Lineally Adjustable Molds, Molding Methods, And Products Therefrom

Abstract

A mold for producing a variety of fenestration members having different predetermined lengths is disclosed. Generally, the mold has a first lineal mold part that has an extended length and a second lineal mold part also having an extended length. The mold may also have mold end parts that are adapted to form end features of the fenestration member. In use, the first lineal mold part and the second lineal mold part fit together to define a profile. The first and second mold end parts can be positioned in a range of positions to define the lengths of a variety of different molded fenestration members.

What is claimed is: 
     
         1 . A method for molding a variety of fenestration members having different predetermined lengths comprising the steps of:
 providing a mold comprising:   a first lineal profile mold part having an extended length;   a second lineal profile mold part having an extended length;   a first mold end part adapted to form a first end feature of the member, and   a second mold end part adapted to form a second end feature of the member, wherein
 the first lineal profile mold part and the second lineal mold part fit together to define a lineal profile, and 
 at least one of the first mold end part and the second mold end part can be positioned in a range of positions along the first lineal mold part and the second lineal mold part to define the lengths of a variety of molded fenestration members; 
 assembling the mold parts into a closed mold defining a molded shape; 
 filling the mold with a reaction injection molding material; 
 allowing the molding material to at least partially cure; and 
 opening the mold and removing the molded member. 
   
     
     
         2 . The method of  claim 1  further comprising the step of removing mold end parts from the molded member. 
     
     
         3 . The method of  claim 1  wherein the reaction injection molding material further comprises a foaming agent. 
     
     
         4 . The method of  claim 1  further comprising the step of painting selected portions of the mold parts prior to assembly. 
     
     
         5 . The method of  claim 1  comprising the further step of using the molded member as an end part in a mold and molding an additional portion onto the molded member to form a second molded member. 
     
     
         6 . The method of  claim 1  comprising the steps of cutting the molded member into two parts and using the two parts as end parts in a mold for forming a molded member. 
     
     
         7 . The method of  claim 1  further comprising the steps of
 molding a second member; 
 assembling the two molded members with lineal mold parts, using the two molded members as mold end parts, and; 
 molding a third member comprising the two previously molded members along with a newly molded lineal portion joining the two previously molded members. 
 
     
     
         8 . A joint between a first member and a second member, wherein:
 the first member comprises a first mitered portion, a mortise portion, and at least one of a sidewall portion and a sidewall receiving portion;   the second member comprises a second mitered portion, a tenon portion, and at least one of a sidewall portion and a sidewall receiving portion, wherein:
 the sidewall portions are adapted to fit over the sidewall receiving portions to provide the appearance of a mortise and tenon joint, and wherein the tenon portion fits into the mortise portion. 
   
     
     
         9 . The joint of  claim 8  further comprising an injection port and flow channel for injection of sealant or adhesive material into the joint. 
     
     
         10 . The joint of  claim 9  further comprising an internal reservoir for receiving injected material. 
     
     
         11 . The joint of  claim 8  further comprising a resilient gasket material between the first member and the second member. 
     
     
         12 . The joint of  claim 8  wherein the mortise portion and the tenon portion are located on the first mitered portion and the second mitered portion respectively. 
     
     
         13 . The joint of  claim 8 , wherein the first member comprises one sidewall portion and wherein the second member comprises one sidewall receiving portion. 
     
     
         14 . The joint of  claim 13  wherein the lineal portion of at least one of the joints extends to a second joint. 
     
     
         15 . The joint of  claim 8  wherein the first member comprises one sidewall receiving portion and the second member comprises one sidewall portion. 
     
     
         16 . The joint of  claim 8  wherein at least one of the first member and the second member further comprises a lineal portion. 
     
     
         17 . The joint of  claim 8  wherein at least one member comprises a reaction injection molding material. 
     
     
         18 . A lineal member comprising a first end feature and a second end feature, wherein the member is produced by a molding process. 
     
     
         19 . The member of  claim 18  wherein the molding process is a reaction injection molding process. 
     
     
         20 . The member of  claim 18  wherein at least one of the end features of a first member is adapted to engage a second member to form a joint. 
     
     
         21 . The member of  claim 20  wherein the second member is also a lineal member. 
     
     
         22 . The member of  claim 18  wherein at least one of the end features serves a decorative function. 
     
     
         23 . The member of  claim 18  wherein the member is a cornice. 
     
     
         24 . The member of  claim 18  wherein the member is a stile or rail of a window sash. 
     
     
         25 . The member of  claim 18  wherein the member is a stile or rail of a window frame and sill. 
     
     
         26 . The member of  claim 18  wherein the member is a stile or rail of a door panel. 
     
     
         27 . The member of  claim 18  wherein the member is a part of a door frame. 
     
     
         28 . The member of  claim 18  wherein the member is part of a door threshold. 
     
     
         29 . A collection of at least two molded lineal members of differing lengths, wherein each member comprises a first end feature and a second end feature, and wherein all members in the collection are produced in the same adjustable mold. 
     
     
         30 . The collection of  claim 29  wherein at least one of the first and second end features of a first member in the collection is adapted to engage an end feature of a second member in the collection to form a joint. 
     
     
         31 . The collection of  claim 30  wherein the second member is also contained in the collection. 
     
     
         32 . The collection of  claim 29  wherein at least one of the first and second end features serves a decorative function. 
     
     
         33 . The collection of  claim 29  wherein all of the first end features are the same and all of the second end features are the same.