A corner joint for fenestration frames and the like includes first and second frame members having hollow interiors and ends joined in abutment. A corner key insert has legs inserted into the ends of the frame members. End portions of the legs engage the hollow interiors of the frame members forming adhesive cavities within the frame members and along the end portions of the corner key legs. Adhesive is disposed within the cavities to bond the corner key legs to the frame members, thereby creating a structural joint between the frame members. The corner key insert may include multiple injection ports for delivering adhesive to the cavities from a selected side of the frame assembly. Legs of the corner key may have notches formed therein to receive an internal wall of the frame members, and distal ends of the legs may include a flow barrier that contours along the notches.

An apparatus for melting and dispensing thermoplastic material is provided that includes an un-heated hopper having an inlet for receiving particles of a thermoplastic material and an outlet for discharging the particles and a heated manifold including at least one cavity formed therein and having an inlet and an outlet the inlet communicating with the outlet of the hopper for receipt of the particles from the hopper. The hopper is disposed external of the heated manifold. The heated manifold is effective for melting the particles into molten thermoplastic material therein. The apparatus further includes a pump having an inlet in fluid communication with the cavity. An outlet of the pump is in fluid communication with an inlet of a dispenser and an outlet of the dispenser is effective for dispensing the molten thermoplastic material therethrough.

A door frame and a door frame component thereof. The door frame component includes an elongate body having first and second opposite sides which are structurally distinct from one another; the first side having a door stop which comprises an abutment for engaging by a door; the second side being configured for engaging a wall; and a third side extending across the first and second sides, wherein, a decorative portion is integrally formed on the third side, which extends beyond the second side in a direction away from the door stop such that the decorative portion and the second side embraces adjoining sides of said wall structure.

A fenestration unit includes a first glass unit, a first panel frame, a second glass unit, a second panel frame, a sill flashing, and a frame. The frame includes a header, jambs, and a frame sill including a first track and a second track. The first panel frame and the first glass unit are slidable along the first track when positioned in the frame. The second panel frame and the second glass unit are slidable along the second track when positioned in the frame. The sill flashing includes a base extending under the first and second tracks and a wall extending upward from the base to inhibit moisture intrusion through the fenestration unit. The frame sill is removable from the frame without disassembling the sill flashing, the jambs, and the header.

A corner joint for fenestration frames and the like includes first and second frame members having hollow interiors and ends joined in abutment. A corner key insert has legs inserted into the ends of the frame members. End portions of the legs engage the hollow interiors of the frame members forming adhesive cavities within the frame members and along the end portions of the corner key legs. Adhesive is disposed within the cavities to bond the corner key legs to the frame members, thereby creating a structural joint between the frame members. The corner key insert may include multiple injection ports for delivering adhesive to the cavities from a selected side of the frame assembly. Legs of the corner key may have notches formed therein to receive an internal wall of the frame members, and distal ends of the legs may include a flow barrier that contours along the notches.

A door frame and a door frame component thereof. The door frame component includes an elongate body having first and second opposite sides which are structurally distinct from one another; the first side having a door stop which comprises an abutment for engaging by a door; the second side being configured for engaging a wall; and a third side extending across the first and second sides, wherein, a decorative portion is integrally formed on the third side, which extends beyond the second side in a direction away from the door stop such that the decorative portion and the second side embraces adjoining sides of said wall structure.

An apparatus for melting thermoplastic material is disclosed. The apparatus includes a heated manifold and at least one heating element disposed within the heated manifold. The heated manifold defines a plurality of cavities, a pump supply passage, and a discharge passage. The plurality of cavities are spaced apart from one another, and each receives particles of thermoplastic material from a hopper. The particles of thermoplastic material are melted within the plurality of cavities. The pump supply passage receives molten thermoplastic material from the plurality of cavities and supplies the molten thermoplastic material to a pump. The discharge passage receives pressurized molten thermoplastic material from the pump and is in fluid communication with a dispenser. The heating element transfers heat substantially throughout the heated manifold.

A hybrid window frame assembly includes a primary window frame formed of a first material connected to a cladding frame formed of a second material. The cladding frame includes a peripheral channel defining a recess that receives a peripheral bead of the window frame to connect the cladding frame to the window frame. The hybrid window frame further includes injection block cutouts at each corner. Each injection block cutout exposes at least a portion of respective inner sidewalls of the channel and bead. The hybrid window frame assembly further includes injection blocks inserted in each injection block cutout. Each injection block includes at least one injection hole accessible from an exterior of the hybrid window frame assembly. The hybrid window frame assembly further includes sealant injected through the at least one injection hole of each injection block to seal respective corners of the window frame and cladding frame together.

Methods of joining members, forming molded portions with members, securing inserts with members, and joined members, such as for a frame or a frame for a fenestration unit, formed thereby, are disclosed. One embodiment of the method includes placing a first member with a first cavity in a joining position, placing a second member proximate the first cavity of the first member in the joining position, injecting a resin into the first cavity, allowing the resin to solidify at least partially to join the first member and second member to form a joined member, and removing the joined member from the joining position. Optionally, the joined member can be formed in a fixture, can include molded portions formed by the resin, and/or can include inserts held in place by the resin. Further, members without cavities can form a cavity that can receive the resin.

An apparatus for melting thermoplastic material is disclosed. The apparatus includes a heated manifold and at least one heating element disposed within the heated manifold. The heated manifold defines a plurality of cavities, a pump supply passage, and a discharge passage. The plurality of cavities are spaced apart from one another, and each receives particles of thermoplastic material from a hopper. The particles of thermoplastic material are melted within the plurality of cavities. The pump supply passage receives molten thermoplastic material from the plurality of cavities and supplies the molten thermoplastic material to a pump. The discharge passage receives pressurized molten thermoplastic material from the pump and is in fluid communication with a dispenser. The heating element transfers heat substantially throughout the heated manifold.