Method of making an integrated window sash

A method of making an integrated window sash, comprising:

• providing a sash frame having a first sheet supporting surface, a second sheet supporting surface, and a base extending from the first sheet supporting surface to toward the second sheet supporting surface;
• applying a barrier layer comprising a film of a low gas and moisture permeability material at least on the base, the film selected from plastic and metal;
• applying simultaneously or in any sequence a layer of an adhesive sealant having a low gas and moisture permeability on the first sheet supporting surface, a layer of an adhesive sealant having a low gas and moisture permeability on the second sheet supporting surface, and a layer of a moisture pervious matrix having a desiccant therein on the barrier layer;
• moving a first sheet having a first major surface and an opposite second major surface into the spacer frame over and spaced from the matrix to move the first major surface of the first sheet against the first layer, and
• moving a second sheet having a first major surface and an opposite major surface toward the second layer to move the first major surface of the second sheet against the second layer, wherein the first surface of the second sheet is spaced from the second surface of the first sheet to provide a compartment therebetween and the desiccant is in communication with the compartment.

A method of making an integrated window sash, comprising:

• feeding a plastic resin into a first material receiver of a co-extruder, an adhesive resin into a second receiver of the co-extruder and a barrier layer resin into a third receiver of the co-extruder;
• moving the resins through a forming die of the co-extruder to form a lineal having first and second sheet supporting surfaces interconnected by a base and a barrier layer secured to the base by the adhesive resin;
• cutting the lineal to provide a plurality of sash members;
• joining the ends of adjacent sash member to provide a sash frame;
• applying simultaneously or in any sequence a layer of a moisture impervious adhesive sealant on the first sheet supporting surface, a layer of moisture impervious adhesive sealant on the second sheet supporting surface, and a layer of a moisture pervious matrix having a desiccant therein on the base;
• moving a first sheet having a first major surface and an opposite second major surface into the spacer frame over and spaced from the matrix to move the first major surface of the first sheet against the first layer, and
• moving a second sheet having a first major surface and an opposite major surface toward the second layer to move the first major surface of the second sheet against the second layer, wherein the first surface of the second sheet is spaced from the second surface of the first sheet to provide a compartment therebetween and the desiccant is in communication with the compartment.

A method of making an integrated window sash, comprising:

• feeding a plastic resin into a material receiver of an extruder;
• moving the resin through a die of the extruder to form a lineal having first and second sheet supporting surfaces and a base having a surface the interconnects the first and second sheet supporting surfaces;
• securing a metal barrier layer to at least the surface of the base as the lineal is formed;
• cutting the lineal to provide a plurality of sash members;
• joining the ends of adjacent sash member to provide a sash frame;
• applying simultaneously or in any sequence a layer of a moisture impervious adhesive sealant on the first sheet supporting surface, a layer of moisture impervious adhesive sealant on the second sheet supporting surface, and a layer of a moisture pervious matrix having a desiccant therein on the base;
• moving a first sheet having a first major surface and an opposite second major surface into the spacer frame over and spaced from the matrix to move the first major surface of the first sheet against the first layer, and
• moving a second sheet having a first major surface and an opposite major surface toward the second layer to move the first major surface of the second sheet against the second layer, wherein the first surface of the second sheet is spaced from the second surface of the first sheet to provide a compartment therebetween and the desiccant is in communication with the compartment.

A method of making an integrated window sash, comprising:

• providing continuous fiber glass strand through a forming die of a pultrusion device;
• feeding a polymeric material into a first material receiver of a pultrusion device, an adhesive material into a second receiver of the pultrusion device, and a barrier layer material into a third receiver of the pultrusion device;
• pulling the fiber glass strand through the die as the polymeric materials is formed around the strand to produce a lineal having first and second sheet supporting surfaces, a base having a surface the interconnects the first and second sheet supporting surfaces, and a barrier layer secured to the base by the adhesive material;
• cutting the lineal to provide a plurality of sash members;
• joining the ends of adjacent sash member to provide a sash frame;
• applying simultaneously or in any sequence a layer of a moisture impervious adhesive sealant on the first sheet supporting surface, a layer of moisture impervious adhesive sealant on the second sheet supporting surface, and a layer of a moisture pervious matrix having a desiccant therein on the base;
• moving a first sheet having a first major surface and an opposite second major surface into the spacer frame over and spaced from the matrix to move the first major surface of the first sheet against the first layer, and
• moving a second sheet having a first major surface and an opposite major surface toward the second layer to move the first major surface of the second sheet against the second layer, wherein the first surface of the second sheet is spaced from the second surface of the first sheet to provide a compartment therebetween and the desiccant is in communication with the compartment.

A method of making an integrated window sash, comprising:

• providing continuous fiber glass strand through a forming die of a pultrusion device;
• feeding polymeric material into a material receiver of the pultrusion device;
• pulling the fiber glass strand through the die as the polymeric material is formed around the strand to produce a lineal having first and second sheet supporting surfaces and a base having a surface the interconnects the first and second sheet supporting surfaces;
• securing a metal barrier layer to at least the surface of the base as the lineal is formed;
• cutting the lineal to provide a plurality of sash members;
• joining the ends of adjacent sash member to provide a sash frame;
• applying simultaneously or in any sequence a layer of a moisture impervious adhesive sealant on the first sheet supporting surface, a layer of moisture impervious adhesive sealant on the second sheet supporting surface, and a layer of a moisture pervious matrix having a desiccant therein on the base;
• moving a first sheet having a first major surface and an opposite second major surface into the spacer frame over and spaced from the matrix to move the first major surface of the first sheet against the first layer, and
• moving a second sheet having a first major surface and an opposite major surface toward the second layer to move the first major surface of the second sheet against the second layer, wherein the first surface of the second sheet is spaced from the second surface of the first sheet to provide a compartment therebetween and the desiccant is in communication with the compartment.