Screen bar corner reinforcement, a screen frame including such a reinforcement and methods of manufacturing these products

A screen frame including screen bar corner reinforcements, said frame comprising:

• first and second short segments of screen bar and first and second long segments of screen bar, each segment being formed into a desired profile and each having a hollow interior portion;
• four reinforcing channels, each reinforcing channel having a first leg and a second leg arranged at approximately ninety degrees to the first leg, with ends of the channel securing first and second extensions to extend the first and second legs, respectively, at least one of (i) a portion of the first extension of a respective reinforcing channel being inserted through an end of each short segment of the screen bar into and substantially spaced from surfaces of the hollow interior portion of the short segment and (ii) a portion of the second extension of a respective reinforcing channel being inserted through an end of each long segment of the screen bar into and substantially spaced from surfaces of the hollow interior portion of the long segment;
• and
• a rigid reinforcing and structural material, formed from a foamed chemical, inside at least one of (i) the hollow interior portion of each short segment for securing respective inserted portions of the first extensions of the reinforcing channels therewithin and (ii) the hollow interior portion of each long segment for securing respective inserted portions of the second extensions of the reinforcing channels therewithin.

A method of making a screen bar corner reinforcement for use in strengthening frames, said method comprising:

• providing at least a first segment and a second segment of screen bar, each being formed into a desired profile and each having a hollow interior portion;
• providing a reinforcing channel having a first leg and a second leg arranged at approximately ninety degrees to the first leg, with ends of the channel securing first and second extensions to extend the first and second legs, respectively;
• inserting a portion of the first extension of the reinforcing channel through a first end of the first segment of the screen bar into and substantially spaced from surfaces of the hollow interior portion of the first segment;
• inserting a portion of the second extension of the reinforcing channel through a first end of the second segment of the screen bar into and substantially spaced from surfaces of the hollow portion of the second segment;
• and
• injecting, with a curable reinforcing and structural material, at least one of (i) the hollow interior portion of the first segment for securing the inserted portion of the first extension of the reinforcing channel therewithin and (ii) the hollow interior portion of the second segment for securing the inserted portion of the second extension of the reinforcing channel therewithin.

A method of making a screen frame including screen bar corner reinforcements, said method comprising:

• providing first and second short segments of screen bar and first and second long segments of screen bar, each segment being formed into a desired profile and each having a hollow interior portion;
• providing four reinforcing channels, each channel having a first leg and a second leg arranged at approximately ninety degrees to the first leg, with ends of each channel securing first and second extensions to extend the first and second legs, respectively;
• inserting a portion of the first extension of a respective reinforcing channel through an end of a short segment of the screen bar into and substantially spaced from surfaces of the hollow interior portion of the short segment;
• inserting a portion of the second extension of a respective reinforcing channel through an end of a long segment of the screen bar into and substantially spaced from surfaces of the hollow interior portion of the long segment;
• and
• injecting, with a curable reinforcing and structural material, at least one of (i) the hollow interior portions of the short segments for securing respective inserted portions of the first extensions of the reinforcing channels therewithin and (ii) the hollow interior portions of the long segments for securing respective inserted portions of the second extensions of the reinforcing channels therewithin.