A window unit including a glazing panel and a frame

Abstract

The present invention discloses a window unit comprising a glazing panel and a frame having a frame profile, surrounding the edge of the glazing panel on at least one periphery, and comprising a plastic primary part, characterized in that the primary part comprises at least 10% by weight of recycled material.

Description

[Technical Field]

[0001] The present invention relates to a window unit comprising a glazing panel and a frame having a frame profile, surrounding the edge of the glazing panel on at least one periphery, and comprising a plastic primary part. [Background technology]

[0002] Window units having glazing panels and frames are known, and to manufacture the frame surrounding the window, a primer or adhesive is applied to the inner, front, and outer edge areas of the window before a primary portion is formed onto the peripheral edge areas of the glass panel.

[0003] Today, the total amount of material used to overmold window units in the automotive industry is very large. It is estimated to weigh between 300 and 1000 grams per vehicle, depending on the car. This therefore represents a large amount of virgin material being used to create these overmolded window units, which is therefore very resource intensive.

[0004] The management of plastic waste and resources is known to be a global issue, with plastic pollution becoming a challenge that every country must address.

[0005] The ingestion of plastic particles, marine pollution, and the existence of plastic waste loops are some of the examples related to this known global problem, and plastic consumption is increasing, causing problems for the environment and human society in the medium to long term.

[0006] Today, plastic waste can be managed in three different ways: recycling, energy recovery, and landfilling. These three categories are divided differently in different parts of the world. Landfilling must be minimized to reduce the negative impact of its footprint on our environment.

[0007] According to the ISO 14021 standard, recycled materials come from either virgin materials, which means waste coming from a manufacturing process other than the one used to make the part, or post-consumer materials, which means the reuse of materials coming from a product at the end of its life.

[0008] It is known that virgin materials have a better quality level than used materials. It is generally one of the constituent materials for which it is easier to obtain information about the origin and properties of the product. Even if the effect is small, the effect on material properties still exists. Summary of the Invention [Problem to be solved by the invention]

[0009] The object of the present invention is to alleviate these problems and to provide a window unit with a frame that has a reduced environmental footprint while minimizing landfill waste and reducing the negative impacts of plastic use. [Means for solving the problem]

[0010] According to a first aspect of the invention, the invention relates to an improved window unit comprising a glazing panel and a frame having a frame profile, surrounding an edge of the glazing panel on at least one periphery, and comprising a plastic primary part.

[0011] The solution defined in the first aspect of the invention is based on a primary part and comprises at least 10% by weight of recycled material of the total polymeric material of the primary part, said recycled material having the same polymeric base material as the virgin material of the primary part.

[0012] Accurate management of plastic waste, proper sorting, and mixing of recycled and virgin materials can reduce or enhance the drawbacks mentioned in the background art. This is a common use of mixing virgin and recycled materials. Cold runners and sprues are examples of direct reuse of regrind in standard manufacturing. With regard to the ISO standards listed here above, this regrind is not considered recycled material.

[0013] According to the standard, a Möbius loop with a weight percentage value written inside the loop can be placed as a logo on the window unit to certify the recycling level of certain elements of the window unit, in particular the frame. Verification of the source and amount of recycled material may then be performed through the use of the logo used and / or purchasing documents and other available records.

[0014] On the other hand, the use of recycled thermoplastics also has some drawbacks, such as a negative impact on the properties of the reground material (lower mechanical resistance), a deterioration in the surface aspect quality, an increase in viscosity, an increase in the range of material properties, and the potential presence of hazardous materials associated with incorrect classification.

[0015] Increasing the amount of recycled plastics can mean reduced energy recovery and / or landfill management, reduced consumption of virgin materials, development of new technologies and new jobs to increase the level of plastics that can be reused at end of life, a greener image for companies that use these materials, etc.

[0016] More particularly, the present invention uses recycled materials within certain levels that allow for a significant reduction in the consumption of virgin materials.

[0017] In some embodiments, the frame has a frame profile, surrounds the edges of the glazing panel on at least two peripheries, and includes a plastic primary portion.

[0018] The primary portion can be overmolded onto the glazing panel, meaning that the primary portion is fabricated before being placed in a mold with the glazing panel and then secured to the glazing panel with another material, such as the secondary portion. To facilitate the process, the primary portion can be poured into a mold to wrap directly over the glazing panel. In some other embodiments, the primary portion can be fabricated first and then secured to the glazing panel with a securing means, such as an adhesive.

[0019] Alternatively, the primary portion is in the form of a hard component.

[0020] The hard material is sometimes used to provide a slightly higher rigidity to the part, reduce the soft material thickness, and / or add functions to the wrapped window unit, such as guides integrated into the rear door fixing, fixings used to assemble the window unit to the vehicle body, etc. The hard material can be polypropylene (PP), polycarbonate (PC)-based blends, acrylic-based blends, polyamide, or others. In preferred embodiments, the hard material is not visible after assembly of the wrapped window unit in the vehicle. The hard material, which may be filled with fillers such as glass fiber, ball glass, talc, etc., is covered with the soft material after the overmolding process. In preferred embodiments, the hard component is a polypropylene-based material. Other hard materials with a Young's modulus greater than 1000 MPa, such as polyamide, styrene, and others, can also be used.

[0021] Alternatively, the primary section may include glass fibres mixed with a hard material to reinforce the primary section.

[0022] Alternatively, the primary portion is in the form of a soft component. The soft component can be a thermoplastic elastomer-based material. Typically, a styrene-based vulcanized thermoplastic elastomer is used. In another embodiment, the soft component is a soft polyvinyl chloride. The soft material is used to provide the final surface aspect of the frame and to fit the window unit to the vehicle body. In effect, the softness of the material allows for interference between the vehicle body and the window unit using a soft lip. The soft material is sometimes also used to ensure a seal between the vehicle body and the wrapped window unit.

[0023] In some embodiments of the invention, the frame is in the form of a flexible component and includes a secondary part that rests at least partially on the primary part, allowing the window unit to be anchored on the structure to which it is fixed. Such a structure may be a car body, a building, etc.

[0024] The secondary portion can be poured at least partially over the primary portion in a second step. Preferably, the secondary portion is a single portion. In some embodiments, the secondary portion can be in localized contact with the glazing panel to ensure aesthetic value and robustness of the window unit.

[0025] In some embodiments, at least a portion of the secondary portion is in contact with the glazing panel.

[0026] In a preferred embodiment, the soft component is a thermoplastic elastomer-based material. Styrene-based vulcanized thermoplastic elastomers are commonly used. In another embodiment, the soft component is soft polyvinyl chloride.

[0027] In some embodiments, the soft component of the primary and / or secondary portion can be a thermoplastic elastomer-based material, hi some embodiments, the soft component of the primary and / or secondary portion can be a PMMA-based material.

[0028] In some embodiments, the primary portion is in direct contact with the glazing panel.

[0029] The glazing panels can be flat or curved panels to match the design of the vehicle. The glazing panels can be treated, i.e., annealed, tempered, etc., to take into account specific security and anti-theft requirements. For example, a heatable system, e.g., a coating or a network of wires, can be added onto the glazing panel to add defrosting and / or anti-fogging functionality.

[0030] In some embodiments of the present invention, the primary portion is in direct contact with the glazing panel, meaning that the primary portion is poured onto the glazing panel, which may have a localized bonding agent or primer material to ensure rigidity and / or facilitate the wrapping of the primary portion onto the glazing panel.

[0031] The primary part can be overmolded onto the glazing panel. For ease of processing, the primary part can be injected into a mold to wrap over the glazing panel.

[0032] In some embodiments, the glazing panel is a glass panel, which comprises at least one glass sheet.

[0033] Alternatively, the glazing panel can be a laminated glass panel. Laminated glazing includes glass sheets held together by one or more interlayers positioned between the glass sheets. The interlayers employed are typically polyvinyl butyral (PVB) or ethylene vinyl acetate (EVA), which can be adjusted for stiffness. These interlayers hold the glass sheets together even when broken in a way that prevents the glass from breaking into large, sharp shards.

[0034] The glass sheets can be clear glass or tinted glass, tinted with a particular composition of glass or by adding, for example, a coating or plastic layer.

[0035] In embodiments where the glazing panel is a laminated glass panel, it may be advantageous to have varying thicknesses of the glass sheets to reduce weight and noise. Thin glass sheets with thicknesses of less than 1 mm can be used without bending or deforming due to the deformation induced on the glazing panel. Thus, such thin glass sheets can maintain the desired design.

[0036] In some embodiments, the primary portion can include a core portion. The core portion can be in direct contact with the glazing panel, meaning that the core portion is injected onto the glazing panel. The glazing panel can have a localized bonding agent or primer material to ensure rigidity and / or facilitate wrapping of the core portion over the glazing panel. The core portion can be overmolded onto the glazing panel, meaning that the core portion is fabricated before being placed in a mold with the glazing panel and then secured to the glazing panel with another material, such as a peripheral portion. To facilitate processing, the core portion can be injected into a mold to wrap over the glazing panel. In some other embodiments, the core portion can be fabricated first and then secured to the glazing panel with a fastening means, such as an adhesive.

[0037] In these embodiments, the primary portion includes two portions, a core portion and a peripheral portion, with the peripheral portion at least partially resting on the core portion. The peripheral portion can be in direct local contact with the glazing panel, meaning that the peripheral portion is injected onto the glazing panel at least partially over the core portion. The glazing panel can have a local bonding agent or primer material to ensure rigidity and / or facilitate the wrapping of the peripheral portion onto the glazing panel.

[0038] A method of making a window unit according to these embodiments includes the following steps. (1) Inserting the glass panel and the core portion into a mold. (2) Closing the mold to create at least one cavity around the glass panel and / or around the core portion. (3) injecting a peripheral portion of the primary portion into at least one cavity; (4) The step of opening the mold. (5) Removing the window unit from the mold.

[0039] In these embodiments, the frame may include a secondary portion, as described below, which is injected after the peripheral portion.

[0040] In some embodiments, the composition of the core portion of the primary portion comprises a weight percentage of recycled material of the total polymeric material of the core portion that is greater than the weight percentage of recycled material of the total polymeric material of the peripheral portion, where the weight percentage of recycled material in the primary portion is the total weight of recycled material in the core and peripheral portions divided by the total weight of the combined virgin and recycled material in the core and peripheral portions multiplied by 100.

[0041] In some embodiments, the frame can include a decorative element, which is attached to the primary portion or to the secondary portion of the frame.

[0042] The invention also relates to a method for producing a window unit according to the invention, comprising the following steps: (1) Inserting a glass panel into a mold. (2) closing the mold to create at least one cavity around the glass panel; (3) injecting a primary portion into at least one cavity; (4) The step of opening the mold. (5) Removing the window unit from the mold.

[0043] In some embodiments, the secondary portion can be injected after the primary portion is injected.

[0044] In some embodiments, the primary portion is not poured onto the glazing panel, but can be placed in a mold with the glazing panel and overmolded with the secondary portion.

[0045] The window unit of the present invention may be placed in an opening in a vehicle body, window frame, or door frame.

[0046] It is to be noted that the invention relates to all possible combinations of the features recited in the claims.

[0047] Although the following description relates to automotive window units, it will be understood that the invention may be applicable to other fields, such as transportation vehicles such as trains, buses, boats, etc., or structural windows that may provide a wrap around the edge of the window on at least one periphery.

[0048] This and other aspects of the invention will now be described in more detail with reference to the accompanying drawings, which illustrate various exemplary embodiments of the invention, provided by way of illustration and not by way of limitation. The drawings are schematic and not to scale. They are not intended to limit the invention in any way. Many more advantages will be explained by way of example. [Brief explanation of the drawings]

[0049] [Figure 1a] 1 is a schematic diagram of a window unit placed on a vehicle body according to an exemplary embodiment of the present invention;

[0050] [Figure 1b] This is a cross section taken along section AA in FIG. 1a.

[0051] [Figure 1c] This is a cross section taken along section BB in FIG. 1a.

[0052] [Figure 2a] 4 is a schematic diagram of a window unit placed on a vehicle body according to a second exemplary embodiment of the present invention; FIG.

[0053] [Figure 2b] This is a cross section taken along section AA in FIG. 2a.

[0054] [Figure 2c] This is a cross section taken along section BB in FIG. 2a.

[0055] [Figure 2d] This is a cross section taken along section CC in Figure 2a.

[0056] [Figure 2e] This is a cross section taken along section DD in Figure 2a.

[0057] [Figure 3a] FIG. 10 is a schematic diagram of a window unit placed on a vehicle body according to a third exemplary embodiment of the present invention.

[0058] [Figure 3b] This is a cross section taken along section AA in FIG. 3a.

[0059] [Figure 3c] This is a cross section taken along section BB in FIG. 3a.

[0060] [Figure 3d] This is a cross section taken along section CC in FIG. 3a.

[0061] [Figure 3e] This is a cross section taken along section DD in FIG. 3a.

[0062] This is a cross section taken along section DD in FIG. 3a.

[0063] [Figure 3f] FIG. 1 is a schematic view of the area of ​​cross section BB.

[0064] [Figure 4a] FIG. 10 is a schematic diagram of a window unit placed on a vehicle body according to a fourth exemplary embodiment of the present invention.

[0065] [Figure 4b] FIG. 10 is a schematic diagram of a glazing panel and core portion of a primary section according to a fourth exemplary embodiment of the present invention.

[0066] [Figure 4c] This is a cross section taken along section AA in FIG. 4a. DETAILED DESCRIPTION OF THE INVENTION

[0067] The examples provided herein are illustrative of the scope of the invention as defined in the claims. They do not represent limiting embodiments of the invention in any way. It should be noted that the present invention relates to all possible combinations of features described in the following embodiments.

[0068] Referring to Figures 1a to 1c, a first embodiment of the present invention is described.

[0069] 1a, 1b, and 1c show a window unit 100 comprising a glazing panel 101 and a frame 102 with a frame profile that surrounds the edge of the glazing panel 101. The primary part 103 is poured directly onto the glass panel that has been previously placed in the mold. The primary part comprises at least 10% recycled material by weight, meaning that the polymeric matrix of the primary part comprises at least 10% recycled material and at most 90% virgin material by weight of the total polymeric material of the primary part. The primary part, in the form of a rigid component, comprises polypropylene-based virgin material. The recycled material is a polypropylene-based material, meaning that the recycled material has the same polymeric matrix as the virgin material of the primary part.

[0070] The window unit 100 has a polygonal shape, in particular a trapezoidal shape. The glazing panel 101 has approximately the same shape. The frame has a frame profile and surrounds the edges of the glazing panel on four peripheries.

[0071] In these embodiments, the primary portion comprises at least 50% to 100% recycled material by weight. In this embodiment, the percentage of polypropylene is 50% to 70% by weight of the recycled material. Advantageously, because most of the primary portion is invisible, the polymeric material of the primary portion can have a higher weight percentage of recycled material.

[0072] The primary portion may include other materials, such as glass fiber, to reinforce the primary portion.

[0073] The frame also includes a secondary portion 104. The secondary portion 104 is a TPE-based material. In some embodiments, the polymeric material of the secondary portion has a lower percentage of recycled material than the percentage of recycled material of the primary portion.

[0074] In some embodiments, the TPE material may contain some polypropylene, and recycled polypropylene may also be used. In these embodiments, the maximum amount of polypropylene is about 20-25% by weight, so even if we only consider the use of recycled polypropylene, the percentage of recycled material in the secondary portion is limited for the TPE.

[0075] The glazing panel may include a fastening means 106 that can secure the window unit 100 to another element, such as the vehicle body C, a door frame, etc. The fastening means 106 is secured to the frame within the primary part 102. In some embodiments, the fastening means may be overmolded with the primary part. In some embodiments, the fastening means is injected with the primary part. Other fastening means, such as division bars, may be used.

[0076] In some embodiments, the primary portion can have a specific design to meet requirements and reinforce the frame and window unit 100. The secondary portion can have a specific design, such as with a lip, to connect the window unit 100. As shown in FIGS. 1b and 1c, the frame has a frame profile and surrounds the edge of the glazing panel. The primary portion surrounds the edge of the glazing panel. The primary portion contacts two major faces and the edge of the glazing panel. The secondary portion overlies at least a portion of the primary portion. In this embodiment, the secondary portion contacts the glazing panel on one major face.

[0077] The secondary portion includes a lip 104a that allows for rigidity between the window unit and the vehicle body C.

[0078] In this embodiment, the window unit is fabricated by a multi-component injection molding process, which includes the following steps: (1) Inserting a glass panel into a mold. (2) closing the mold to create at least one cavity around the glass panel; (3) injecting a primary portion into at least one cavity; (4) transferring the glass panel with the primary portion to a second portion of the mold with a different cavity; (5) Injecting the secondary portions into the different cavities. (6) The step of opening the mold. (7) Removing the window unit from the mold.

[0079] As shown in Figures 2a to 2e, a second embodiment of the present invention is described.

[0080] 2a, 2b, 2c, 2d, and 2e show a window unit 200 comprising a glazing panel 201 and a frame 202 with a frame profile that surrounds the edge of the glazing panel 201. The primary part is poured onto a glass panel that has been previously placed in a mold. The primary part comprises at least 10% recycled material by weight, meaning that the polymeric matrix of the primary part comprises at least 10% recycled material and at most 90% virgin material by weight of the total polymeric material of the primary part. The primary part, in the form of a soft component, comprises TPE-based virgin material. The recycled material is a TPE-based material, meaning that the recycled material has the same polymeric matrix as the virgin material of the main technology.

[0081] The window unit 200 has a polygonal shape, in particular a trapezoidal shape. The glazing panel 201 has approximately the same shape. The frame has a frame profile and surrounds the edge of the glazing panel on four peripheries.

[0082] In these embodiments, the primary portion comprises at least 50%-100% recycled material by weight. In this embodiment, the percentage of TPE is 50%-70% by weight of recycled material. Advantageously, because most of the primary portion is invisible, the polymeric material of the primary portion can have a higher weight percentage of recycled material.

[0083] The primary portion may include other materials, such as glass fiber, to reinforce the primary portion.

[0084] The frame also includes a decorative element 205. The decorative element can be a single element that at least partially surrounds the top of the frame as shown in Figure 2a. In some embodiments, the decorative element can be several pieces that are secured to the primary portion. The decorative element can cover only a portion of the primary portion. In this embodiment, the decorative element covers three of the four sides of the window unit.

[0085] The decorative element can be made of plastic, metal and in different top configurations such as metallized configurations etc. The decorative element can be fixed onto the primary part by a fixing means or can be overmolded with the primary part.

[0086] The glazing panel may include fastening means 206 that can secure the window unit 200 to another element, such as the vehicle body C, a door frame, etc. The fastening means 206 is secured onto the frame within the primary part 202. In some embodiments, the fastening means may be overmolded with the primary part. In some embodiments, the fastening means is injected with the primary part. Other fastening means, such as division bars, may be used.

[0087] In some embodiments, the primary portion can have a specific design to meet requirements and reinforce the frame and window unit 200. The secondary portion and / or the primary portion can have a specific design, such as with a lip, to connect the window unit 200. As shown in Figures 1b-1e, the frame has a frame profile and surrounds the edges of the glazing panel. The primary portion surrounds the edges of the glazing panel. The primary portion contacts the two major faces and the edges of the glazing panel.

[0088] The primary portion includes a lip 203a that allows for rigidity between the window unit and the vehicle body C.

[0089] In this embodiment, the window unit is fabricated by an injection molding process, which includes the following steps: (1) Inserting a glass panel into a mold. (2) closing the mold to create at least one cavity around the glass panel; (3) injecting a primary portion into at least one cavity; (4) The step of opening the mold. (5) Removing the window unit from the mold. (6) Fixing a decorative element onto the primary part.

[0090] The decorative element can also be overmolded by the primary part, which means that the decorative strip is inserted into the mold together with the glass panel and then the primary part is injected into at least one cavity instead of being fixed after the injection step.

[0091] With reference to Figures 3a to 3f, a first embodiment of the present invention is described.

[0092] Figures 3a, 3b, 3c, 3d, 3e, and 3f show a window unit 300 comprising a glazing panel 301 and a frame 302 with a frame profile that surrounds the edge of the glazing panel 301. The primary part is poured onto a glass panel that has been previously placed in a mould. The primary part comprises at least 10% recycled material by weight, meaning that the polymeric matrix of the primary part comprises at least 10% recycled material and at most 90% virgin material by weight of the total polymeric material of the primary part. The primary part, in the form of a rigid component, comprises polypropylene-based virgin material. The recycled material is a polypropylene-based material, meaning that the recycled material has the same polymeric matrix as the virgin material of the main technology.

[0093] The window unit 300 has a polygonal shape, in particular a trapezoidal shape. The glazing panel 301 has approximately the same shape. The frame has a frame profile and surrounds the edge of the glazing panel on three peripheries.

[0094] In these embodiments, the primary portion comprises at least 50% to 100% recycled material by weight. In this embodiment, the percentage of polypropylene is 50% to 70% by weight of virgin recycled material. Advantageously, because most of the primary portion is invisible, the polymeric material of the primary portion can have a higher weight percentage of recycled material.

[0095] The primary portion may include other materials, such as glass fiber, to reinforce the primary portion.

[0096] The frame also includes a secondary portion. The secondary portion is a TPE-based material. In some embodiments, the polymeric material of the secondary portion has a lower percentage of recycled material than the percentage of recycled material in the primary portion.

[0097] In some embodiments, the TPE material may contain some polypropylene, and recycled polypropylene may also be used. In these embodiments, the maximum amount of polypropylene is about 20-25% by weight, so even if we only consider the use of recycled polypropylene, the percentage of recycled material in the secondary portion is limited for the TPE.

[0098] The glazing panel may include fastening means 306 that can secure the window unit 300 to another element, such as the vehicle body C, a door frame, etc. The fastening means 306 is secured onto the frame within the primary part 302. In some embodiments, the fastening means may be overmolded with the primary part. In some embodiments, the fastening means is injected with the primary part. Other fastening means, such as division bars, may be used.

[0099] In some embodiments, the primary portion can have a specific design to meet requirements and reinforce the frame and window unit 300. The secondary portion can have a specific design, such as with a lip, to connect the window unit 300. As shown in Figures 3b-3f, the frame has a frame profile and surrounds the edge of the glazing panel. The primary portion surrounds the edge of the glazing panel. The primary portion contacts two major faces and the edge of the glazing panel. The secondary portion overlies at least a portion of the primary portion. In this embodiment, the secondary portion contacts the glazing panel on one major face.

[0100] The primary and secondary parts have different shapes on either side of the glazing unit depending on the local needs for rigidity and fastening.

[0101] In Figure 3b, the secondary section surrounds most of the surface of the primary section. In Figure 3c, the secondary section overlies a small portion of the surface of the primary section. In Figure 3d, the secondary section is only locally placed to ensure rigidity with the vehicle body C via lip 304a. In Figure 3e, the secondary section is locally placed on the primary section to directly contact the glazing panel and mate with the division bar cover 308, allowing a second glazing panel to move inside this thus-formed U-shaped division bar with an aftermarket gasket 309.

[0102] In Figure 3f the secondary part is over a part of the primary part, the primary part having fastening means 306 by which the window unit can be fastened to the vehicle body.

[0103] In this embodiment, most of the primary part is not overmolded by the secondary part and is hidden by elements of the vehicle body.

[0104] The secondary portion includes a lip 304a that allows for rigidity between the window unit and the vehicle body C.

[0105] In this embodiment, the window unit is fabricated by a multi-component injection molding process, which includes the following steps: (1) Inserting a glass panel into a mold. (2) closing the mold to create at least one cavity around the glass panel; (3) injecting a primary portion into at least one cavity; (4) transferring the glass panel with the primary portion to a second portion of the mold with a different cavity; (5) Injecting the secondary portions into the different cavities. (6) The step of opening the mold. (7) Removing the window unit from the mold.

[0106] With reference to Figures 4a to 4c, a first embodiment of the present invention is described.

[0107] 4a, 4b, and 4c show a window unit 400 comprising a glazing panel 401 and a frame 402 with a frame profile that surrounds the edge of the glazing panel 401. The primary part is poured onto a glass panel that has been previously placed in a mold. The primary part comprises at least 10% recycled material by weight, meaning that the polymeric matrix of the primary part comprises at least 10% recycled material and at most 90% virgin material by weight of the total polymeric material of the primary part. The primary part, in the form of a soft component, comprises TPE-based virgin material. The recycled material is a TPE-based material, meaning that the recycled material has the same polymeric matrix as the virgin material of the main technology.

[0108] The window unit 400 has a polygonal shape, in particular a triangular shape. The glazing panel 401 has approximately the same shape. The frame has a frame profile and surrounds the edges of the glazing panel on four peripheries.

[0109] In these embodiments, the primary portion comprises at least 50%-100% recycled material by weight. In this embodiment, the percentage of TPE is 50%-70% by weight of virgin recycled material. Advantageously, because most of the primary portion is invisible, the polymeric material of the primary portion can have a higher weight percentage of recycled material.

[0110] The primary portion may include other materials, such as glass fiber, to reinforce the primary portion.

[0111] The primary portion includes a core portion 403b and a peripheral portion 403c.

[0112] The core portion contains at least 50% to 100% recycled material by weight, and the peripheral portion has a lower percentage of recycled material than the core portion.

[0113] In some embodiments, the primary portion can have a specific design to meet requirements and reinforce the frame and window unit 400. The peripheral portion can have a specific design, such as with a lip, to connect the window unit 400. As shown in Figures 4b-4c, the frame has a frame profile and surrounds the edge of the glazing panel. The primary portion surrounds the edge of the glazing panel. The primary portion contacts two major surfaces and the edge of the glazing panel. The secondary portion overlies at least a portion of the primary portion. In this embodiment, the secondary portion contacts the glazing panel on one major surface.

[0114] In this embodiment, the core portion is overmolded with the peripheral portion.

[0115] The peripheral portion surrounds most of the surface of the core portion and is in direct contact with the glass panel, even at the edge of the glass panel.

[0116] This core portion is hidden by the peripheral portion.

[0117] In this embodiment, the window unit is fabricated by an injection molding process, which includes the following steps: (1) Inserting the glass panel and the core portion of the primary section into a mold. (2) closing the mold to create at least one cavity around the glass panel and core portion; (3) injecting the peripheral portion into at least one cavity; (4) The step of opening the mold. (5) Removing the window unit from the mold.

[0118] The core portion may also be injected onto the glass panel, in which case the method comprises the following steps: (1) Inserting the glass panel into the mold. (2) closing the mold to create at least one cavity around the glass panel; (3) injecting a core portion into at least one cavity; (4) transferring the glass panel with the core portion to a second portion of the mold having a different cavity; (5) Injecting the peripheral portions into the different cavities. (6) The step of opening the mold. (7) Removing the window unit from the mold.

Claims

1. A window unit (100, 200, 300, 400) comprising a glazing panel (101, 201, 301, 401) and a frame (102, 202, 302, 402) having a frame profile, surrounding an edge of said glazing panel on at least one periphery and comprising a plastic primary part (103, 203, 303, 403), 10. A window unit comprising: said primary part comprising at least 10% by weight of recycled material of the total polymeric material of said primary part; said primary part being in the form of a rigid component, said rigid component being a polypropylene based material; said frame comprising a secondary part (104), said secondary part (104) being in the form of a flexible component and at least partially placed on said primary part, said flexible component being a thermoplastic elastomer based material; and said glazing panel being a glass panel.

2. A window unit as described in claim 1, wherein the polymeric material of the secondary portion has a lower percentage of recycled material than the percentage of recycled material of the primary portion.

3. 3. A window unit according to claim 1 or 2, wherein the rigid components comprise glass fibres.

4. A window unit as described in any one of claims 1 to 3, wherein the secondary part is in contact with the glazing panel on one main surface.

5. A window unit according to any one of the preceding claims, wherein the primary part is in direct contact with the glazing panel.

6. A window unit according to any one of the preceding claims, wherein the glazing panel is a laminated glass panel.

7. 7. The window unit according to any one of the preceding claims, wherein the primary part (403) comprises a core part (403b) and a peripheral part (403c), the peripheral part being at least partially positioned on the core part.

8. 8. The window unit of claim 7, wherein a composition of the core portion of the primary section comprises a higher percentage of recycled material than a composition of the peripheral portion.

9. 9. A window unit according to any one of the preceding claims, wherein the frame comprises a decorative element (105), the decorative element (105) being attached to the primary part of the frame.

10. A method for producing a window unit according to any one of claims 1 to 9, comprising the steps of: (1) inserting the glass panel into a mold; (2) closing the mold to create at least one cavity around the glass panel; (3) injecting the primary portion into the at least one cavity; (4) opening the mold; and (5) removing the window unit from the mold; A method comprising:

11. A method for producing a window unit according to claim 7 or 8, comprising the steps of: (1) inserting the glass panel and the core portion into a mold; (2) closing the mold to create at least one cavity around the glass panel and / or around the core portion; (3) injecting the peripheral portion of the primary portion into the at least one cavity; (4) opening the mold; and (5) removing the window unit from the mold; A method comprising:

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