Windows and methods of making and installing windows

Abstract

A material used to fabricate sashes used by window assemblies. The material comprises a foam core covered by a cladding material. The foam core acts as a filler and provides insulation, while the cladding material protects the foam core from the environment and physical abuse. Often, a structural assembly or member is provided to stiffen the sash material. The cladding and structural assembly are placed into a mold and resin is injected into the mold between the cladding and the structural assembly. The resin cures to form the foam core. The foam core bonds the cladding and structural assembly together to form the sash material. The sash material is cut with woodworking tools to form a sash for a window assembly. The cladding is configured such that, when the window assembly is installed in a wall, interior vapor barrier material and exterior air barrier material applied to the wall overlap with the cladding material to reduce air flow through the wall around the window assembly.

Dependencies are inferred from the claim text.