Abstract: A method of joining two components of a vinyl frame provides first and second components each having an end and having surfaces defining at least one channel open at the end and extending into the associated component. A coupling structure is provided and has at least a first member and a second member and includes energy receiving structure. The first member is inserted to extend at least partially into the channel of the first component and the second member is inserted so as to extend at least partially into the channel of the second component so that the energy receiving structure is generally adjacent to certain surfaces defining the associated channel. Energy is directed to the coupling structure to cause the energy receiving structure to fuse with the certain surfaces, thereby joining the first and second components together. Improved component sealing and water pathways are also provided.

Abstract: A method for producing window components using polymer based, metallurgy based, extruded, injection molded, or wood material is provided. This invention provides a low cost, highly reliable, low defect method of producing window components by machining from a singular piece of material, providing bendable portions, with angled portions adapted to fit together to define a wide range of window shapes and sizes.