear components in order to form one window. In addition, each sash linear component and each frame linear component require several additional assembly steps in order to form a window. For example, mitered corners must be formed on each linear component of the sash and the frame. Also, the sash lineal components and the frame lineal components are separately assembled into the sash and the frame, respectively. Because the sash and the frame are assembled separately, it is possible for some discrepancies to exist between the shape of the sash and the shape of the frame so that the two components may not fit perfectly together. A substantial need exists for a less expensive, more efficient, and higher quality method of producing a window, especially using linear members.
SUMMARY OF THE INVENTION
Generally, the present invention provides efficiencies and quality improvements in methods for manufacturing windows by combining the formation of certain components, such as a sash and a frame, and by combining assembly steps. In one particular embodiment of the invention, a method for assembling a window includes the steps of forming a lineal member having a cross-sectional profile, where the profile includes a sash portion and a frame portion. The method includes separating the lineal member into a plurality of lengths, joining the lengths to form a shape of the window, where the sash portions form a sash and the frame portions form a frame, and separating the sash from the frame.
In one embodiment of the invention, the method may include the step of installing hardware onto the frame and sash, such as a lock, an operator, and/or a hinge. In a preferred embodiment, the sash portion includes an extension portion that at least partially conceals a platform of the frame where the actuator is attached to the frame when the sash and frame are in a closed position.
In another particular embodiment of the invention, a cover portion may be included in the profile of the lineal member. The cover may be capable of enclosing hardware that is installed on the frame. In another particular embodiment, the cover portion includes a hinge portion and the method may include the steps of bending the cover portion at the hinge portion, installing hardware on the frame portion and securing the cover portion to the frame portion.
The present invention also includes a method for manufacturing windows whereby a single production operation is used to form both venting windows and non-venting windows until a final step of separating a sash from a frame for venting windows. First, a lineal member is formed having a cross-sectional profile, the profile including a sash portion and a frame portion. The method further includes cutting the lineal member into lengths sized for forming a window, joining at least four of the lengths of the lineal member to form a shape of a window, where the sash portions form a sash and the frame portions form a frame. The method further includes separating the sash from the frame where a venting window is desired and allowing the sash and frame to remain connected for a non-venting window.
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Andersen Corporation
Hong John C.
Hughes S. Thomas
Merchant & Gould P.C.
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