Method of modifying the surface of a fenestration member

Abstract

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.

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·Ft 2 ·° 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.