Fenestration thermal break design

A thermal break for a profile of a fenestration system, comprising:

• a body having opposing first and second ends and extending along a centerline;
• and
• a tab provided at each end and extending laterally from the body along the centerline, the tab including a head extending from the body, and a stem extending from the head, the stem including an outer surface including a first side, a second side, a lateral end, and a plurality of first grooves defined on the first and second sides,
• wherein the head exhibits a larger cross-section than the stem, and
• wherein the head and the stem are sized to be received and secured within a channel provided by the profile of the fenestration system, the channel defining a first chamber sized to receive the head and a second chamber sized to receive the stem, wherein the first and second sides are in contact with an inner surface of the second chamber when the head and the stem are secured within the channel, and
• wherein each first groove is axially aligned with a corresponding second groove formed in the inner surface of the second chamber when the stem is received in the second chamber, thereby forming corresponding pockets at an interface between the stem and the inner surface of the second chamber.

A method of assembling a profile for a fenestration system, the method comprising:

• providing first and second members of the profile;
• arranging a thermal break within an inner space defined between the first and second members, the thermal break including:
• a body having opposing first and second ends and extending along a centerline;
• and
• first and second tabs provided at the first and second ends, respectively, and extending laterally in opposite directions from the body along the centerline, each tab including a head extending from the body, and a stem extending from the head, wherein the head exhibits a larger cross-section than the stem, the stem including an outer surface including a first side, a second side, a lateral end, and a plurality of first grooves defined on the first and second sides;
• advancing the first and second tabs into first and second channels, respectively, provided by the first and second members, respectively, wherein each channel includes a first chamber defined by upper and lower flanges configured to receive the head of the respective first and second tabs, and a second chamber configured to receive the stem of the respective first and second tabs, each second chamber having a size configured to form an interference fit with the first and second sides of the stem of the respective first and second tabs;
• temporarily securing the thermal break to the first and second channels by receiving the first and second tabs into the first and second channels, respectively, thereby forming an interference fit between the stem of the first and second tabs and the second chamber of the first and second channels, respectively, wherein each first groove is axially aligned with a corresponding second groove formed on an inner surface of the second chamber when the stem is received in the second chamber, thereby forming corresponding pockets at an interface between the stem and the inner surface of the second chamber;
• and
• crimping the upper and lower flanges of each channel against the first and second tabs, respectively, and thereby permanently securing the thermal break to the first and second members.