Thermally insulated composite frame member and method for the manufacture thereof

A thermally insulated architectural frame member comprised of an elongated first metal section, an elongated second metal frame section and a preformed thermal break section;

• said first metal member having a longitudinal first outer wall and an extension extending laterally and inwardly from the outer wall thereof which in combination with the outer wall forms a first channel of a first predetermined cross sectional shape;
• the second metal frame section having a second outer wall portion and an integral extension extending laterally and inwardly from the second outer wall portion of a second predetermined cross sectional configuration including a generally ell shaped locking foot;
• said first and second predetermined cross sectional shapes being selected so that when the first and second metal sections are in an opposing relationship the ell shaped locking foot of the second metal section can be inserted into the channel of the first metal section in a spaced apart relationship;
• said preformed thermal break section being preformed from a rigid material having a low thermal conductivity as compared to metal and having an outer wall substantially mating the cross section of the channel of the first metal section and including a second channel for receiving the ell shaped locking foot in locking engagement spaced apart from the outer wall of the thermal break section;
• said thermal break section being positioned within the channel of the first metal section and said second metal section being positioned in an opposing relationship to the first metal section with the ell shaped locking foot engaged with the second channel in the thermal break section whereby the first metal section and the second metal section are mechanically secured together and thermally insulated from each other by the thermal break section and wherein the ell shaped locking foot includes vertical and horizontal elements which together substantially conform to the interior of the second channel and wherein the horizontal element of the locking foot is wider than the width of the second channel by an amount sufficient to cause the locking foot to snap lock in place within the second channel.