Appeal No. 1998-2039
Application No. 08/326,806
32. A method of manufacturing windows, including
a window plate and a frame member which is composed of
a thermoplastic synthetic resin material and formed
integrally with the window plate along at least one
edge thereof, said frame member including a lip
section and a web section which are spaced from and
opposed to each other on outer and rear surfaces of
the window plate, respectively, and further including
a bridge section connecting the lip and web sections
with each other, and an ornamental element arranged on
outer surfaces of the lip section, wherein said method
comprises the steps of:
(A) placing at least one edge of the window
plate between a cavity plate and a core plate of an
injection mold, with the ornamental element placed on
the cavity plate, and connecting the cavity plate and
the core plate to each other with said at least one
edge of the window plate clamped therebetween, to
define a mold cavity, having a volume, which
corresponds to the frame member along the clamped edge
of the window plate;
(B) pressurizing and injecting a predetermined
amount of a molten thermoplastic synthetic resin
material into the mold cavity, said predetermined
amount being sufficient to form a frame member with a
continuous hollow inner space;
(C) injecting into the synthetic resin material
within said mold cavity a compressed gas under a
predetermined pressure, from that side of the core
plate which forms part of the web section of the frame
member, thereby causing the synthetic resin material
to flow along the clamped edge of the window plate
forcing the resin against the window plate while
forming a continuous hollow inner space within the
synthetic resin material, said hollow space acting to
reduce the pressure of the resin material against the
window plate;
(D) maintaining said pressure of the compressed
gas thereby urging the synthetic resin material
against surfaces of the mold defining the mold cavity
and against outer and rear surfaces of the window
plate along the clamped edge thereof, while placing
the synthetic resin material under cooling and
solidification conditions in the mold cavity; and
(E) separating the cavity plate and the core
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