Method of making an integrated window sash

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, wherein the first and the second sheet supporting surfaces face in the same direction;
• cutting the lineal to provide at least one sash member;
• forming a sash frame from the at least one sash member;
• applying 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;
• providing a flexible sheet retainer having a first end portion and a second end portion, and positioning the sheet retainer between the first and the second sheet supporting surfaces with the first end portion of the sheet retainer in facing relationship to the second surface of the first sheet, and
• moving a second sheet having a first major surface and an opposite major surface toward the second layer to move the first end portion of the sheet retainer against the second surface of the first sheet to compress the sheet retainer between the second surface of the first sheet and the first surface of the second sheet and to move the first major surface of the second sheet against the second layer, wherein the first end portion of the sheet retainer is biased against at least the second surface of the first sheet to move the first sheet toward the first sheet supporting surface and 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 fiber glass strands through a forming die of a pultrusion device;
• feeding a polymeric material into a first material receiver of the 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 strands through the forming die as the polymeric material is formed around the strands to produce a lineal having first and second sheet supporting surfaces facing in the same direction, a base having a surface that connects the first and second sheet supporting surfaces, and a barrier layer secured to the surface of the base by the adhesive material;
• cutting the lineal to provide a plurality of sash members;
• joining the ends of adjacent sash members to provide a sash frame;
• applying 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, an opposite second major surface and a peripheral edge connecting the first and the second major surfaces into the spacer frame against the first layer of the adhesive sealant to secure the first surface of the first sheet against the first sheet supporting surface, wherein as the first sheet is moved over the moisture pervious matrix toward the first layer, the peripheral edge of the first sheet moves over, is spaced from, and out of contact with, the layer of the moisture pervious matrix;
• providing a compressible sheet retainer having a first end portion and an opposite second end portion, and positioning the first end portion of the sheet retainer against the second surface of the first sheet, and
• moving a second sheet having a first major surface and an opposite major second 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, wherein during the moving of the second sheet, contacting the second end portion of the sheet retainer with the first surface of the second sheet to compress the sheet retainer between the second surface of the first sheet and the first surface of the second sheet.