Hybrid window frame assembly with improved corner seals

A hybrid window frame assembly comprising:

• a) a window frame formed of a first material and including at least three window frame members arranged to define a central window opening,
• the window frame having a peripheral bead extending about and projecting from a perimeter of the window frame,
• the window frame having at least three window frame corners, each window frame corner formed at a junction between two abutting window frame members of the at least three window frame members;
• b) a cladding frame formed of a second material and including at least three cladding frame members, each cladding frame member associated with a respective one of the window frame members,
• the cladding frame having a peripheral channel extending about a perimeter of the cladding frame, the channel defining a recess in which the peripheral bead is received to connect the cladding frame to the window frame,
• the cladding frame having at least three cladding frame corners, each cladding frame corner aligned with a respective one of the window frame corners and formed at a junction between two abutting cladding frame members of the at least three cladding frame members;
• c) at least three injection block cutouts, each injection block cutout extending through at least a portion of the peripheral bead and the peripheral channel to provide a cut bead inner sidewall portion and to expose a portion of the inner sidewall of the channel at a respective one of the cladding frame corners;
• d) at least three injection blocks, each injection block sized to fit in a respective one of the injection block cutouts, each injection block including at least one injection hole accessible from an exterior of the window frame assembly;
• and
• e) sealant injected through the at least one injection hole of each injection block to seal the bead inner sidewall of the window frame to the cladding frame along an interior junction of the window frame and the cladding frame, the interior junction comprising a width of the channel inner sidewall of the cladding frame, wherein the sealant seals the width of the channel inner sidewall to the cut bead inner sidewall portion.

A method of manufacturing a hybrid window frame assembly, the method comprising:

• positioning a cladding frame made from a first material on a window frame made from a second material to produce a hybrid window frame;
• providing an opening at each outer corner of the hybrid window frame that exposes an inner sidewall of the cladding frame;
• inserting an injection block into each of the openings, each injection block having at least one injection hole;
• and
• injecting sealant through the at least one injection hole of each injection block to create watertight seals between the cladding frame and the window frame at an interior junction of the window and cladding frames at each corner of the hybrid window frame.

A hybrid window frame injection block sized to fit in a respective injection block cutout extending through at least a portion of a channel outer sidewall of a cladding frame, a bead outer sidewall of a window frame, and a bead inner sidewall of the window frame at an outer corner portion of the window frame assembly, the cutout exposing a width of a channel inner sidewall of the cladding frame and providing a cut bead inner sidewall portion, comprising:

• an inner face configured to sealingly engage the exposed width of the channel inner sidewall of the cladding frame and the cut bead inner sidewall portion along an interior junction when the injection block is inserted in the injection block cutout;
• an outer face comprising at least one injection hole configured to receive injection of a sealant from an exterior corner of the window frame assembly when the injection block is inserted in the injection block cutout, the injection block being configured for a tight interference fit in the injection block cutout such that the outer face is concealed behind a protruding portion of a cladding front wall when viewed from the front of the window frame assembly;
• and
• at least one sealant channel defined along the inner face, wherein the sealant channel is confluent with the at least one injection hole and is configured to distribute the sealant injected into the injection hole along an interior junction of a window frame and a cladding frame comprised in the window frame assembly, and one or more vents disposed at a distal end and confluent with the at least one sealant channel, the one or more vents being configured to provide visual feedback when the interior junction is filled with the sealant.