Method of making an insulated window space assembly

Claim 1

A method of making an insulated window spacer assembly comprising: forming a tubular element with a longitudinal inner flat wall having a plurality of transversal grooves; forming a corner piece having two legs joined at a preselected angle, at least one leg having a free end and a flat surface with a plurality of flexible fingers extending outwardly therefrom and obliquely away from said free end, said fingers being spaced at a distance different than the distance separating said grooves, said leg having a cross-sectional external size exceeding a correspondingly shaped tubular element cross-sectional inside size; cutting said tubular element transversally into tubular members of preselected lengths, independently of the positions of said grooves; and joining two of the members by said corner piece by inserting the legs into the members, whereby an interference fit is formed between the one leg and the corresponding member with some of the fingers engaging some of the grooves.

Claim 2

A method of making an insulated window spacer assembly comprising: forming a tubular element with a longitudinal inner flat wall having a plurality of transversal grooves; forming a corner piece having two legs joined at a preselected angle, at least one leg having a free end and a flat surface with a plurality of flexible fingers extending outwardly therefrom and obliquely away from said free end, said fingers being spaced at a distance different than the distance separating said grooves, said leg having a cross-sectional external size exceeding a correspondingly shaped tubular element cross-sectional inside size; cutting said tubular element transversally into tubular members of preselected lengths, independently of the positions of said grooves; and joining two of the members by said corner piece by inserting the legs into the members, whereby an interference fit is formed between the one leg and the corresponding member with some of the fingers engaging some of the grooves.

Claim 6

A method of making an insulated window spacer assembly comprising: forming a tubular element with a longitudinal inner flat wall having a plurality of transversal grooves; forming a corner piece having two legs joined at a preselected angle, at least one leg having a free end and a flat surface with a plurality of flexible fingers extending outwardly therefrom, said fingers being spaced at a distance different than the distance separating said grooves, said leg having a cross-sectional external size exceeding a correspondingly shaped tubular element cross-sectional inside size; cutting said tubular element transversally into tubular members of preselected lengths, independently of the positions of said grooves; and joining two of the members by said corner piece by inserting the legs into the members, whereby an interference fit is formed between the one leg and the corresponding member with some of the fingers engaging some of the grooves to interlock same and prevent separation.

Claim 7

A method of making an insulated window spacer assembly comprising: forming a tubular element with a longitudinal inner flat wall having a plurality of transversal grooves; forming a corner piece having two legs joined at a preselected angle, at least one leg having a free end and a flat surface with a plurality of flexible fingers extending outwardly therefrom, said fingers being spaced at a distance different than the distance separating said grooves, said leg having a cross-sectional external size exceeding a correspondingly shaped tubular element cross-sectional inside size; cutting said tubular element transversally into tubular members of preselected lengths, independently of the positions of said grooves; and joining two of the members by said corner piece by inserting the legs into the members, whereby an interference fit is formed between the one leg and the corresponding member with some of the fingers engaging some of the grooves to interlock same and prevent separation.

Claim 11

A method of making an insulated window spacer assembly comprising: forming a tubular element with a longitudinal inner flat wall having a plurality of transversal grooves; forming a corner piece having two legs joined at a preselected angle, at least one leg having a free end and a flat surface with a plurality of flexible fingers extending outwardly therefrom and said fingers being spaced at a distance different than the distance separating said grooves, said leg having a cross-sectional external size exceeding a correspondingly shaped tubular member cross-sectional inside size; cutting said tubular element transversally into tubular members of preselected lengths, independently of the positions of said grooves; and joining two of the members by said corner piece by inserting the legs into the members with the fingers extending obliquely away from said free end, whereby an interference fit is formed between the one leg and the corresponding member with some of the fingers engaging some of the grooves.

Claim 12

A method of making an insulated window spacer assembly comprising: forming a tubular element with a longitudinal inner flat wall having a plurality of transversal grooves; forming a corner piece having two legs joined at a preselected angle, at least one leg having a free end and a flat surface with a plurality of flexible fingers extending outwardly therefrom and said fingers being spaced at a distance different than the distance separating said grooves, said leg having a cross-sectional external size exceeding a correspondingly shaped tubular member cross-sectional inside size; cutting said tubular element transversally into tubular members of preselected lengths, independently of the positions of said grooves; and joining two of the members by said corner piece by inserting the legs into the members with the fingers extending obliquely away from said free end, whereby an interference fit is formed between the one leg and the corresponding member with some of the fingers engaging some of the grooves.