Bay Mills Limited

John K Donaldson

A method of forming a foam-filled decorative muntin bar includes the steps of roll-forming a sheet of aluminum to form a hollow outer shell, and depositing a mixture of foaming components on the sheet of aluminum as it is being roll-formed, so the outer shell encases the mixture. The mixture is allowed to react, expand and harden to form a foamed material that substantially fills the shell. The filled shell is cut to form a segment of a foam-filmed decorative muntin bar of desired length with open ends.

Method of forming foam-filled decorative muntin bar for windows and the like

A decorative window assembly includes a peripheral frame, and a plurality of foam-filled decorative muntin bars interconnected in a grid which is connected to the peripheral frame. Each muntin bar includes an elongated outer shell with open ends and defining a hollow interior, and a foamed filler substantially filling the interior of the shell between the ends thereof.

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Oakville, Canada

John K Donaldson