Abstract: A method of forming a foam-filled decorative muntin bar includes the steps of roll-forming a sheet of aluminum to form a hollow outer shell, and depositing a mixture of foaming components on the sheet of aluminum as it is being roll-formed, so the outer shell encases the mixture. The mixture is allowed to react, expand and harden to form a foamed material that substantially fills the shell. The filled shell is cut to form a segment of a foam-filmed decorative muntin bar of desired length with open ends.

Abstract: A decorative window assembly includes a peripheral frame, and a plurality of foam-filled decorative muntin bars interconnected in a grid which is connected to the peripheral frame. Each muntin bar includes an elongated outer shell with open ends and defining a hollow interior, and a foamed filler substantially filling the interior of the shell between the ends thereof.

Abstract: A corner reinforcement for use in strengthening screen frames, for example, includes at least a first segment and a second segment of screen bar, each formed into a desired profile and each having a hollow interior portion, a reinforcing channel and a rigid reinforcing and structural material. The reinforcing channel has a first leg and a second leg arranged at approximately ninety degrees to the first leg with ends of the channel securing first and second extensions to extend the first and second legs, respectively. At least a portion of (i) the first extension of the channel is inserted through a first end of the first segment of the screen bar into and substantially spaced from surfaces of the hollow interior portion thereof and (ii) the second extension is inserted through a first end of the second segment of the screen bar into and substantially spaced from surfaces of the hollow portion thereof.

Abstract: A corner reinforcement for use in strengthening screen frames, for example, includes at least a first segment and a second segment of screen bar, each formed into a desired profile and each having a hollow interior portion, a reinforcing channel and a rigid reinforcing and structural material. The reinforcing channel has a first leg and a second leg arranged at approximately ninety degrees to the first leg. At least a portion of (i) the first leg of the channel is inserted through a first end of the first segment of the screen bar into and substantially spaced from a surface of the hollow interior portion thereof and (ii) the second leg is inserted through a first end of the second segment of the screen bar into and substantially spaced from a surface of the hollow portion thereof.

Abstract: A method of making an enclosed, hollow insulating spacer for spacing apart panes of a multiple pane unit. The method includes steps of forming metal into first and second leg members for a spacer, preheating the first and second leg members of the spacer near the melting point of one of a synthetic resin material and a composite synthetic resin material, feeding the preheated first and second leg members of the spacer into a crosshead extruder together with one of the resin materials to embed by crosshead extrusion only a portion of each of the first and second leg members into the material, to affix the embedded portion of each of the leg members to the material and to form from the material a first bridge member that extends between the leg members and spans across one end of each of the leg members, and providing a second bridge member that connects the opposite ends of the leg members.

Abstract: An open grid fabric for reinforcing wall systems and a method of making same. First and second sets of substantially parallel, selected rovings are combined using certain knits, leno weaves, or adhesive methods. The rovings are direct-sized with at least a silane sizing and preferably have a linear density between 100 and 2000 grams per thousand meters and are arranged at an average of 3 to 10 ends per inch. A polymeric coating is applied to the fabric at a level of 10 to 150 parts dry weight of resin to 100 parts by weight of the fabric while assuring that the open grid remains open. A method for reinforcing a wall system and a wall segment product utilizing the novel open grid fabric of the present invention are also disclosed.

Abstract: A preformed, unitary composite for reinforcing while suppressing curl in bituminous roofing membranes includes as a first layer, an open, non-woven grid of low shrinkage, continuous filament polyester yarns that are at low tension and adhesively secured together, and as a second layer, a lightweight, preformed fiberglass mat, the second layer being adhesively secured to one side of the first layer. The adhesive secures the two layers together such that at least some of the individual yarns of the first layer are at least partially coated and impregnated by the adhesive without forming a film that closes all openings through the composite. The adhesive that secures the continuous filament yarns of the first layer together and that secures the first and second layers together is a vulcanizable rubber binder, such as cross-linked styrene butadiene rubber, which includes about 50 to about 80% styrene.

Abstract: An insulating spacer for creating a thermally insulating bridge between inner and outer panes of, for example, a multiple pane window unit. The spacer defines an insulated space between the panes and includes a top bridge member, first and second metallic leg members, a bottom bridge member and a channel portion. The top bridge member is provided for contacting the inner and outer panes of the window unit. The top bridge member is made of a synthetic resin or composite material and can include openings. Perforated extensions of the first and second leg members are secured to the top bridge member. The first and second leg members can be bent into a zig-zag configuration. The bottom bridge member is substantially parallel to the top bridge member and cooperates with the first and second leg members. The channel portion is defined by the configuration of the top bridge member, the first and second leg members and the bottom bridge member.

Abstract: Thermoplastic, thermoshapable composite laminate bars, an orthopedic brace using the shaped composite bars as integral components, and a method of thermoshaping the composite bars for use as fitted components in the orthopedic brace are provided. The composite bars contain multiple fiber layers oriented in at least two directions with respect to the bar length to provide high flexural and torsional strength. The novel method of thermoshaping yields improved results over prior thermoshaping methods by providing an uncomplicated shaping capability while maintaining the structural and mechanical properties of the composite bar.

Abstract: A puncture resisting and processability improving composite for reinforcing bituminous roofing membranes that are free of organic mats. The composite includes a lightweight open grid of over-under construction, the grid having polyester yarns of about 30 to about 300 denier in the machine direction and about 30 to about 300 denier in the cross-machine direction, a yarns per inch count of about 3.times.3 to about 10.times.10 in each of the machine and cross-machine directions, and a dry weight pick-up of about 60 to about 250 parts of binder to 100 parts by weight of polyester in the grid, in which an adhesive that is one of dissolved and dispersed in a liquid is applied to the composite so that the open grid is held together by the adhesive alone.

Abstract: An open grid fabric for reinforcing wall systems and a method of making same. First and second sets of substantially parallel, selected rovings are combined using certain knits, leno weaves, or adhesive methods. The rovings are direct-sized with at least a silane sizing and preferably have a linear density between 100 and 2000 grams per thousand meters and are arranged at an average of 3 to 10 ends per inch. A polymeric coating is applied to the fabric at a level of 10 to 150 parts dry weight of resin to 100 parts by weight of the fabric while assuring that the open grid remains open. A method for reinforcing a wall system and a wall segment product utilizing the novel open grid fabric of the present invention are also disclosed.

Abstract: An insulating spacer for creating a thermally insulating bridge between spaced apart panes of a multiple pane window unit. The spacer defines an insulated space between the panes and includes a top bridge member, first and second leg members for supporting the top bridge member, a bottom bridge member and a channel portion. The top bridge member provides the sole contact with the inner and outer panes of the window unit. The top bridge member is made of a synthetic resin or composite material and can include openings. A portion of the first and second leg members adheres onto a lower surface of the top bridge member, and each member extends from that lower surface such that it is adapted to remain free from contact with the spaced apart outer panes. The first and second leg members can be bent into a zig-zag configuration. The bottom bridge member cooperates with each of the first and second leg members.

Abstract: A reinforced bituminous roofing membrane includes a first layer, a second layer, a third layer and bituminous material. The first layer consists essentially of a lightweight, open grid of adhesively bound non-woven fabric in which yarns in the cross-machine direction are held between pairs of yarns in the machine direction, each such pairs of yarns having one yarn that is essentially above the other and each such pair of yarns being coated and bound next to the other by adhesive which accumulates between the yarns of each pair. The second layer consists essentially of a high strength reinforcing fabric, while the third layer consists essentially of a porous fiberglass mat. The bituminous material saturates and contains the first, second and third layers, such that the three layers are completely embedded within the bituminous material and the bituminous material on one side of the membrane bonds through the layers to the bituminous material on the other side of the membrane.

Abstract: A reinforced, impervious, unitary film and a method for making the same are disclosed. In a preferred embodiment, a film is produced from a layer of weft inserted warp knit scrim and at least one layer of lightweight, porous mat, together being impregnated with a suitable thermoformable plastic in liquid form such as PVC plastisol, then being set and calendered under pressure to deform the plastic and create a continuous, non-porous, unitary film. The resulting product is highly resistant to water absorption and hydrostatic pressure and essentially non-wicking.

Abstract: A process for reinforcing paving in which a second layer of paving is placed on top of a first layer. The process includes selecting a semi-rigid, open grid reinforcement of multi-filament reinforcing strands being fixed at cross-over points, the grid being in the form of a roll, a resin being applied to the strands of the grid and an activatable adhesive being applied on the resin to one side of the grid, continuously unrolling the grid, adhesive side down, essentially directly, evenly and flatly onto the first layer of paving, while maintaining the respective strands of the grid in substantially parallel alignment, activating the adhesive by applying one of heat and pressure to adhere the grid to the first paving layer and substantially eliminate bubbles, raised portions or sideways distortion of the strands of the grid during application of the second layer and applying the second layer of paving on top of the grid and the first layer.

Abstract: Disclosed is a process of manufacturing a roofing membrane that is free of any organic mat. The process includes selecting a lightweight polyester fabric including an open grid of over-under construction in which fill yarns are held between pairs of machine direction yarns lying essentially one above the other, the fabric including polyester yarns having about 30 to about 300 denier yarns in the machine direction, about 30 to about 300 denier yarns in the fill direction, a yarn per inch count of about 3.times.3 to about 10.times.10, and a dry weight pick-up of about 60 to about 250 parts by weight of binder relative to 100 parts by weight of polyester in the fabric; selecting a high strength reinforcing open grid; and passing the lightweight polyester open fabric, the high strength reinforcing open grid and any additional reinforcements free of any organic mat through bituminous material to form the roofing membrane.

Abstract: A reinforcement for asphaltic pavings comprises a prefabricated resin impregnated, adhesive coated grid of continuous glass fibers. The grid is laid on top of an underlying paving and adhered to it. An asphaltic paving layer is then applied on top of the grid.