Overmolded fenestration building product and method of manufacture

Abstract

A method for manufacturing a fenestration article includes placing a light transmitting pane on a first conformable seal in a first mold portion. The pane has an overmold flange. The method also includes placing a second conformable seal is situated opposed to and positioned on the second side of the pane, the second seal positioned in cooperation with the first conformable seal and a second mold portion to form a center opening in the pane. The first and second portions of the mold are closed, defining a mold cavity therebetween, into which a plastic material is introduced encapsulating the overmold flange and forming in the mold cavity a frame about the light transmitting pane with the center opening situated further away from the wall than the frame, when the fenestration article is installed in the wall.

1 - 49 . (canceled) 
     
     
         50 . A method for manufacturing a fenestration article enclosing an opening in a wall, the method comprising the steps of:
 placing a light transmitting pane on a first conformable seal in a first mold portion, the pane further having a width and a length, positioning the first side of the pane on the first conformable seal having an interior width that measures less than the width of the pane, a difference defining a width of an overmold flange and an interior length that measures less than the length of the pane, a difference defining a length of the overmold flange;   placing a second conformable seal such that the second seal is situated opposed to and positioned on the second side of the pane, the second seal positioned in cooperation with the first conformable seal and a second mold portion to form a center opening in the pane;   closing the first and second portions of the mold, defining a mold cavity therebetween, into which a plastic material is introduced encapsulating the overmold flange and forming in the mold cavity a frame about the light transmitting pane with the center opening situated further away from the wall than the frame, when the fenestration article is installed in the wall;   solidifying the plastic material; and   opening the second portion of the mold to remove the fenestration article.   
     
     
         51 . The method of  claim 50 , wherein the plastic material has a thermoset composition. 
     
     
         52 . The method of  claim 50 , wherein introducing the plastic material includes injecting in a reaction injection molding (RIM) plastic. 
     
     
         53 . The method of  claim 50 , wherein introducing the plastic material into the mold cavity to form the frame includes forming a flashing capable of being capable of being attached to the wall. 
     
     
         54 . The method of  claim 53 , wherein introducing the plastic material into the mold cavity simultaneously forms a curb integrally bonded with the flashing and the frame forming a unitized article. 
     
     
         55 . The method of  claim 53 , wherein the frame forms a unitary annular ring. 
     
     
         56 . The method of  claim 50 , wherein introducing the plastic to the mold cavity simultaneously forms a curb connected to the frame. 
     
     
         57 . The method of  claim 50 , wherein the pane is glass or plastic. 
     
     
         58 . The method of  claim 50 , wherein the fenestration article is selected from the group consisting of a unitized skylight, a unitized tubular skylight, a unitized window, a unitized doorlite, and a unitized sidelight. 
     
     
         59 . The method of  claim 50 , wherein the light transmitting pane comprises an insulated glass unit. 
     
     
         60 . A method for manufacturing a fenestration article enclosing an opening in a wall of a building, the method comprising the steps of:
 placing a first side of a light transmitting panel having an insulated unit and a overmold flange at the periphery of the panel on a first conformable seal in a first mold portion, the seal suitable for defining a central opening in the panel;   placing a second conformable seal opposite the first conformable seal and on a second side of the light transmitting panel, the second seal cooperating with a second mold portion to form the center opening in the panel;   closing the first and section portions of the mold, defining a mold cavity therebetween capable of forming a frame and a flashing, into which plastic material is introduced encapsulating the overmold flange of the light transmitting panel with the plastic material forming the frame configured as an unjointed, unitary annular frame situated immediately adjacent to the panel periphery and fixing the panel to the frame, the annular frame including the flashing being disposed all the way around the window and being capable of sealing with the wall, the wall flashing being situated closer to the wall than the insulated unit;   solidifying the plastic material; and   opening the second mold portion to remove the fenestration article.   
     
     
         61 . The method of  claim 60 , wherein the fenestration article is selected from the group consisting of a window, a door, a doorlite, a sidelight, a skylight, and a tubular skylight. 
     
     
         62 . The method of  claim 60 , wherein the plastic material has a composition including a thermoplastic composition or a thermoset composition. 
     
     
         63 . The method of  claim 60 , wherein the frame forms a thin shell frame. 
     
     
         64 . The method of  claim 63 , wherein the thin shell frame includes an exterior-facing surface skin having a thermoset composition, the surface skin defining an interior shell cavity including a foamed thermoset composition material. 
     
     
         65 . The method  claim 60 , wherein introducing the plastic includes a process selected from the group consisting of a closed mold process, a reaction injection molding (RIM) process, an injection molding process, a low-pressure injection molding process, a casting process, and a rotomolding process. 
     
     
         66 . A method for manufacturing a fenestration article enclosing an opening in a wall of a building, the method comprising the steps of:
 placing a first side of a light transmitting panel having an insulated unit and a overmold flange at the periphery of the panel on a first conformable seal in a first mold portion, the seal suitable for defining a central opening in the panel;   placing a second conformable seal opposite the first conformable seal and on a second side of the light transmitting panel, the second seal cooperating with a second mold portion to form the center opening in the panel;   closing the first and section portions of the mold, defining a mold cavity therebetween capable of forming a thin shell frame and a flashing, into which plastic material is introduced encapsulating the overmold flange of the light transmitting panel with the plastic material forming the thin shell frame configured as an unjointed, unitary annular thin shell frame situated immediately adjacent to the panel periphery and having an exterior-facing surface skin defining an interior shell cavity filled with a foamed composition material, the annular thin shell frame including the flashing being capable of sealing with the wall, the wall flashing being situated closer to the wall than the insulated unit;   solidifying the plastic material; and   opening the second mold portion to remove the fenestration article.   
     
     
         67 . The method of  claim 66 , wherein introducing the plastic includes an open mold process capable of having the plastic material encapsulate the periphery of the first insulated unit without damaging or distorting the panel. 
     
     
         68 . The method of  claim 66 , wherein introducing the plastic to the mold cavity simultaneously forms a curb connected to the annular thin-shell frame. 
     
     
         69 . The method of  claim 66 , further comprising forming the panel as a domed panel. 
     
     
         70 . The method of  claim 66 , further comprising the step of connecting the fenestration article to a light pipe. 
     
     
         71 . The method of  claim 66 , wherein introducing the plastic material includes introducing a reinforced plastic material.