Window component notching system and method

Abstract

A system and method for producing window components using polymer based, metallurgy based, extruded, injection molded, or wooden lineal material. The lineal material is notched at intervals calculated to include a stretch treatment and folded to form window components such as window sashes, frames, and the like. Internal reinforcing members may be welded within the joints formed by folding at the notches. The notching system and method provide low cost, highly reliable, low defect production of multi-sided window components from a continuous piece of lineal material.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a divisional of co-pending U.S. Ser. No. 11 / 539,846, entitled “WINDOW COMPONENT NOTCHING SYSTEM AND METHOD”, filed on Oct. 9, 2006. U.S. Ser. No. 11 / 539,846 is a continuation-in-part of U.S. Ser. No. 10 / 175,021, entitled “METHOD AND PROCESS OF A UNIVERSAL WINDOW SYSTEM USING SINGULAR ADVANCED COMPONENTS OF A POLYMER BASED OR METALLURGY BASED PRODUCT” filed on Jun. 18, 2002 (now U.S. Pat. No. 7,117,576). U.S. Ser. No. 10 / 175,021 is a continuation of U.S. Ser. No. 09 / 679,220, entitled “METHOD AND PROCESS OF A UNIVERSAL WINDOW SYSTEM USING SINGULAR ADVANCED COMPONENTS OF A POLYMER BASED OR METALLURGY BASED PRODUCT” filed on Oct. 3, 2000 (now U.S. Pat. No. 6,678,934). U.S. Ser. No. 09 / 679,220 is a non-provisional of U.S. Provisional No. 60 / 157,625 filed on Oct. 4, 1999, and priority is claimed thereto. The entire contents of all of the foregoing applications are hereby incorporated by reference.FIELD OF INVENTION[0002]This...

AI Technical Summary

Benefits of technology

The present invention is a system and method for manufacturing window systems using an automated notching machine to form notches in lineal material. The notches define connected intermediate and end sections of the lineal, which are adjusted by a stretch treatment based on the selected lineal profile and frame shape. The notcher forms notches positioned along the lineal such that the lengths of the intermediate sections are reduced by up to 0.5 inches and those of the end sections by up to 0.25 inches relative to the target finished production lengths. The continuous portion of the lineal that stretches around the end of each folded joint protects against joint separation and provides a significant structural advantage over known joints formed from fully sectioned components. The notched lineal is folded into a finished frame shape, and the folded intermediate joints and abutting end joints may further include internal or external reinforcing structures. The system and method reduce labor costs, improve structural joints, and make use of automation techniques to improve product quality. It also produces window frames using a continuous lineal and reduces the production floor space required for mass-production.

Problems solved by technology

Sectioning of these separate components typically includes cutting entirely through the lineal material at two opposite angles producing numerous pie-shaped scraps and other scraps and resulting in a significant cumulative waste of the lineal material.

Furthermore, excessive operator time and equipment set-up and handling are typically required to properly align and weld each of the joints of the sash and casing.

Welding of secondary or primary materials often creates flashing or “sprue” waste at the welded joint requiring tedious and labor intensive flashing removal, joint cleaning or other preparation.

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