Method of modifying the surface of a fenestration member

A method of making a fenestration frame member including at least one fenestration member that includes a channel defined by at least a first side wall, a second side wall, and a bottom wall, and a thermal break composition disposed in the channel, the method includes exposing the surface of the channel to a flame for period sufficient to oxidize the surface of the channel, and depositing a thermal break composition on the oxidized surface of the channel, the thermal break composition having a thermal conductivity less than the thermal conductivity of the walls of the channel.

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Description
BACKGROUND

The invention relates to modifying the surface of a fenestration member.

Fenestration frames, e.g., metal exterior window and door casings, which are often made of aluminum, are widely used in a variety of structures including office and industrial buildings. Such metal casings are good thermal conductors and therefore can cause considerable heat loss in winter and heat gain in summer in buildings in which they are installed. To reduce this problem it is common to employ a “thermal barrier” between the interior and the exterior components of the fenestration frame. The thermal barrier often includes a material of a relatively low thermal conductivity, which serves to interrupt the transfer of thermal energy between the interior and exterior components.

Thermal barriers often consist of a channel and a thermal break composition disposed in the channel.

Thermal barriers, when being part of a fenestration frame such as a window, are often subjected to high stresses caused by day, night and seasonal thermal cycling of the metal segments, which have much lower thermal expansion coefficients relative to the thermal break composition disposed in the channel of the thermal barrier. These stresses are different on each side of the thermal barrier due to the differential between the interior and exterior temperatures. Over time these stresses may cause the thermal break composition to debond from the metal segments of, or the finish on, the thermal barrier, which can lead to gaps and water infiltration in the thermal barrier assembly.

Various attempts have been made to increase the adhesion of the thermal break composition to the finish of the channel surface including mechanically roughening the surface of the channel using methods such as abrading, scratching, lancing, sand blasting, and scraping. These processes tend to negatively impact the aesthetics of the assembly. Chemical treatments such as solvent bonding and chemical etching processes are also known. These processes can not be performed “in line” and are inconsistent in their effectiveness on different types of finishes. Other channel treatment methods employ a plasma or a corona, an example of which is disclosed in U.S. Pat. No. 6,962,025.

SUMMARY

In one aspect, the invention features a method of making a fenestration frame member that includes at least one fenestration member that includes a channel defined by at least a first side wall, a second side wall, and a bottom wall, and a thermal break composition disposed in the channel, the method includes exposing the surface of the channel to a flame for period sufficient to oxidize the surface of the channel, and depositing a thermal break composition on the oxidized surface of the channel, the thermal break composition having a thermal conductivity less than the thermal conductivity of the walls of the channel. In one embodiment, the method further includes removing at least a portion of the bottom wall of the channel.

In another embodiment, the fenestration member includes a plurality of channels.

In one embodiment, the method includes making a plurality of the fenestration frame members. In another embodiment, the method further includes assembling a plurality of the fenestration frame members to form a fenestration frame.

In one embodiment, the fenestration member includes metal. In another embodiment, the fenestration member includes aluminum.

In one embodiment, the fenestration member includes a surface treatment. In some embodiments, the surface treatment is selected from the group consisting of polyester, melamine, mill finish, conversion coating, primer, paint, acrylic, polyester, enamel, polyurethane, fluoropolymer, anodic finishes, powder coats, and combinations thereof.

In one embodiment, the oxidized surface of the channel has a surface temperature of at least 110° F. during the treatment. In another embodiment, the thermal break composition exhibits a thermal conductivity of no greater than 1.5 Btu·inch/hr-Ft2·° F. In another embodiment, the thermal break composition exhibits a thermal conductivity of no greater than 1.62 Btu·inch/hr-Ft2·° F. In some embodiments, the thermal break composition includes polyurethane, isocyanurate, epoxies, acrylics, or combinations thereof.

In some embodiments, the flame is created by the combustion of gas including oxygen, propane, natural gas, butane, methane, acetylene, or combinations thereof. In one embodiment, the gas is combusted with air in a gas-to-air stoichiometric ratio of from about 4:1 to about 44:1.

In one embodiment, the oxidized surface of the channel exhibits a surface energy of at least 38 Dynes. In another embodiment, the oxidized surface of the channel exhibits a surface energy of at least 44 Dynes.

In one embodiment, the thermal break composition exhibits no greater than 0.2% dry shrinkage in the channel when the fenestration frame member is tested in accordance with AAMA 505-98 manual entitled, “Dry Shrinkage and Composite Performance Thermal Cycling Test Procedure.” In another embodiment, the fenestration frame member exhibits a shear strength of at least 1500 psi when tested in accordance with AAMA 505-98 manual entitled, “Dry Shrinkage and Composite Performance Thermal Cycling Test Procedure.”

In one aspect the invention features a method of making a fenestration frame that includes making a plurality of fenestration frame members according a method described herein, and assembling a plurality of the fenestration frame members to form the fenestration frame.

In another aspect, the invention features an automated process for manufacturing a fenestration frame member. The process includes a) transporting a fenestration member, which includes a channel defined by at least a first side wall, a second side wall, and a bottom wall, b) exposing the surface of the channel to a flame for period sufficient to oxidize the surface of the channel, c) transporting the fenestration member to an application station, and d) depositing a thermal break composition to the oxidized surface of the channel, the thermal break composition having a thermal conductivity less than the thermal conductivity of the walls of the channel. In one embodiment, the automated process further includes transporting the fenestration member to a debridging station, and removing at least a portion of the bottom wall of the channel. In another embodiment, the automated process manufactures fenestration frames and the process further includes transporting the fenestration frame member to an assembly station, and assembling a plurality of the fenestration frame members to form a fenestration frame.

The invention provides a fenestration frame member that exhibits good tensile strength and good shear properties. The fenestration frame member includes a surface-modified channel to which a thermal break composition maintains good adhesion, and in which the thermal break composition exhibits low levels of dry shrinkage over repeated thermal cycling relative to the same fenestration frame without a surface-modified channel. The surface-modified channel also enhances the thermal break composition's ability to resist debonding from the surface-modified channel.

Other features and advantages will be apparent from the following description of the preferred embodiments and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective view of a fenestration member.

FIG. 2 shows a perspective view of a fenestration frame member.

FIG. 3 is sectional view of a fenestration frame member that includes a bridge extending across one side of a channel in the fenestration member.

FIG. 4 is a sectional view of the fenestration frame member of FIG. 3 in which the channel bridge is being removed to create the fenestration frame member of FIG. 2.

FIG. 5 is a sectional view of a burner emitting a flame into a channel of a fenestration member.

FIG. 6 shows a perspective view of an automated process for treating a fenestration member channel with surface-oxidizing flame and applying a thermal break composition to the surface-oxidized channel of the fenestration member.

FIG. 7 is a sectional view of another embodiment of a burner.

DETAILED DESCRIPTION

The method of making at least a portion of a fenestration frame (i.e., a fenestration frame member 20) includes exposing the cavity surface of a channel 23 of a fenestration member 10 to a flame 33 for a period sufficient to oxidize the surface of the channel 23, as illustrated in FIGS. 1 and 5. The method further includes depositing a thermal break composition 16 in the channel 23 to form the fenestration frame member 20, as illustrated in FIGS. 2 and 3. The fenestration frame member 20 thus formed includes a thermal break composition 16 disposed in the oxidized 18 channel 23 of the fenestration member 10. A portion 22 of the fenestration member 10 that partially defines the channel 23 is then removed (e.g., by milling), which changes the fenestration member 10 from a unitary body to two distinct components 12, 14, as illustrated in FIGS. 2 and 4. The two components 12, 14 remain bonded to each other through the thermal break composition 16. Because the thermal break composition has a thermal conductivity less than the thermal conductivity of the two components, the thermal break composition interrupts the transfer of thermal energy from the first component to the second component.

During the flame treatment process, a flame 33 is emitted from the nozzle 32 of a burner 31 toward the surfaces of the channel 23 including the top walls 24, 25, side walls 28, 30, and bottom wall 21 of the channel, in such a manner that the flame 33 is in oxidizing contact with the surfaces of the channel 23, as illustrated in FIG. 5. As the flame 33 oxidizes the surface of the channel 23, the surface energy of the channel 23 increases, which improves the ability of a thermal break composition 16 that is subsequently disposed in the channel 23 to adhere to the channel surface. The flame 33 also removes residual oils and monols from various surface treatments such as paints and seal coats that may be present on the surface of the channel and that may interfere with the adhesion of the thermal break composition to the channel surface.

Preferably the surface of the fenestration frame channel is oxidized such that a thermal break composition disposed in the channel exhibits less than 0.2% dry shrinkage, less than 0.1% dry shrinkage, or even no dry shrinkage, a shear strength before thermal cycling of at least 2500 psi (pounds per square inch), at least 3000 psi, or even at least 9000 psi, a shear strength after 90 cycles of the Thermal Cycling Method of at least 1500 psi, and minimal wet shrinkage, or even no wet shrinkage.

The flame also causes an increase in the temperature of the channel surface, which can facilitate crosslinking of those crosslinkable thermal break compositions that are applied to the channel while the channel surface temperature is elevated. The increased temperature at the channel surface enables the thermal break composition to undergo more uniform crosslinking at the interface between the channel and thermal break composition.

The flame is generated by combusting gas and oxygen. The temperature of the flame, the orientation of the flame in relation to the channel surface, and the amount of time during which the channel surface is exposed to the flame affects the rate at which the channel surface is oxidized. Flame temperature may be controlled by gas selection, gas-to-air stoichiometric ratio, oxygen ratio in air, amount of gas and oxygen, and the rate at which the gas and oxygen is supplied. Useful gases include, e.g., methane, ethane, propane, butane, acetylene, natural gas, and combinations thereof. Useful sources of oxygen include, e.g., air, compressed air, and oxygen supply tanks.

The burner delivers gas and air in a gas-to-air stoichiometric ratio sufficient to oxidize the surface of the channel. Preferably the ratio is selected to optimize oxidation. The specific gas-to-air ratio depends on the type of gas. Suitable gas-to-air ratios for ethane include, e.g., from about 12:1 to about 22:1, for propane include, e.g., from about 4:1 to about 32:1, for butane include, e.g., from about 26:1 to about 44:1, for acetylene include, e.g., from about 10:1 to about 18:1, and for natural gas include, e.g., from about 7:1 to about 13:1.

The flame can be delivered by any suitable source including any suitable burner configuration. FIG. 7, for example, illustrates an embodiment of a burner 35 having three nozzles 40, 42, and 44, which emit flames 41, 43, and 45 toward the interior surface of the channel 23 of the fenestration member 20. Nozzle 40 emits flame 41 toward bottom wall 21, nozzle 42 emits flame 43 towards side wall 28, and nozzle 44 emits flame 45 towards side wall 30. The flames 41, 42, and 43 merge and are in oxidizing contact with the surface of the channel 23.

A useful automated process for manufacturing a portion of a fenestration frame is illustrated in FIG. 6. A fenestration member 10 in the form of a unitary metal extrusion that includes a channel 23 defined by top walls 24, 25, side walls 28, 30, and bottom wall 21, components 12 and 14, and a bridge 22 that connects components 12 and 14, is advanced to a first drive station 62. The first drive station 62 advances and guides the fenestration member 10 through a flame treatment station 60 where the channel 23 is exposed to a flame 33 emitted by a nozzle 32 of a burner 31. The first drive station 62 controls the amount of time the channel 23 of the fenestration member 10 is exposed to the flame 33. The nozzle 32 of the burner 31 is positioned such that the flame 33 oxidizes the surface of the channel 23. The nozzle 32 controls the flame 33 dimensions, which can be altered to be suitable for treating channels having a variety of different widths including, e.g., from about 0.125 inch to about 1.0 inch as measured from the interior surface 27 of the side wall 28 to the interior surface 29 of the side wall 30.

The flame treated fenestration member 10 is then transferred to a second drive station 72, which advances and guides the flame treated fenestration member 10 through an application station 70. At the application station, a mixing head 50 deposits a thermal break composition 52 into the surface-oxidized channel 23 of the fenestration member 10. The filled fenestration member 10 can then be subjected to further processing including, e.g., removing the bridge 22 with a mill 26. Removal of the bridge 22 breaks the metal connection between components 12 and 14 of the flame treated fenestration member 10.

Any suitable thermal break composition can be applied to the channel of the fenestration member. Useful thermal break compositions include, e.g., polyurethanes, epoxies, epoxy-urethane hybrids, oxazolidones, isocyanurates, acrylics, and combinations thereof. Examples of useful polyurethane compositions include two-part formulations in which one part includes glycols, polyols or a combination thereof, and the other part includes polyisocyanate, useful examples of which are disclosed in U.S. Pat. No. 5,391,436 (Reid) and incorporated herein. Examples of useful polyols include those polyols having backbones of polyether, polyester and combinations thereof, and molecular weights in the range of about 62 to about 9000. Preferably the polyol is present in the composition in an amount sufficient to provide effective crosslinking of the composition, more preferably the polyol includes an average of from about 2.0 to about 4.0 hydroxyl groups per molecule. An example of a useful polyisocyanate is methylene-di-p-phenylene isocyanate. Useful polyurethane compositions are disclosed in U.S. Pat. No. 5,391,436 (see, e.g., Examples 7-17 therein) and incorporated herein., Useful polyurethanes are commercially available under the trade designations SU-311 and SU-207 from Azon USA, Inc. (Kalamazoo, Mich.), 70215R from BASF Corporation (Florham Park, N.J.), and UR-2391, UR-2359, UR-2360, UR-2361 and UR-2380 from H. B. Fuller Company (St. Paul, Minn.).

The polyurethane composition may also include a catalyst. Examples of useful catalysts include tertiary amines including, e.g., diazabicyclo- and triazabycyclo-alkanes and alkenes including, e.g., 1,4-diazobicyclo-2,2,2-octane, 1,8-diazobicyclo-5,4,0-undec-7-ene, 1,5-diazobicyclo-4,3,0-non-5-ene, and 1,5,7-triazabicyclo-4,4,0-dec-5-ene, N-(3-dimethylamino) propyl-N,N′,N′-trimethyl-1,3-propanediamine, acrylic tertiary triamine N-(3-dimethylamino) propyl-N,N′,N′-trimethyl-1,3-propanediamine, and combinations thereof.

The thermal break composition can further include a variety of additives including, e.g., additives that decrease shrinkage, enhance bonding to metallic substrates, and combinations thereof. Examples of such additives include soft fillers such as calcined clay and mica, hard fillers such as glass fibers, wollastonite and ceramic fibers, hydrophobic silicas, and glass beads. The composition can also include silane coupling agents including, e.g., glycidoxypropyltrimethoxysilane.

The channel of the fenestration member can have a variety of cross-sectional profile configurations including, e.g., a “U-shaped” channel, and can define a variety of shapes including, e.g., a channel having a curved bottom wall and two parallel sidewalls. Commercially available profiles having a variety of configurations are commercially available under the trade designations 1150, 1550H, 2250, 3325CW, 3325SF, 3350, 1450L, and 1485L from Winco Window Company (St. Louis, Mo.), 900 from Saint Cloud Window, Inc., (St. Cloud, Minn.), 8400TL and 6200T from Kawneer Inc. (Norcross, Ga.), and 7500 from Metal Industries (Gratz, Pa.).

The fenestration member 10 is a unitary extrusion and can be made from a variety of metals including, e.g., aluminum and aluminum alloys. The fenestration member can also include a surface treatment including, e.g., mill finish, conversion coating, primer (e.g., chromium pretreatment), melamine, paint, organic paint compositions including, e.g., acrylic, polyester, enamel, polyurethane and fluoropolymer, anodic finishes including, e.g., clear, integral color and electrolytically deposited color, anodic finishes resulting from sealing processes including, e.g., processes that employ a boiling water seal, nickel acetate and nickel sulfinate sealing additives, and anti-smut additives. Suitable commercial classes of finishes are described in the American Architectural Manufacturers Association (AAMA) TIR-A8-04 Structural Performance of Composite Thermal Barrier Framing Systems manual, section 4.2 entitled, “Cavity Surface Treatment” (2004).

The fenestration frame member 20 is suitable for use in a variety of constructions including, e.g., window frames, door frames, glass curtain walls (i.e., walls of glass that include framed units), curtain walls (i.e., wall sections defined by a metal frame (e.g., aluminum, stainless steel, and copper), storefronts, and skylights. A number of fenestration frame members 20 can be combined together to form fenestration frames having a variety of shapes as sizes including, e.g., polygonal shapes (e.g., triangle, square, and rectangle), arcuate shapes, and combinations thereof.

The invention will now be described by way of the following examples.

EXAMPLES Test Procedures

Test procedures used in the examples include the following.

Surface Energy Test Method

Surface energy is determined by using a Dyne pen, e.g., an Ener-Dyne Dyne pen.

The solution of the dyne pen is applied to the channel surface. The required time for the applied solution to form into droplets is observed. The dyne level is recorded as the dyne level associated with the solution of the dyne pen that holds for exactly four seconds before either droplets occur or shrinkage occurs.

% Decrease In Wet Shrinkage Test Method

The length of a channel containing cured thermal break composition is measured and recorded as Li and the length of the thermal break composition within the channel is measured and recorded as Lf.

The percentage decrease in wet shrinkage is determined relative to a control sample (i.e., a sample that has not undergone flame treatment) according to the following formula: ( 1 - L ti - L tf L ci - L cf ) × 100 = % ⁢   ⁢ Decrease ⁢   ⁢ in ⁢   ⁢ Wet ⁢   ⁢ Shrinkage

Where:

    • Lti=Channel length of the flame treated sample.
    • Ltf=Thermal break composition length of the flame treated sample.
    • Lci=Channel length of the control sample.
    • Lcf=Thermal break composition length of the control sample.
      Thermal Cycling Method

A sample specimen is cycled as follows: 1) The sample specimen is held at 75° F. for one hour, 2) the sample specimen is heated to 180° F. over a period of 10 minutes and then held at 180° F. for one hour, 3) the sample specimen is then cooled to 75° F. over a period of 10 minutes and then held at 75° F. for one hour, 4) the sample specimen is then cooled to −20° F. over a period of 10 minutes and then held at −20° F. for one hour, and 5) then the sample specimen is heated to 75° F. over a period of 10 minutes, which constitutes one cycle.

% Decrease In Dry Shrinkage Test Method

A sample specimen is cycled according to the Thermal Cycling Method set forth above for three sets of 30 cycles, for a total of 90 cycles. After each set of cycling (i.e., 30, 60 and 90 cycles), the length of the channel of a sample specimen is measured and recorded as Li and the length of the thermal break composition within the channel is measured and recorded as Lf.

The percentage decrease in dry shrinkage is determined relative to a control sample specimen according to the following formula: ( 1 - L tf / L ti L cf / L ci ) × 100 = % ⁢   ⁢ Decrease ⁢   ⁢ in ⁢   ⁢ Dry ⁢   ⁢ Shrinkage

Where:

    • Lti=Channel length of the flame treated sample specimen.
    • Ltf=Thermal break composition length of the flame treated sample specimen.
    • Lci=Channel length of the control sample specimen.
    • Lcf=Thermal break composition length of the control sample specimen.
      Shear Force Test Method

Shear is determined according to AAMA TIR-A8-04 Structural Performance of Composite Thermal Barrier Framing Systems manual, section 7.3 entitled, “Shear, Tension and Eccentric Load Tests” (2004).

A sample specimen is cut into four inch sections. A four inch section is locked into a vice of an Instron 55R4507 universal shear testing machine (Instron, Inc., Canton, Mass.) that is capable of exerting a force of up to 10,000 pounds. The inside wall of the channel is held rigid using load cell No. 95. Testing continues until failure, i.e., either the thermal break composition is sheared from the metal or the metal deforms. The value displayed on the Instron is recorded in units of psi (pounds per square inch).

The percentage increase in shear force is determined relative to a control sample specimen according to the following formula: ( F t F c - 1 ) × 100 = % ⁢   ⁢ Increase ⁢   ⁢ in ⁢   ⁢ Shear ⁢   ⁢ Force

Where:

    • Ft=Shear force of the flame treated sample specimen.
    • Fc=Shear force of the control sample specimen.
      Control Sample Preparation

A control sample is prepared according to the Treated Sample Preparation, set forth below, with the exception that the control sample is not subject to the flame treatment of Stage One.

Treated Sample Preparation

Stage One

A fenestration member (“the sample”) as defined by the AAMA TIR-A8-04 Structural Performance of Composite Thermal Barrier Framing Systems manual, section 4.1.1 entitled, “Poured in Place Cavity Design” (2004), is fed into a flame treatment station. The flame treatment station includes a gas burner assembly and two drive stations. The gas burner assembly is mounted so as to be capable of tilting and moving in the X, Y, and Z directions, and is fitted with a nozzle such that the emitted flame oxidizes only the cavity surface of the channel. The first drive station advances and guides the sample to the flame treatment station where the channel cavity surface is exposed to the flame, and the second drive station advances and guides the sample away from the burner for further processing. Both drive stations are calibrated to drive at the same rate of speed and expose the channel to the flame for the appropriate time to optimize oxidation, for example one minute.

The gas used to generate the flame is propane and the propane-to-air ratio is 6:1. The gas burner assembly is positioned such that the blue tip of the flame is about 0.5 inch from the bottom wall of the channel. The channel surface temperature increases during the flame treatment process to about 130° F. to about 140° F.

Prior to any further processing, some of the samples are tested according to the Surface Energy Test Method and subsequently discarded. The expected Surface Energy test results are reported in Table 1.

TABLE 1 Control Treated Surface Energy Surface Energy Finish (dyne) (dyne) Mill 34-36  44* Mill Double E <30 44 Mill D TB-78 40-42 44 Mill C-serated 34-36 44 Bronze Anodized   32 44 Brown Polyester Paint 32-34 44 Eggshell Kynar <30 44 Dirty Mill Finish   36 44 Velo 30-32 42
*Maximum dyne pen available

Stage Two

After Stage One, the sample is transferred to an application station that includes a thermal break composition dispenser and two drive stations. The first drive station advances and guides the channel while the thermal break composition is deposited in the channel, and the second drive station advances and guides the sample away from the dispenser. Both drive stations are calibrated to drive at the same rate of speed and are configured to allow the proper amount of thermal break composition to be dispensed into the channel. The dispenser deposits UR-2391 polyurethane thermal break composition (H. B. Fuller Company, St. Paul, MN) into the channel according to AAMA TIR-A8-04 Structural Performance of Composite Thermal Barrier Framing Systems manual, section 4.3.3 entitled, “Pouring” (2004). The thermal break composition in the channel is allowed to cure.

The sample is tested according to the % Decrease In Wet Shrinkage Test Method. The expected % Decrease In Wet Shrinkage test results are reported in Table 2.

TABLE 2 Finish Cavity Size % Decrease in Wet Shrinkage Bronze Duranar D 87.3 Mill Finish D 93.5 Clear Anodize B 39.5 303 Bronze Anodize C 27.3

The sample is then debridged, e.g., by milling or sawing (see, AAMA TIR-A8-04 Structural Performance of Composite Thermal Barrier Framing Systems manual, section 4.3.4 entitled, “Cure Time and Debridging” (2004)) and cut into 12 inch long sample specimens. The sample specimens are tested according to the % Decrease In Dry Shrinkage Test Method in conjunction with the Thermal Cycling Method, and the Shear Force Test Method. The expected % Decrease In Dry Shrinkage and Shear Force test results are reported in Table 3.

TABLE 3 Control Treated % Decrease in Dry Shrinkage Cavity Shear Shear % Increase 30 60 90 Finish Size (psi) (psi) in Shear Cycles Cycles Cycles Velo D 629 4,428 85.8 82.9 64.7 46.9 Mill D 337 7,031 95.2 66.8 32.9 11.0 Mill Double E 2,517 4,690 46.3 92.6 77.2 71.2 Mill D 52 2,755 98.1 NA NA NA Red C NA NA NA 44.0 47.5 62.7 Kynar Bronze B 11 12,993 99.9 96.4 97.6 97.6 Anodize Bronze B 0 9,953 100 95.2 NA NA Anodize Green B NA NA NA 45.0 45.6 55.6 Polyester Paint Mill A 151 12,111 98.8 82.4 98.2 96.7 Light C-serated NA NA NA 96.9 96.0 94.8 Bronze Anodize Mill C-serated 236 13,437 98.2 98.2 97.5 95.7 Clear B 7,743 11,885 34.9 NA NA NA Anodize Black B 13,869 24,078 42.4 NA NA NA Duracron Bronze D 675 11,821 94.3 NA NA NA Duranar
NA: Not Applicable

Other embodiments are within the claims. All of the patents and references cited herein are incorporated herein by reference.

Claims

1. A method of making a fenestration frame member comprising at least one fenestration member comprising a channel defined by at least a first side wall, a second side wall, and a bottom wall, and a thermal break composition disposed in said channel, said method comprising:

exposing the surface of said channel to a flame for period sufficient to oxidize said surface of said channel; and
depositing a thermal break composition on said oxidized surface of said channel, said thermal break composition having a thermal conductivity less than the thermal conductivity of said walls of said channel.

2. The method of claim 1, further comprising removing at least a portion of said bottom wall of said channel.

3. The method of claim 1, wherein said fenestration member comprises a plurality of channels.

4. The method of claim 1, wherein said fenestration member comprises metal.

5. The method of claim 1, wherein said fenestration member comprises aluminum.

6. The method of claim 1, wherein said fenestration member comprises a surface treatment.

7. The method of claim 6, wherein said surface treatment is selected from the group consisting of polyester, melamine, mill finish, conversion coating, primer, paint, acrylic, polyester, enamel, polyurethane, fluoropolymer, anodic finishes, powder coats, and combinations thereof.

8. The method of claim 1, wherein said oxidized surface of said channel has a surface temperature of at least 110° F. during said depositing.

9. The method of claim 1, wherein said thermal break composition exhibits a thermal conductivity of no greater than 1.5 Btu·inch/hr·Ft2·° F.

10. The method of claim 1, wherein said flame is created by the combustion of gas comprising oxygen, propane, natural gas, butane, methane, acetylene, or a combination thereof.

11. The method of claim 10, wherein said gas is combusted with air in a gas-to-air stoichiometric ratio of from about 4:1 to about 44:1.

12. The method of claim 1, further comprising removing at least a portion of said bottom wall of said channel.

13. The method of claim 1, wherein said oxidized surface of said channel exhibits a surface energy of at least 38 Dynes.

14. The method of claim 1, wherein said oxidized surface of said channel exhibits a surface energy of at least 44 Dynes.

15. The method of claim 1, wherein said thermal break composition exhibits no greater than 0.2% dry shrinkage in said channel when said fenestration frame member is tested in accordance with AAMA 505-98 manual entitled, “Dry Shrinkage and Composite Performance Thermal Cycling Test Procedure.”

16. The method of claim 1, wherein said fenestration frame member exhibits a shear strength of at least 1500 psi when tested in accordance with AAMA 505-98 manual entitled, “Dry Shrinkage and Composite Performance Thermal Cycling Test Procedure.”

17. The method of claim 1, wherein said thermal break composition comprises polyurethane, isocyanurate, epoxies, acrylics, or a combination thereof.

18. A method of making a fenestration frame comprising:

making a plurality of fenestration frame members according to the method of claim 1; and
assembling a plurality of said fenestration frame members to form said fenestration frame.

19. An automated process for manufacturing a fenestration frame member, said process comprising:

transporting a fenestration member to a first station, said fenestration member comprising a channel defined by at least a first side wall, a second side wall, and a bottom wall;
exposing the surface of said channel to said flame at said first station for period sufficient to oxidize said surface of said channel;
transporting said fenestration member to an application station; and
depositing a thermal break composition on said oxidized surface of said channel, said thermal break composition having a thermal conductivity less than the thermal conductivity of said walls of said channel.

20. The process of claim 19, further comprising

transporting said fenestration member to a debridging station, and
removing at least a portion of said bottom wall of said channel.

21. An automated process for manufacturing a fenestration frame comprising:

manufacturing a plurality of fenestration frame members according to the process of claim 19;
transporting said fenestration frame members to an assembly station, and
assembling a plurality of said fenestration frame members to form said fenestration frame.
Patent History
Publication number: 20070193205
Type: Application
Filed: Jan 31, 2006
Publication Date: Aug 23, 2007
Inventor: Nathanael Hill (Columbia Heights, MN)
Application Number: 11/344,927
Classifications
Current U.S. Class: 52/745.150; 52/717.020
International Classification: E04C 2/38 (20060101); E04B 1/00 (20060101); E04G 21/00 (20060101); E04G 23/00 (20060101);