Thermally broken fenestration systems are provided that improve performance characteristics or combinations thereof, including strength and thermal conductivity. Embodiments disclosed include one or more fenestration frame assemblies, each having an interior frame member and an exterior frame member. The interior frame members and exterior frame members are coupled together via a plurality of bridges distributed along the length of the respective fenestration frame assembly. The bridges provide structural rigidity, while providing a plurality of air gaps between interior frame member and the exterior frame member to provide a thermal break.

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.

Thermally broken fenestration systems are provided that improve performance characteristics or combinations thereof, including strength and thermal conductivity. Embodiments disclosed include one or more fenestration frame assemblies, each having an interior frame member and an exterior frame member. The interior frame members and exterior frame members are coupled together via a plurality of bridges distributed along the length of the respective fenestration frame assembly. The bridges provide structural rigidity, while providing a plurality of air gaps between interior frame member and the exterior frame member to provide a thermal break.

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.

Thermally broken fenestration systems are provided that improve performance characteristics or combinations thereof, including strength and thermal conductivity. Embodiments disclosed include one or more fenestration frame assemblies, each having an interior frame member and an exterior frame member. The interior frame members and exterior frame members are coupled together via a plurality of bridges distributed along the length of the respective fenestration frame assembly. The bridges provide structural rigidity, while providing a plurality of air gaps between interior frame member and the exterior frame member to provide a thermal break.

The present invention relates to an elongated structure 20 for a window frame 200 suitable for supporting a panel 19 for separating an inner environment from an outer environment. The elongated structure comprises a first crosspiece 21 defining a first abutment surface 211; a second crosspiece 22 defining a second abutment surface 222, parallel to the first abutment surface, and a truss structure 23 which connects the first crosspiece to the second crosspiece. The truss structure comprises rods 230 extending from connection zones 213 of the first crosspiece to connection zones 223 of the second crosspiece; in the elongated structure according to the invention, the rods are tapered.

Thermally broken fenestration systems are provided that improve performance characteristics or combinations thereof, including strength and thermal conductivity. Embodiments disclosed include one or more fenestration frame assemblies, each having an interior frame member and an exterior frame member. The interior frame members and exterior frame members are coupled together via a plurality of bridges distributed along the length of the respective fenestration frame assembly. The bridges provide structural rigidity, while providing a plurality of air gaps between interior frame member and the exterior frame member to provide a thermal break.

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.