Corner key for window component assembly

Abstract

The present invention relates to corner keys used in assembling structural components to form various structural shapes, such as a frame and sash section for a window, door panel, or other building or architectural construction. The structural members are formed by a process that includes continuously roll-forming a first sub-part and a second sub-part from pre-treated metal in flat coil-stock form. A thin layer of Extrudable Thermal plastic (ETP) is then selectively extruded to both the outside and inside surfaces of the sub-parts. Some of the ETP is extruded onto the roll-formed sub-parts in a functional shape, such as a 'C' shaped pocket used to clip parts together. The sub-parts are joined together to form structural component material that can then be cut and fabricated to form individual structural components. Once the roll-formed structural components are selectively joined or coupled together to form a frame or sash, a shot of urethane foam is injected into the frame or sash and allowed to expand to fill the interior of the frame or sash. The addition of the foam provides permanent adhesion among the various structural components and significantly improves the structural integrity of the window casement. Hollow corner keys, the subject of the present invention, can be further added to improve the structural integrity of the window casement.