Window component and method of manufacture

A structural frame adapted to receive an injection of insulating foam, said structural frame including:

• a plurality of hollow frame members, said frame members having ends and including a roll-formed shape of metal forming a hollow body with an inner and outer surface and a layer of synthetic material extruded over selected portions of said outer surface of said roll-formed shape;
• a plurality of corner keys, one disposed at each corner of said structural frame, thereby connecting adjacent frame members to each other;
• one or more entrance apertures on the outer surface of at least one frame member in communication with said hollow interior;
• one or more vent apertures on the outer surface of at least one frame member in communication with said hollow interior, and
• a functional shape extruded from said synthetic material and integral with said roll-formed shape.

A window frame including:

• a plurality of hollow frame members, said frame members having miter-cut ends and including a roll-formed shape of metal forming a hollow body with an inner and outer surface, and a layer of synthetic material extruded over selected portions of said outer surface of said roll-formed shape, said synthetic material extruded to form a functional shape that is integral with said roll-formed shape;
• said ends of said frame members coupled to form frame joints, said frame joints attached to create a structure having an exterior surface and a hollow interior;
• a plurality of hollow corner keys, one disposed at each corner of said frame, thereby connecting adjacent frame members to each other to create a structural frame having an exterior surface and a hollow interiors;
• an entrance aperture on the outer surface of at least one frame member in communication with said hollow interior;
• a vent aperture on the outer surface of at least one frame member in communication with said hollow interior;
• an insulation foam injected into said entrance aperture and expanded to fill said hollow interior of said structural frame;
• first seal means located in one or more of said entrance apertures and adapted to have a nozzle inserted into it;
• and
• second seal means located in one or more of said vent apertures and adapted to prevent the escape of said foam from said hollow interior but to allow the escape of the air.