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.

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 se cond walls and formed by curing a flowable material.

A method of forming a thermally enhanced extrudate for a door or window includes providing an extrudate including a channel shaped to receive glass or a frame and having a completely enclosed cavity. The method further includes forming openings in a first flange of the extrudate. The remaining portion of the first flange form bridges that extend between a first wall and a second wall. The method further includes position a flowable material into the cavity through the openings. The flowable material cures to create a solid insulation material in the cavity and the bridges resist warping of the extrudate as the flowable material cures.

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.

A composite structure has a pair of parallel aluminum extrusions bridged by a polymer cap and defining a U-shape hollow. The hollow is filled with an expandable foam that adheres to and mechanically interdigitates with the extrusions, which have channels for receiving insertion legs of the extrusions and have extensions, which the foam encapsulates. End caps may be used to further delimit the hollow. The caps and the foam have a thermal conductivity less than that of the extrusions, providing a thermal break. An upper cap may be used and may incorporate features to compensate for the foam expansion. Excess foam may be trimmed. A forked tool may be used to hold the extrusions during joining.

A composite structure has a pair of parallel aluminum extrusions bridged by a polymer cap and defining a U-shape hollow. The hollow is filled with an expandable foam that adheres to and mechanically interdigitates with the extrusions, which have channels for receiving insertion legs of the extrusions and have extensions, which the foam encapsulates. End caps may be used to further delimit the hollow. The caps and the foam have a thermal conductivity less than that of the extrusions, providing a thermal break. An upper cap may be used and may incorporate features to compensate for the foam expansion. Excess foam may be trimmed. A forked tool may be used to hold the extrusions during joining.

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.

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 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.