IL309515A - Cast profiles of complex shape and methods for their production and combined use in construction - Google Patents

Description

CAST STRUCTURED PROFILED MEMBERS AND METHODS OF MANUFACTURE AND COMBINED USAGE TEREOF IN CONSTRUCTION TECHNICAL FIELD id="p-1" id="p-1" id="p-1" id="p-1"

[0001] In general, the present invention pertains to the art of metallurgy, [0001] including the processing by metallic extrusion and casting. In particular, the invention relates to structured profiled members and methods of manufacturing the same by die casting, as well as to combined usage thereof in combination with extruded linear profiled members, in construction of frames of glazing support structures. [0001] BACKGROUND ART id="p-2" id="p-2" id="p-2" id="p-2"

[0002] Glazing support structures are widely used in internal and external constructions and may be found in large variety of forms and in different methods of installations. Glazing is widely used for constructing internal and external walls, [0001] doors and windows. There is an ongoing effort to provide glazing structures that employing a combination of arcuate and linear members for the construction of frames having structured form, while sustaining seamless appearance of the joints between the arcuate and linear members.

SUMMARY OF THE INVENTION id="p-3" id="p-3" id="p-3" id="p-3"

[0003] The following summary of the invention is provided to exhibit the basic understanding of some principles, underlying various aspects and features of the invention. This summary is not an extensive overview of the invention and as such it is not necessarily intended to particularly identify all key or critical elements of the [0001] invention and is not to delineate the scope of the invention. Its sole purpose is to present some concepts of the invention in a simplified form as a prelude to the following more detailed. id="p-4" id="p-4" id="p-4" id="p-4"

[0004] The invention was made in view of the deficiencies of the prior art and provides systems, methods and processes for overcoming these deficiencies. [0001] According to some embodiments and aspects of the present invention, there is provided a method of constructing an assembly and the respective assembly to be used in construction of frames for doors or windows including: at least one structured member including: an elongated bar shape having an essentially constant exterior profile, wherein the elongated bar shape is manufactured by die [0001] casting; at least one butt-end having a form of the exterior profile; a terminal face formed by the butt-end configured to adjoin to a matching terminal face formed by a butt-end of an extruded linear member, having an essentially constant exterior profile matching the essentially constant exterior profile of the structured member, so that exterior surfaces of the structured and linear members flush together to [0001] visually form an apparent continuum, wherein a plane of the terminal face of the butt-end of the structured member forms an angle ranging between 0 and 0.0 arcdegrees, relative to a perfect perpendicular of the structured member; and at least one linear member including: an elongated bar shape having an essentially constant exterior profile, wherein the elongated bar shape is manufactured by extrusion; at least one butt-end having a form of the exterior profile; a terminal face formed by the butt-end of the linear member configured to adjoin to the matching terminal face formed by the butt-end of the structured member, so that exterior surfaces of the structured and linear members flush together to visually form the [0001] apparent continuum; a joint formed between the structured member and the linear member, wherein a gap in-between the terminal faces of the butt-ends of the structured and linear members ranging between 0 and 100 microns. id="p-5" id="p-5" id="p-5" id="p-5"

[0005] In some embodiments, the butt-end of the structured member comprises a manually break-away tab. [0001] id="p-6" id="p-6" id="p-6" id="p-6"

[0006] In accordance with some embodiments and aspects of the present invention, there is provided a process of manufacturing a structured member to be used in construction of frames for doors or windows comprises: providing a mold of an elongated bar shape having an essentially constant exterior profile; forming at least one butt-end having a form of the exterior profile; forming a terminal face at [0001] the butt-end configured to adjoin to a matching terminal face formed by a butt-end of an extruded linear member, having an essentially constant exterior profile matching the essentially constant exterior profile of the structured member, so that exterior surfaces of the structured and linear members flush together to visually form an apparent continuum; forming an angle between a plane of the terminal face [0001] of the butt-end of the structured member and a perfect perpendicular of the structured member ranging between 0 and 0.025 arcdegrees; die casting a metal or metallic alloy into the mold; colling the mold and extracting the structured member, wherein a joint is formable between the structured member and the extruded linear member, wherein a gap in-between the butt-end of the structured member and the butt-end of the extruded linear member ranging between 0 and 100 microns. id="p-7" id="p-7" id="p-7" id="p-7"

[0007] In accordance with some embodiments and aspects of the present invention, there is provided a die-cast metallic structured member to be used in [0001] assemblies for construction of frames for doors or windows comprises: an elongated bar shape having an essentially constant exterior profile, wherein the elongated bar is manufactured by metal die casting; at least one butt-end having a form of the exterior profile; a terminal face formed by the butt-end configured to adjoin to a matching terminal face formed by a butt-end of an extruded linear [0001] member, having an essentially constant exterior profile matching the essentially constant exterior profile of the structured member, so that exterior surfaces of the structured and linear members flush together to visually form an apparent continuum; a plane of the terminal face of the butt-end of the structured member forming an angle ranging between 0 and 0.025 arcdegrees, relative to a perfect [0001] perpendicular of the structured member, wherein a joint is formable between the structured member and the linear member, wherein a gap in-between the butt-end of the structured member and the butt-end of the linear member ranging between and 100 microns.

Technical Problem [0001] id="p-8" id="p-8" id="p-8" id="p-8"

[0008] The present invention at general is aimed at providing glazing structures that employing a combination of arcuate and linear members, for the construction of frames having structured form, while sustaining seamless appearance of the joints between the arcuate and linear members overtime and with temperature changes. id="p-9" id="p-9" id="p-9" id="p-9"

[0009] It is an object of the present invention to overcome the tendency of arcuate members manufactured by the process of bending to deform overtime and with temperature changes, typically by a means of torsion, thereby obviating the [0001] seamless appearance of the joints between the arcuate and linear members. id="p-10" id="p-10" id="p-10" id="p-10"

[0010] It is another object of the present invention to overcome the problem of texture roughness and inconsistency of the exterior surface of arcuate members manufactured by die-casting of aluminum.

Solution to Problem [0001] id="p-11" id="p-11" id="p-11" id="p-11"

[0011] In order to achieve a seamless appearance of the joints between the arcuate and linear members and further to sustain such seamless appearance overtime and with temperature changes, a combination of arcuate members manufactured by die-casting and linear members manufactured by extrusion, which was found to overcome the tendency of arcuate members manufactured by the [0001] process of bending to deform overtime and with temperature changes, typically by a means of torsion, has been implemented. id="p-12" id="p-12" id="p-12" id="p-12"

[0012] In order to achieve smooth texture and constant shape of the exterior surface of arcuate members, manufacturing the arcuate members by die-casting of a zinc alloy, which was found to overcome the problem of texture roughness and [0001] inconsistency of the exterior surface of arcuate members manufactured by die- casting of aluminum, which is used for the manufacture of the extruded linear members, has been further implemented.

Advantageous Effects of Invention id="p-13" id="p-13" id="p-13" id="p-13"

[0013] The combination of arcuate members manufactured by die-casting and linear members manufactured by extrusion was found to be beneficial for achieving a seamless appearance of the joints between the arcuate and linear members and further to sustain such seamless appearance overtime and with [0001] temperature changes. id="p-14" id="p-14" id="p-14" id="p-14"

[0014] The manufacture of arcuate members by die-casting of a zinc alloy, rather than of aluminum used to manufacture the linear members, was found to achieve smooth texture and constant shape of the exterior surface of arcuate members and to overcome the problem of texture roughness and inconsistency of [0001] the exterior surface of arcuate members manufactured by die-casting of aluminum.

DEFINITIONS id="p-15" id="p-15" id="p-15" id="p-15"

[0015] An arcdegree is a degree of arc, a measurement of a plane angle in which one full rotation is 360 degrees. [0001] id="p-16" id="p-16" id="p-16" id="p-16"

[0016] The term matching or a term similar thereto, as referred to herein, is to be construed as having a cross-sectional area and/or shape of a component equal or essentially similar to a cross-sectional area and/or shape of another component. It should be acknowledged that the components may only to be similar in the cross-sectional areas and/or shapes, to satisfy the term matching or similar, [0001] so long as the cross-sectional areas of the components can be mated and/or inserted into each other and/or the combination thereof essentially fits together and/or occupy essentially the same space. id="p-17" id="p-17" id="p-17" id="p-17"

[0017] The term structured, as referred to herein, is to be construed as including any geometrical shape, exceeding in complexity a plain linear shape, contour or profile. Any more complex shape than a plain linear shape, contour or profile constitutes an example of structured geometry, including a shape embodying [0001] a circular, elliptical or polygonal contour or shape, contour or profile. id="p-18" id="p-18" id="p-18" id="p-18"

[0018] The term/s door and/or window, as referred to herein, is/are to be used interchangeably and broadly construed as any closing element of an opening, whether stationary or movable back and forth between an open position and a closed position. Along with standard doors and/or windows, the term/s door and/or [0001] window in a non-limiting manner also include/s: flaps, hatches, covers, vitrines and the like. id="p-19" id="p-19" id="p-19" id="p-19"

[0019] The term modular, as referred to herein, should be construed as a including a stand-alone and/or autonomically functioning of structured unit. The term modular inter alia means a standardized unit that may be conveniently installed [0001] or deployed without significant impact to the environment. The term modular, however, doesn’t necessarily mean providing for ease of interchange or replacement. The term modular is optionally satisfied solely by providing for ease of onetime deployment or installation. id="p-20" id="p-20" id="p-20" id="p-20"

[0020] The terms connected, coupled, connectable and "in connection with" [0001] refer to any form of interaction between two or more entities, including mechanical, electrical, magnetic, electromagnetic, fluid, and thermal interactions. Components can be operatively coupled to each other even though they are not in direct contact with each other. The term "abutting" refers to items that are in direct physical contact with one another, although the items do not necessarily have to be attached to one another. id="p-21" id="p-21" id="p-21" id="p-21"

[0021] By operationally connected and operably coupled or similar terms used herein is meant connected in a specific way (e.g., in a manner allowing fluid [0001] to move and/or electric power or signal to be transmitted) that allows the disclosed system and its various components to operate effectively in the manner described herein. id="p-22" id="p-22" id="p-22" id="p-22"

[0022] The terms firm rigid, or stiff, as referred to herein, are to be construed as having rigidity modulus value, otherwise referred to as the shear modulus, of [0001] 4800 MPa or more. Materials are considered to be firm rigid, or stiff but not tensile, when such materials are incapable of being efficiently elastically flexed or bent. Stiff materials, such as steel, are defined as having rigidity modulus value well exceeding 4800 MPa. id="p-23" id="p-23" id="p-23" id="p-23"

[0023] The terms method and process as used herein are to be construed [0001] as including any sequence of steps or constituent actions, regardless a specific timeline for the performance thereof. The particular steps or constituent actions of any given method or process are not necessarily in the order they are presented in the claims, description or flowcharts in the drawings, unless the context clearly dictates otherwise. Any particular step or constituent action included in a given [0001] method or process may precede or follow any other particular step or constituent action in such method or process, unless the context clearly dictates otherwise. Any particular step or constituent action and/or a combination thereof in any method or process may be performed iteratively, before or after any other particular step or action in such method or process, unless the context clearly dictates otherwise.

Moreover, some steps or constituent actions and/or a combination thereof may be combined, performed together, performed concomitantly and/or simultaneously and/or in parallel, unless the context clearly dictates otherwise. Moreover, some steps or constituent actions and/or a combination thereof in any given method or [0001] process may be skipped, omitted, spared and/or opted out, unless the context clearly dictates otherwise. id="p-24" id="p-24" id="p-24" id="p-24"

[0024] In the specification or claims herein, any term signifying an action or operation, such as: a verb, whether in base form or any tense, gerund or present/past participle, is not to be construed as necessarily to be actually [0001] performed but rather in a constructive manner, namely as to be performed merely optionally or potentially. id="p-25" id="p-25" id="p-25" id="p-25"

[0025] The term substantially as used herein is a broad term, and is to be given its ordinary and customary meaning to a person of ordinary skill in the art (and is not to be limited to a special or customized meaning), and refers without limitation [0001] to being largely but not necessarily entirely of that quantity or quality which is specified. id="p-26" id="p-26" id="p-26" id="p-26"

[0026] The term essentially means that the composition, method or structure may include additional ingredients, stages and or parts, but only if the additional ingredients, the stages and/or the parts do not materially alter the basic and new [0001] characteristics of the composition, method or structure claimed. id="p-27" id="p-27" id="p-27" id="p-27"

[0027] As used herein, the term essentially changes a specific meaning, meaning an interval of plus or minus ten percent (± 10%). For any embodiments disclosed herein, any disclosure of a particular value, in some alternative embodiments, is to be understood as disclosing an interval approximately or about equal to that particular value (i.e., ± 10%). id="p-28" id="p-28" id="p-28" id="p-28"

[0028] As used herein, the terms about or approximately modify a particular value, by referring to a range equal to the particular value, plus or minus twenty [0001] percent (+/−20%). For any of the embodiments, disclosed herein, any disclosure of a particular value, can, in various alternate embodiments, also be understood as a disclosure of a range equal to about that particular value (i.e. +/−20%). id="p-29" id="p-29" id="p-29" id="p-29"

[0029] As used herein, the term or is an inclusive or operator, equivalent to the term and/or, unless the context clearly dictates otherwise; whereas the term and [0001] as used herein is also the alternative operator equivalent to the term and/or, unless the context clearly dictates otherwise. id="p-30" id="p-30" id="p-30" id="p-30"

[0030] It should be understood, however, that neither the briefly synopsized summary nor particular definitions hereinabove are not to limit interpretation of the invention to the specific forms and examples but rather on the contrary are to cover [0001] all modifications, equivalents and alternatives falling within the scope of the invention.

DESCRIPTION OF THE DRAWINGS id="p-31" id="p-31" id="p-31" id="p-31"

[0031] The present invention will be understood and appreciated more [0001] comprehensively from the following detailed description taken in conjunction with the appended drawings in which: id="p-32" id="p-32" id="p-32" id="p-32"

[0032] FIG 1 is a top view of an embodiment of an assembly to be used in construction of frames for doors or windows, comprising a structured member and a pair of linear members; id="p-33" id="p-33" id="p-33" id="p-33"

[0033] FIG 2A is a front-top perspective view, of an embodiment of a structured member; id="p-34" id="p-34" id="p-34" id="p-34"

[0034] FIG 2B is an enlarged front-top perspective view, of an embodiment [0001] of a butt-end of a structured member; id="p-35" id="p-35" id="p-35" id="p-35"

[0035] FIG 2C is a rear-top perspective view, of an embodiment of a linear member; id="p-36" id="p-36" id="p-36" id="p-36"

[0036] FIG 2D is a rear-top perspective view, of an embodiment of a butt- end of a linear member; [0001] id="p-37" id="p-37" id="p-37" id="p-37"

[0037] FIG 3A is a front-top perspective view, of another embodiment of a structured member having a manually break-away tab; id="p-38" id="p-38" id="p-38" id="p-38"

[0038] FIG 3B is an enlarged front-top perspective view, of an embodiment of a butt-end of a structured member, having a manually break-away tab; id="p-39" id="p-39" id="p-39" id="p-39"

[0039] FIG 4is a flowchart of an embodiment of a method of constructing an [0001] assembly of frames for doors or windows; id="p-40" id="p-40" id="p-40" id="p-40"

[0040] FIG 5is a flowchart of an embodiment of a process of manufacturing a structured member to be used in construction of frames for doors or windows; id="p-41" id="p-41" id="p-41" id="p-41"

[0041] FIG 6A is a front-top perspective view of a specific empiric example of an assembly comprising an extruded linear member and a structured member [0001] manufactured by bending of an extruded linear member; id="p-42" id="p-42" id="p-42" id="p-42"

[0042] FIG 6B is an enlarged front-top perspective view of a specific empiric example of a joint in-between an extruded linear member and a structured member manufactured by bending of an extruded linear member; id="p-43" id="p-43" id="p-43" id="p-43"

[0043] FIG 7A is a technical drawing showing a front view of a specific empiric example of a structured member manufactured by die-casting of zinc alloy; id="p-44" id="p-44" id="p-44" id="p-44"

[0044] FIG 7B is a technical drawing showing a top view of a specific empiric [0001] example of a structured member manufactured by die-casting of zinc alloy, denoting specific exemplary dimensions of the structured member; id="p-45" id="p-45" id="p-45" id="p-45"

[0045] FIG 7C is a technical drawing showing an enlarged front view of a specific empiric example of a butt-end of structured member manufactured by die- casting of zinc alloy, denoting specific exemplary dimensions of the structured [0001] member; id="p-46" id="p-46" id="p-46" id="p-46"

[0046] FIG 7C is a technical drawing showing an enlarged front side of a specific empiric example of a break-away tab of structured member manufactured by die-casting of zinc alloy, denoting specific exemplary dimensions of the structured member; [0001] id="p-47" id="p-47" id="p-47" id="p-47"

[0047] FIG 8A is a front-top perspective view of a specific empiric example of an assembly comprising a structured member manufactured by die-casting of zinc alloy and an extruded linear member; id="p-48" id="p-48" id="p-48" id="p-48"

[0048] FIG 8B is an enlarged front-top perspective view of a specific empiric example of a joint in-between a structured member manufactured by die-casting of [0001] zinc alloy and an extruded linear member. id="p-49" id="p-49" id="p-49" id="p-49"

[0049] While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown merely by way of example in the drawings. The drawings are not necessarily complete and components are not essentially to scale; emphasis instead being placed upon clearly illustrating the principles underlying the present invention.

DETAILED DISCLOSURE OF EMBODIMENTS [0001] id="p-50" id="p-50" id="p-50" id="p-50"

[0050] Illustrative embodiments of the invention are described below. In the interest of clarity, not all features of actual implementation are described in this specification. It should be appreciated that various features or elements described in the context of some embodiment may be interchangeable with features or elements of any other embodiment described in the specification. Moreover, it will [0001] be appreciated that for the development of any actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with technology- or business-related constraints, which may vary from one implementation to another, and the effort of such a development might be complex and time-consuming, but would nevertheless be a routine [0001] undertaking for those of ordinary skill in the art having the benefit of this disclosure. id="p-51" id="p-51" id="p-51" id="p-51"

[0051] In accordance with some embodiments of the present invention, reference is now made to FIG 1 to 3B , showing assembly 10 to be used in construction of frames for doors or windows. In some embodiments, assembly 10 comprises at least one structured member 20 , a pair of linear members 30and joints [0001] 40 formed between structured member 20 and linear members 30 . id="p-52" id="p-52" id="p-52" id="p-52"

[0052] In some embodiments, at least one structured member 20 comprises elongated bar shape 12 . Elongated bar shape 12has essentially constant exterior profile 14 . In some examples, at least one structured member 20 in a non-limiting manner comprises a sinusoidal, hyperbolical, parabolical and/or arcuate bar shape.

In some embodiments, elongated bar shape 12 is manufactured by die-casting. In some examples, elongated bar shape 12 is manufactured by a zinc aluminum alloy die-casting, in which a base zinc metal is typically alloyed with magnesium, copper [0001] and aluminum elements. id="p-53" id="p-53" id="p-53" id="p-53"

[0053] In some embodiments, at least one structured member 20 further comprises at least one butt-end 16A having a form of exterior profile 14 . In some embodiments, at least one structured member 20 further comprises terminal face 18 formed by butt-end 16A . [0001] id="p-54" id="p-54" id="p-54" id="p-54"

[0054] In some embodiments, terminal face 18 is configured to adjoin to matching terminal face 24 formed by butt-end 26 of extruded linear member 30 , having essentially constant exterior profile 28 , essentially matching constant exterior profile 14 of structured member 20 , so that exterior surfaces 32 and 34 of structured and linear members 20 and 30 flush together to visually form an apparent [0001] continuum at joints 40 in-between structured member 20 and linear members 30 . id="p-55" id="p-55" id="p-55" id="p-55"

[0055] In some embodiments, as shown in FIG 2A , structured member 20 comprises first butt-end 16A and second butt-end 16B . In some embodiments, the plane of terminal face 18 of butt-end 16A of structured member 20 forms an angle ranging between 0 and 0.025 arcdegrees, relative to a perfect perpendicular axis [0001] A1 of structured member 20 . id="p-56" id="p-56" id="p-56" id="p-56"

[0056] It is noted that the angle ranging between 0 and 0.025 arcdegrees, between the plane of terminal face 18 of butt-end 16A of structured member 20 relative to a perfect perpendicular axis A1 of structured member 20 , is in a non- limiting manner formed by: the rotation of terminal face 18 relative to axis A1 and/or the rotation of terminal face 18 relative to axis A2 and/or a linear displacement of terminal face 18 relative to axis A1 in any direction and/or a linear displacement of terminal face 18 relative to axis A2 in any direction and/or by forming an angle other [0001] than a perpendicular between terminal face 18 and the plane defined by axes A1 and A2 and/or by a gap forming in-between terminal face 18 and terminal face 24 formed by butt-end 26 of extruded linear member 30 and/or by a gap forming exterior profile 14 of structured member 20 and exterior profile 28 of extruded linear member 30 . [0001] id="p-57" id="p-57" id="p-57" id="p-57"

[0057] In some embodiments, the plane of terminal face 18 of butt-end 16B of structured member 20 forms an angle ranging between 0 and 0.025 arcdegrees, relative to a perfect perpendicular axis A1 of structured member 20 . A perfect perpendicular is when angle α formed between axis A1 and axis A2equals degrees. [0001] id="p-58" id="p-58" id="p-58" id="p-58"

[0058] In some embodiments, assembly 10 further comprises at least one linear member 30 . At least one linear member 30 comprises elongated bar shape 36 having essentially constant exterior profile 28 . In some embodiments, elongated bar shape 36 is manufactured by extrusion. In some examples, elongated bar shape 36is manufactured by extrusion of aluminum. [0001] id="p-59" id="p-59" id="p-59" id="p-59"

[0059] In some embodiments, at least one linear member 30 further comprises at least one butt-end 26 having a form of exterior profile 28 . In some embodiments, at least one linear member 30 further comprises terminal face 24 .

Terminal face 24 is formed by butt-end 26 of linear member 30 . id="p-60" id="p-60" id="p-60" id="p-60"

[0060] In some embodiments, terminal face 24 is configured to adjoin to matching terminal face 18 formed by butt-end 16 of structured member 20 , so that exterior surfaces 14 and 28 of structured and linear members 20 and 30 flush together to visually form an apparent continuum. id="p-61" id="p-61" id="p-61" id="p-61"

[0061] In some embodiments, assembly 10 further comprises joints 40 . [0001] Joints 40 are formed between structured member 20 and linear members 30 , in which a gap in-between exterior profiles 14 and 28 at butt-ends 16 and 26 of structured and linear members 20 and 30 ranging between 0 and 100 microns. In some embodiments a gap in-between terminal faces 18 and 24 of butt-ends 16 and 26 of structured and linear members 20 and 30 ranging between 0 and 100 microns. [0001] id="p-62" id="p-62" id="p-62" id="p-62"

[0062] In some embodiments, as shown in FIG 3A and 3B , butt-end 17 of structured member 20 comprises manually break-away tab 22 . Manually break- away tab 22 is used for suspending structured member 20 for painting. Moreover, zinc alloys are typically not sawed well, therefore for the removal of tab 22 a manually break-away mechanism, comprising a portion of thinned and/or [0001] weakened material was found to be beneficial. id="p-63" id="p-63" id="p-63" id="p-63"

[0063] In accordance with some embodiments of the present invention, reference is now made FIG 4 showing a flowchart of method 100 of constructing an assembly of frames for doors or windows. Method 100 of the embodiment of FIG 4 illustrates various features that may be interchangeable with elements of any other [0001] embodiment described in the specification. id="p-64" id="p-64" id="p-64" id="p-64"

[0064] In some embodiments, method 100 commences at step 102 of providing at least one structured member. In some embodiments, at least one structured member comprises an elongated bar shape having an essentially constant exterior profile, in which the elongated bar shape is manufactured by die- casting. In some embodiments, at least one butt-end having a form of the exterior profile. id="p-65" id="p-65" id="p-65" id="p-65"

[0065] In some embodiments, method 100 comprises step 104 of providing [0001] at least one linear member. In some embodiments, at least one linear member comprises an elongated bar shape having an essentially constant exterior profile, in which the elongated bar shape is manufactured by extrusion. id="p-66" id="p-66" id="p-66" id="p-66"

[0066] In some embodiments, at least one structured member further comprises a terminal face formed by the butt-end configured to adjoin to a matching [0001] terminal face formed by a butt-end of an extruded linear member, having an essentially constant exterior profile matching the essentially constant exterior profile of the structured member, so that exterior surfaces of the structured and linear members flush together to visually form an apparent continuum. In some embodiments. [0001] id="p-67" id="p-67" id="p-67" id="p-67"

[0067] In some embodiments, method 100 further comprises step 106 of forming a joint between the structured member and the linear member, in which a gap in-between the terminal faces of the butt-ends of the structured and linear members ranging between 0 and 100 microns. id="p-68" id="p-68" id="p-68" id="p-68"

[0068] In accordance with some embodiments of the present invention, [0001] reference is now made FIG 5 showing a flowchart of process 200 of manufacturing a structured member to be used in construction of frames for doors or windows.

Method 200 of the embodiment of FIG 5 illustrates various features that may be interchangeable with elements of any other embodiment described in the specification. id="p-69" id="p-69" id="p-69" id="p-69"

[0069] In some embodiments, process 200 commences with step 202 of providing a mold of an elongated bar shape having an essentially constant exterior profile. In some embodiments, process 200 further comprises step 204 of forming [0001] at least one butt-end having a form of the exterior profile. id="p-70" id="p-70" id="p-70" id="p-70"

[0070] In some embodiments, process 200 further comprises step 206 of forming a terminal face at the butt-end configured to adjoin to a matching terminal face formed by a butt-end of an extruded linear member, having an essentially constant exterior profile matching the essentially constant exterior profile of the [0001] structured member, so that exterior surfaces of the structured and linear members flush together to visually form an apparent continuum. id="p-71" id="p-71" id="p-71" id="p-71"

[0071] In some embodiments, process 200 further comprises step 208 of forming an angle between a plane of the terminal face of the butt-end of the structured member and a perfect perpendicular of the structured member ranging [0001] between 0 and 0.025 arcdegrees. id="p-72" id="p-72" id="p-72" id="p-72"

[0072] In some embodiments, process 200 further includes step 210 of die- casting a metal or metallic alloy into the mold. In some embodiments, process 200 further comprises step 212 of colling the mold and extracting the structured member. In some embodiments, a joint is formable between the structured member [0001] and the extruded linear member, in which a gap in-between the butt-end of the structured member and the butt-end of the extruded linear member ranging between 0 and 100 microns.

WORKING EXAMPLES id="p-73" id="p-73" id="p-73" id="p-73"

[0073] Hereinafter, the present invention will be described more specifically with reference to the following working examples. The following working examples have been empirically produced and/or lab tested. It should be acknowledged that the specific values, parameters, compositions, shapes, structures and [0001] configurations in the following working examples are merely exemplary, as obtained de facto from the record of the actual experiments or tests that have been performed. The specific values, parameters, compositions, shapes, structures and conformations in the following working examples are therefore by no means to limit the scope of the invention thereto but rather denote merely exemplary empirical [0001] values, parameters, compositions, shapes, structures and conformations of the actual experiments and/or tests. id="p-74" id="p-74" id="p-74" id="p-74"

[0074] Example 1 - Exemplary assembly of a bent structured member and an extruded linear member id="p-75" id="p-75" id="p-75" id="p-75"

[0075] In accordance with some specific working examples, reference is now [0001] made to FIG 6A , which is a front-top perspective view of an assembly of extruded linear member 30 and structured member 20 , as well as to FIG 6B which is an enlarged front-top perspective view of a specific empiric example of joint 40 formed in-between extruded linear member 30 and structured member 20 . id="p-76" id="p-76" id="p-76" id="p-76"

[0076] The specific exemplary dimensions of structured member 20 are [0001] generally as denoted in the technical drawings of FIG 7A to 7D . The specific exemplary dimensions of the structured member are denoted in drawings of FIG 7A to 7D in millimeters; the interior radius of the arc of the structured member was 230 mm, the exterior radius of the arc of the structured member was 250 mm, the overall width of the structured member was 20 mm, the overall thickness of the structured member was 3.9 mm. id="p-77" id="p-77" id="p-77" id="p-77"

[0077] Structured member 20 shown in FIG 6A and 6B has been manufactured by bending of a linear member extruded from aluminum. As can be [0001] appreciated from FIG 6A and 6B , structured member 20 has formed an angle between a plane of the terminal face of the butt-end of structured member 20and a perfect perpendicular of structured member 20exceeding 0.025 arcdegrees. As can be further appreciated from FIG 6A and 6B , structured member 20has formed prominently apparent and visually unesthetic joint 40 between structured 20 [0001] member and extruded linear member 30 , in which a gap in-between the butt-end of structured member 20and the butt-end of the extruded linear member 30exceeding 100 microns. id="p-78" id="p-78" id="p-78" id="p-78"

[0078] Example 2 - Exemplary structured member manufactured by die- casting of aluminum [0001] id="p-79" id="p-79" id="p-79" id="p-79"

[0079] Structured member 20manufactured by die-casting of aluminum, has exhibited insufficient density of the metal, which contributed to texture roughness and inconsistency of the exterior surface arcuate member 20 . id="p-80" id="p-80" id="p-80" id="p-80"

[0080] The specific exemplary dimensions of structured member 20 are generally as denoted in the technical drawings of FIG 7A to 7D . The specific [0001] exemplary dimensions of the structured member are denoted in drawings of FIG 7A to 7D in millimeters; the interior radius of the arc of the structured member was 230 mm, the exterior radius of the arc of the structured member was 250 mm, the overall width of the structured member was 20 mm, the overall thickness of the structured member was 3.9 mm. id="p-81" id="p-81" id="p-81" id="p-81"

[0081] The exterior surface of arcuate member 20 manufactured by die- casting of aluminum had an inconsistency exceeding 100 microns. id="p-82" id="p-82" id="p-82" id="p-82"

[0082] Example 3 - Exemplary assembly of a ZAMAC die-cast structured [0001] member and an aluminum extruded linear member id="p-83" id="p-83" id="p-83" id="p-83"

[0083] In accordance with some specific working examples, reference is now made to FIG 7A which is a front-top perspective view of a specific empiric example of an assembly comprising structured member 20manufactured by die-casting and linear member 30 extruded from aluminum, as well as to FIG 7B which is an [0001] enlarged front-top perspective view of a specific empiric example of joint 40 formed in-between structured member 20 and extruded linear member 30 . id="p-84" id="p-84" id="p-84" id="p-84"

[0084] The specific exemplary dimensions of structured member 20have been as set forth in the technical drawings of FIG 7A to 7D . The specific exemplary dimensions of the structured member are denoted in drawings of FIG 7A to 7D in [0001] millimeters; the interior radius of the arc of the structured member was 230 mm, the exterior radius of the arc of the structured member was 250 mm, the overall width of the structured member was 20 mm, the overall thickness of the structured member was 3.9 mm, the width of the break-away tab was 17 mm, the width of the groove between the butt-end of the structured member and the break-away tab at [0001] the breakable connection between the structured member and the break-away tab was 2 mm and the thickness at the bottom of the groove at the breakable connection between the structured member and the break-away tab was 0.5 mm. id="p-85" id="p-85" id="p-85" id="p-85"

[0085] Structured member 20 shown in FIG 7A and 7B has been manufactured by die-casting of ZAMAC. As can be appreciated from FIG 7A and 7B , structured member 20has formed an angle between a plane of the terminal face of the butt-end of structured member 20 and a perfect perpendicular of structured member 20ranging between 0 and 0.025 arcdegrees. As can be further [0001] appreciated from FIG 7A and 7B , structured member 20has formed apparently seamless and visually esthetic joint 40 between structured 20 member and extruded linear member 30 , in which a gap in-between the butt-end of structured member 20and the butt-end of the extruded linear member 30ranging between and 100 microns, where the exterior surfaces of ZAMAC die-cast structured [0001] member 20 and aluminum extruded linear member 30 flash together to form together visually forming an apparent continuum. id="p-86" id="p-86" id="p-86" id="p-86"

[0086] It will be appreciated by persons skilled in the art of the invention that various features and/or elements elaborated in the context of a specific embodiment described hereinabove and/or referenced herein and/or illustrated by a particular [0001] example in a certain drawing enclosed hereto, whether method, system, device or product, is/are interchangeable with features and/or elements of any other embodiment described in the specification and/or shown in the drawings. Moreover, skilled persons would appreciate that the present invention is not limited by what has been particularly shown and described hereinabove. Rather the scope of the [0001] invention is defined by the claims which follow:

Claims (12)

- 23 - CLAIMS

1. An assembly to be used in construction of frames for doors or windows comprises: (a) at least one structured member comprising: (I) an elongated arcuate bar shape having an essentially constant exterior profile; wherein said elongated bar shape is manufactured by die casting; (II) at least one butt-end having a form of said exterior profile; (III) a terminal face formed by said butt-end configured to adjoin to a matching terminal face formed by a butt-end of an extruded linear member, having an essentially constant exterior profile matching said essentially constant exterior profile of said structured member, so that exterior surfaces of said structured and linear members flush together to visually form an apparent continuum; wherein a plane of said terminal face of said butt-end of said structured member forms an angle ranging between 0 and 0.025 arcdegrees, relative to a perfect perpendicular of said structured member; (b) at least one linear member comprising: (I) an elongated bar shape having an essentially constant exterior profile; wherein said elongated bar shape is manufactured by extrusion; (II) at least one butt-end having a form of said exterior profile; (III) a terminal face formed by said butt-end of said linear member configured to adjoin to said matching terminal face formed by said butt-end of said structured member, so that exterior surfaces of said structured and linear - 24 - members flush together to visually form said apparent continuum; (c) a joint formed between said structured member and said linear member, wherein a gap in-between said terminal faces of said butt-ends of said structured and linear members ranging between 0 and 100 microns.

2. The assembly as in claim 1, wherein said butt-end of said structured member comprises a manually break-away tab.

3. The assembly as in claim 1, wherein said at least one structured member is manufactured by die casting of a zinc alloy.

4. The assembly as in claim 1, wherein said at least one linear member is manufactured by extrusion of aluminum.

5. A method of constructing an assembly of frames for doors or windows comprises: (a) providing at least one structured member comprising: (I) an elongated bar shape having an essentially constant exterior profile; wherein said elongated bar shape is manufactured by die casting; (II) at least one butt-end having a form of said exterior profile; (III) a terminal face formed by said butt-end configured to adjoin to a matching terminal face formed by a butt-end of an extruded linear member, having an essentially constant exterior profile matching said essentially constant exterior profile of said structured member, so that - 25 - exterior surfaces of said structured and linear members flush together to visually form an apparent continuum; wherein a plane of said terminal face of said butt-end of said structured member forms an angle ranging between 0 and 0.025 arcdegrees, relative to a perfect perpendicular of said structured member; (b) providing at least one linear member comprising: (I) an elongated bar shape having an essentially constant exterior profile; wherein said elongated bar shape is manufactured by extrusion; (II) at least one butt-end having a form of said exterior profile; (III) a terminal face formed by said butt-end of said linear member configured to adjoin to said matching terminal face formed by said butt-end of said structured member, so that exterior surfaces of said structured and linear members flush together to visually form said apparent continuum; (c) forming a joint between said structured member and said linear member, wherein a gap in-between said terminal faces of said butt-ends of said structured and linear members ranging between 0 and 100 microns.

6. The method as in claim 5, wherein said butt-end of said structured member comprises a manually break-away tab.

7. The method as in claim 5, wherein said at least one structured member is manufactured by die casting of a zinc alloy.

8. The method as in claim 5, wherein said at least one linear member is - 26 - manufactured by extrusion of aluminum.

9. A process of manufacturing a structured member to be used in construction of frames for doors or windows comprises: (a) providing a mold of an elongated bar shape having an essentially constant exterior profile; (b) forming at least one butt-end having a form of said exterior profile; (c) forming a terminal face at said butt-end configured to adjoin to a matching terminal face formed by a butt-end of an extruded linear member, having an essentially constant exterior profile matching said essentially constant exterior profile of said structured member, so that exterior surfaces of said structured and linear members flush together to visually form an apparent continuum; (d) forming an angle between a plane of said terminal face of said butt-end of said structured member and a perfect perpendicular of said structured member ranging between 0 and 0.025 arcdegrees; (e) die casting a metal or metallic alloy into said mold; (f) colling said mold and extracting said structured member; wherein a joint is formable between said structured member and said extruded linear member, wherein a gap in-between said butt-end of said structured member and said butt-end of said extruded linear member ranging between 0 and 100 microns.

10. The process as in claim 9, wherein said butt-end of said structured member - 27 - comprises a manually break-away tab.

11. A die-cast zinc alloy structured member to be used in assemblies for construction of frames for doors or windows comprises: (a) an elongated bar shape having an essentially constant exterior profile; wherein said elongated bar is manufactured by metal die-casting a zinc alloy; (b) at least one butt-end having a form of said exterior profile; (c) a terminal face formed by said butt-end configured to adjoin to a matching terminal face formed by a butt-end of an extruded linear member, having an essentially constant exterior profile matching said essentially constant exterior profile of said structured member, so that exterior surfaces of said structured and linear members flush together to visually form an apparent continuum; (d) a plane of said terminal face of said butt-end of said structured member forming an angle ranging between 0 and 0.025 arcdegrees, relative to a perfect perpendicular of said structured member; wherein a joint is formable between said structured member and said linear member, wherein a gap in-between said butt-end of said structured member and said butt-end of said linear member ranging between 0 and 100 microns.

12. The structured member as in claim 11, wherein said butt-end of said structured member comprises a manually break-away tab.