Window component notching system and method

Abstract

A system and method for producing window components using polymer based, metallurgy based, extruded, injection molded, or wooden lineal material. The lineal material is notched at intervals calculated to include a stretch treatment and folded to form window components such as window sashes, frames, and the like. Internal reinforcing members may be welded within the joints formed by folding at the notches. The notching system and method provide low cost, highly reliable, low defect production of multi-sided window components from a continuous piece of lineal material.

1 . A method of notching lineal material for folding to produce a window frame, said method comprising:
 receiving lineal material at a notching machine; and   activating said notching machine to form notches in the lineal material defining a plurality of elongated window frame sections wherein the length of a first of said sections is reduced from a first desired finished dimension by up to about 0.25 inches and the length of a second of said sections is reduced from a second desired finished dimension by up to about 0.5 inches.   
   
   
       2 . The method of  claim 1 , further comprising receiving a data profile into a processor, said data profile including information defining a finished shape and dimensions for a window frame; and computing a notching sequence based on said finished shape and dimensions, said computing including calculation of a stretch tolerance of up to about 0.25 inches per notch to be folded, said notching sequence informing said activating of said notching machine. 
   
   
       3 . The method of  claim 1 , further comprising cutting a nail fin portion of the lineal material substantially opposite one of said notches to facilitate folding. 
   
   
       4 . The method of  claim 1 , further comprising receiving an internal reinforcing member in one of said notches. 
   
   
       5 . The method of  claim 4 , further comprising folding the lineal material at said one of said notches to form a joint. 
   
   
       6 . The method of  claim 5 , further comprising welding said internal reinforcing member within said joint. 
   
   
       7 . The method of  claim 6 , further comprising substantially simultaneously welding said internal reinforcing member within said joint at multiple sides of said joint using multiple welders. 
   
   
       8 . A method, comprising:
 receiving lineal material; and   notching the lineal material to form a plurality of sections;   wherein the length of a first section is shorter than a first finished dimension by a first distance,   wherein the length of a second section is shorter than a second finished dimension by a second distance, and   wherein the second distance is about twice as large as the first distance.   
   
   
       9 . The method of  claim 8 , wherein the notching creates a notch having an angle of 45 degrees with respect to an axis of the lineal material. 
   
   
       10 . The method of  claim 8 , wherein the notching creates a notch having a nonlinear notch angle. 
   
   
       11 . The method of  claim 8 , wherein the plurality of sections are formed via sequential notching. 
   
   
       12 . The method of  claim 8 , wherein the plurality of sections are formed via simultaneous notching. 
   
   
       13 . The method of  claim 8 , further comprising folding the notched lineal material to form a window frame. 
   
   
       14 . The method of  claim 8 , wherein the first distance corresponds to a first stretch treatment, and wherein the second distance corresponds to a second stretch treatment. 
   
   
       15 . The method of  claim 8 , wherein the first distance is about 0.25 inches, and the second distance is about 0.5 inches. 
   
   
       16 . A method, comprising:
 receiving, at a control processor, a data profile associated with a material;   computing a notching sequence for the material in accordance with the data profile;   creating a plurality of notches in the material in accordance with the computed notching sequence;   inserting a reinforcing member into at least one notch;   folding the material to form at least one corner; and   fixing the material in place at the at least one corner.   
   
   
       17 . The method of  claim 16 , further comprising introducing at least one opening into the material. 
   
   
       18 . The method of  claim 16 , wherein tracking indicia are coupled to the material. 
   
   
       19 . The method of  claim 18 , wherein the tracking indicia are associated with the data profile. 
   
   
       20 . The method of  claim 18 , wherein the tracking indicia are detected at a processing station in order to inform the inserting of the reinforcing member. 
   
   
       21 . The method of  claim 18 , wherein the tracking indicia are utilized in the folding and fixing. 
   
   
       22 . The method of  claim 16 , wherein the creating corresponds to at least one stretch treatment.