There is provided a polymer fabrication method for forming 3-dimensional shapes from a sheet polymer blank (10) by machining at least one re-entrant, elongate groove forming a reduced thickness portion (25) permitting the blank to be folded and having opposed edges (12) at the surface, folding the blank about the groove to form at least a portion of the 3-dimensional shape, the re-entrant of the groove forming an elongate chamber (21) adjacent the reduced thickness portion and opening through an elongate gap (20) between the opposed edges, hot air welding the opposed edges across the gap with filler rod (22), and heating the reduced thickness portion to a selected thermo-reforming temperature via the chamber.

A patio door assembly includes a panel with a glass unit, and a polymer frame including a bottom member with a sill platform. A support beam is coupleable to the bottom member over the sill platform. The support beam defines a first channel between a top surface of the support beam and a platform, defines a second channel between the platform and the sill platform, a slot defined in the platform of the support beam. A structural insert is insertable in an end of the support beam and can be positioned in the support beam such that the structural insert supports a setting block for the glass unit of the panel to facilitate transferring a weight of the panel to the sill platform. The structural insert inhibits deformation of the frame when the patio door assembly is exposed to a high temperature environment (e.g., a desert environment).

A patio door assembly includes a panel with a glass unit, and a polymer frame including a bottom member with a sill platform. A support beam is coupleable to the bottom member over the sill platform. The support beam defines a first channel between a top surface of the support beam and a platform, defines a second channel between the platform and the sill platform, a slot defined in the platform of the support beam. A structural insert is insertable in an end of the support beam and can be positioned in the support beam such that the structural insert supports a setting block for the glass unit of the panel to facilitate transferring a weight of the panel to the sill platform. The structural insert inhibits deformation of the frame when the patio door assembly is exposed to a high temperature environment (e.g., a desert environment).

A method of installing a window and composite window bracket comprises a first member and a second member, and an at least one accessory member to couple the composite window bracket to at least one accessory bracket. The first member includes a first surface extending from a first end of the first member to a second end of the first member, and a second surface extending from the first end first member to the second end first member, the first surface of the first member to be coupled to a support beam. The second member supports a window disposed on the first surface of the second member.

Door frame cover overlay systems, devices, and methods are shown and described. A frame cover overlay for an existing door frame may include a base and a removable top. The cover overlay may be secured to the existing door frame to provide protection against further damage.

A prefabricated integrated window and wall is provided. The prefabricated integrated window and wall includes a window frame, a wall, and a power system. The window frame is configured to hold a variety of different windows. The window frame includes a frame head and a sill. The frame head includes a channel. The sill includes tabs. The wall is configured around the window frame. The wall is configured to connect to the tabs of the sill and the channel of the frame head. The power system is molded into the window frame. A method of assembling the prefabricated integrated window and wall is also provided.

A window assembly includes a polymer (e.g., polyvinyl chloride, vinyl) window frame made and a glass unit carried by the window frame. The window frame includes a pair of jambs and an astragal that extends between and interconnects the pair of jambs. The jambs have a channel or slot sized to receive therethrough one or more end walls of the astragal so that at least a portion of said one or more end walls extend into a hollow cavity in the jambs that is in fluid communication with one or more weep holes of the window assembly. The one or more end walls of the astragal and channel or slot of the jambs define a flow path configured to channel water from the astragal, through the channel or slot in the jambs and into the hollow cavity such that said water exits the hollow cavity and the window assembly via the one or more weep holes.

A polymer window assembly includes a polymer window frame with a pair of jambs and a sill, and a glass unit carried by the window frame. A pair of brackets are attached to the jambs proximate corners between the jambs and the sill. Each bracket has an upright member, a horizontal member orthogonal to the upright member and a hook attached to a rear surface of the upright member. The brackets attach to the jambs so that the hook extends through a hole in the jamb, the upright member is adjacent a surface of the jamb and the horizontal member is disposed above (e.g., spaced above) the sill. The brackets support and transfer the weight of the glass unit to the jambs to inhibit (e.g., prevent) the sill from bearing the load of the glass unit, thereby inhibiting (e.g., preventing) the crushing or bowing of the sill by the glass unit and thereby inhibiting (e.g., preventing) the formation of gaps in the window assembly that allow for air and/or water infiltration through the window assembly.

A first section is in facing contact with an exterior surface of a building. A second section is bent to extend exteriorly from the exterior surface at 90 degrees from the first section. A third section is bent at 90 degrees from the second section. A fourth section is bent at 180 degrees from the third section. A portion of the fourth section is in facing contact with the third section. A fifth section extends laterally and interiorly from the fourth section at an acute angle. A sixth section extends laterally from the fifth section parallel with the first and third and fourth sections. A seventh section is bent to extend interiorly at 90 degrees from the sixth section.

A first section is in facing contact with an exterior surface of a building. A second section is bent to extend exteriorly from the exterior surface at 90 degrees from the first section. A third section is bent at 90 degrees from the second section. A fourth section is bent at 180 degrees from the third section. A portion of the fourth section is in facing contact with the third section. A fifth section extends laterally and interiorly from the fourth section at an acute angle. A sixth section extends laterally from the fifth section parallel with the first and third and fourth sections. A seventh section is bent to extend interiorly at 90 degrees from the sixth section.