The invention described herein generally pertains to the use of low boiling point, low vapor pressure blowing agents with froth polyurethane or polyisocyanurate foams to fill hollow cavities (particularly window lineals) and which have lowered exotherms, which prevent deformation of the hollow cavity (e.g., window lineal) and additional achieve filling of longer lengths of window lineals by increasing the foaming and gel times of the reaction.

A fenestration assembly includes a fenestration frame includes one or more frame members. The fenestration frame is coupled with one or more panels. Each frame member includes a coextruded foam polymer frame member. The coextruded foam polymer frame member includes a foam polymer core and a polymer shell jacketing the foam polymer core. The polymer shell is coextruded with the foam polymer core. The polymer shell braces the foam polymer core against deformation.

A fenestration assembly includes a fenestration frame includes one or more frame members. The fenestration frame is coupled with one or more panels. Each frame member includes a coextruded foam polymer frame member. The coextruded foam polymer frame member includes a foam polymer core and a polymer shell jacketing the foam polymer core. The polymer shell is coextruded with the foam polymer core. The polymer shell braces the foam polymer core against deformation.

A frame member for a fenestration system includes an elongate profile, a flow path provided on a surface of the profile to facilitate drainage of water from the surface, one or more flow path portions forming part of the surface and encompassing the flow path, and one or more non-flow path portions forming part of the surface and encompassing portions of the surface outside of the flow path. At least one of the one or more flow path or non-flow path portions is treated with a surface energy modification process such that the one or more flow path portions exhibit a first surface energy and the one or more non-flow path portions exhibit a second surface energy different from the first surface energy.

A frame member for a fenestration system includes an elongate profile, a flow path provided on a surface of the profile to facilitate drainage of water from the surface, one or more flow path portions forming part of the surface and encompassing the flow path, and one or more non-flow path portions forming part of the surface and encompassing portions of the surface outside of the flow path. At least one of the one or more flow path or non-flow path portions is treated with a surface energy modification process such that the one or more flow path portions exhibit a first surface energy and the one or more non-flow path portions exhibit a second surface energy different from the first surface energy.

A thermally enhanced extrudate includes a channel, a first wall, and a second wall. The channel extends along a longitudinal axis from a first end to a second end of the thermally enhanced extrudate and is shaped to receive glass or a frame. The second wall is spaced from the first wall. The first wall and the second wall partially enclose a thermal break extending along the longitudinal axis. The thermal break has a first width defined between the first wall and the second wall at an upper end of the thermal break and a second width defined between the first wall and the second wall at a lower end of the thermal break. The thermally enhanced extrudate further includes a solid insulation material in the thermal break between the first and second walls and formed by curing a flowable material.

A thermally enhanced extrudate includes a channel, a first wall, and a second wall. The channel extends along a longitudinal axis from a first end to a second end of the thermally enhanced extrudate and is shaped to receive glass or a frame. The second wall is spaced from the first wall. The first wall and the second wall partially enclose a thermal break extending along the longitudinal axis. The thermal break has a first width defined between the first wall and the second wall at an upper end of the thermal break and a second width defined between the first wall and the second wall at a lower end of the thermal break. The thermally enhanced extrudate further includes a solid insulation material in the thermal break between the first and second walls and formed by curing a flowable material.

The present disclosure describes methods of forming thermal barriers or breaks in tubular structures configured for inclusion in a variety of construction products and building features, such as doors and windows. Methods involve using one or more connector members to couple complementary extrusion profiles, which may comprise aluminum or other conductive materials. A low-conductivity material may then be deposited directly over the connector members coupling the extrusion profiles to form thermal barriers therebetween. At least a portion of the extrusion profiles may be knurled to improve the bond strength between the low-conductivity material, which may comprise polyurethane, and the extrusion profiles. Specialized components may be unnecessary to form the thermal barriers, such that the same connector members used to couple the extrusion profiles may be used to form the thermal barriers.

The present disclosure describes methods of forming thermal barriers or breaks in tubular structures configured for inclusion in a variety of construction products and building features, such as doors and windows. Methods involve using one or more connector members to couple complementary extrusion profiles, which may comprise aluminum or other conductive materials. A low-conductivity material may then be deposited directly over the connector members coupling the extrusion profiles to form thermal barriers therebetween. At least a portion of the extrusion profiles may be knurled to improve the bond strength between the low-conductivity material, which may comprise polyurethane, and the extrusion profiles. Specialized components may be unnecessary to form the thermal barriers, such that the same connector members used to couple the extrusion profiles may be used to form the thermal barriers.