One-piece injection molded window frame and sash

Abstract

Window components are made by a fluid-assist injection molding process to reduce manufacturing costs and provide additional flexibility in the configuration of the window. In addition to the inventive product-by-process, two window configurations, a casement window and a picture window, are taught. The casement window has a frame with installation flanges and the window sash has integral mounting posts for handle hardware. Both the window frame and sash have encapsulated insulative air pockets. An acrylic window pane is taught that mimics a glass block window.

1 - 7 . (Canceled)  
     
     
         8 . A casement window comprising 
 a) a one-piece window frame including 
 i) a first hollow body housing an insulative air pocket;  
 ii) a first integrally molded pocket on each side of said window frame for receiving support hinge hardware;  
   b) a one-piece window sash including 
 i) a second hollow body housing an insulative air pocket,  
 ii) a second integrally molded pocket on each side of said sash operating with said first integrally molded pocket on said window frame to house said support hinge hardware;  
   c) said support hinge hardware attached to both said window frame and said window sash in said first and second integrally molded pockets, respectively.    
     
     
         9 . The casement window of  claim 8  wherein said window frame further comprises flexible installation flanges which are trimmed to a size slightly larger than a window opening to receive said casement window and folded back in the opening during installation.  
     
     
         10 . The casement window of  claim 8  wherein said window frame further comprises a recess on an exterior surface about a periphery of an opening in said window frame, said recess receiving a lip seal and lip seal retainer.  
     
     
         11 . The casement window of  claim 8  wherein said window frame further comprises a first integrally molded pivot hinge member.  
     
     
         12 . The casement window of  claim 11  wherein said window sash further comprises a second integrally molded pivot hinge member which mates with said first integrally molded pivot hinge member to permit pivoting movement of said window sash in said window frame.  
     
     
         13 . The casement window of  claim 8  wherein said window sash further comprises glazing bead recess means integrally molded in an external periphery of said window sash.  
     
     
         14 . The casement window of  claim 8  wherein said window sash further comprises latch pivot posts, integrally molded on an interior surface of said window sash.  
     
     
         15 . A casement window comprising 
 a) a one-piece window frame including 
 i) a first hollow body housing an insulative air pocket;  
 ii) a first integrally molded pivot hinge member;  
   b) a one-piece window sash including 
 i) a second hollow body housing an insulative air pocket,  
 ii) a second integrally molded pivot hinge member which mates with said first integrally molded pivot hinge member to permit pivoting movement of said window sash in said window frame.  
   
     
     
         16 . The casement window of  claim 15  wherein said window frame further comprises flexible installation flanges which are trimmed to a size slightly larger than a window opening to receive said casement window and folded back in the opening during installation.  
     
     
         17 . The casement window of  claim 16  wherein said window frame further comprises a recess on an external periphery of said window frame for receiving a lip seal and lip seal retainer.  
     
     
         18 . The casement window of  claim 16  wherein said window frame further comprises a first integrally molded pocket on each side of said window frame for receiving support hinge hardware.  
     
     
         19 . The casement window of  claim 18  wherein said window sash further comprises a second integrally molded pocket on each side of said sash operating with said first integrally molded pockets on said window frame to house said support hinge hardware.  
     
     
         20 . The casement window of  claim 19  wherein said support hinge hardware is attached to both said window frame and said window sash in said first and second integrally molded pockets, respectively.  
     
     
         21 . The casement window of  claim 15  wherein said window sash further comprises glazing bead recess means integrally molded in an external periphery of said window sash.  
     
     
         22 . The casement window of  claim 15  wherein said window sash further comprises latch pivot posts integrally molded on an interior surface of said window sash.  
     
     
         23 . A casement window comprising 
 a) a one-piece window frame including 
 i) a hollow body housing an insulative air pocket;  
 ii) flexible installation flanges which are trimmed to a size slightly larger than a window opening to receive said casement window and folded back in the opening during installation;  
   b) a one-piece window sash including 
 i) a hollow body housing an insulative air pocket,  
 ii) latch pivot posts integrally molded on an inner surface of said window sash.  
   
     
     
         24 . The casement window of  claim 23  wherein said window frame further comprises a recess on an external periphery of said window frame for receiving a lip seal and lip seal retainer.  
     
     
         25 . The casement window of  claim 23  wherein said window frame further comprises a first integrally molded pocket on each side of said window frame for receiving a support hinge.  
     
     
         26 . The casement window of  claim 25  wherein said window sash further comprises a second integrally molded pocket on each side of said sash operating with said first integrally molded pockets on said window frame to house said support hinge.  
     
     
         27 . The casement window of  claim 26  wherein said support hinge is attached to both said window frame and said window sash in said first and second integrally molded pockets, respectively.  
     
     
         28 . The casement window of  claim 23  wherein said window sash further comprises a glazing bead recess integrally molded in an external periphery of said window sash.  
     
     
         29 . The casement window of  claim 23  wherein said window frame further comprises a first integrally molded pivot hinge member.  
     
     
         30 . The casement window of  claim 29  wherein said window sash further comprises a second integrally molded pivot hinge which mates with said first integrally molded pivot hinge member to permit pivoting movement of said window sash in said window frame.  
     
     
         31 . A casement window comprising 
 a) a one-piece window frame including 
 i) a hollow body housing an insulative air pocket,  
 ii) flexible installation flanges which are trimmed to a size slightly larger than a window opening to receive said casement window and folded back in the opening during installation,  
 iii) a first integrally molded pocket on each side of said window frame for receiving support hinge hardware,  
 iv) a recess on an external periphery of said window frame for receiving a lip seal and lip seal retainer,  
 v) a first integrally molded pivot hinge member;  
   b) a one-piece window sash including 
 i) a hollow body housing an insulative air pocket,  
 ii) a second integrally molded pocket on each side of said sash operating with said first integrally molded pockets on said window frame to house said support hinge hardware,  
 iii) a second integrally molded pivot hinge member which mates with said first integrally molded pivot hinge member to permit pivoting movement of said window sash in said window frame,  
 iv) glazing bead recess means integrally molded in an external periphery of said window sash;  
 v) latch pivot posts integrally molded on an interior surface of said window sash;  
   c) said support hinge hardware attached to both said window frame and said window sash in said first and second integrally molded pockets, respectively;    d) said lip seal being secured in said recess by said lip seal retainer with a portion engaging an outer periphery of said sash when said window is in a closed position;    e) a glazing bead which is secured into said bead recess means in said window sash;    f) a latch retainer secured to an inside surface of said window frame;    g) a latch mounted on said integrally molded pivot post, said latch including a latch handle and a latching arm which engages said latch retainer to secure said window sash in a closed position.    
     
     
         32 . The casement window of  claim 31  further comprising a screen securement groove formed in an outwardly protruding surface of said seal retainer.  
     
     
         33 . A picture window frame comprising 
 a) a first outer frame portion comprising a first one-piece, injection molded element with a window pane receiving pocket and having a hollow insulative core;    b) a second inner frame portion comprising a second one-piece, injection molded element with a window pane receiving pocket and having a hollow insulative core;    c) means to secure said second inner frame member to said first outer frame member sandwiching the window pane and retaining the window pane there between.    
     
     
         34 . A window pane fashioned to resemble glass block comprising 
 a) a first molded rectangular acrylic panel formed into a first plurality of apparently separate portions with intervening mortar-like seams, each individual apparently separate portion being slightly outwardly convex and having a light-diffusing rippling therein;    b) a second molded rectangular acrylic panel formed into a second plurality of apparently separate portions with intervening mortar-like seams, each individual apparently separate portion being slightly outwardly convex;    c) means to secure said first and second panels such that the slightly outwardly convex portions extend outwardly and said mortar-like seams extend inwardly in juxtaposed positions.