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Many people are interested in just how a Northerm
Window is manufactured, and while some of our methods are trade
secrets, this article will attempt to show you the basics of how we
manufacture the Northerm Window.
The basic components of a Northerm Window are:
- Frame & Sash
- Insulated Glass Unit
- Hardware
- Interior Trims
- Exterior Trims
We'll explore the design and manufacture of each of these
components, and their successive assembly into the finished product; a
Northerm Window, 3255 series.
| Frame & Sash | [ TOP ] |
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The main frame and sash are made of vinyl profile.
Profile is made by extruding, or pushing, melted plastic through a
metal die (think of children's play-dough).
This allows us to engineer a raw material that is lightweight,
resistant to rot and age, and that will offer a high thermal
performance once assembled. The thermal performance of the frame is
derived from the multiple insulation chambers, as seen in the
illustration to the left.
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These profiles are cut down on our double pull dual head high speed
profile saw, punched to
accomodate hardware, then welded on our two point vinyl welder. The
welder uses teflon covered hot plates to heat the platic profile to its
melting point, which is then joined with the other sections to form a
rectangular frame.
This framework is allowed to cool, then passed through our cnc
(computer numerically controlled) corner cleaner. The corner cleaner
uses a variety of blades and bits to remove the excess plastic from
around the welded corners. The corners are then individually inspected
for flaws, and a finished cleaning with a hand chisel completes the
frame machining processes.
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Insultherm insulated Glass
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While the frame is being prepared for hardware and
trims, the insulated glass unit is being manufactured in our glass
department. Almost all Northerm Windows are built with our Insul-Therm
insulated glass units. The raw glass is cut, using cut specifications
from our state-of-the-art computerized optimization systems, from
sheets of bulk glass.
These glass lites are inspected, washed, re-inspected, joined with Edgetech Super Spacer,
re-inspected again, filled with argon gas, and finally sealed with
butyl hot-melt sealant. Each unit is then subject to a final quality
inspection. Only once it has passed the fourth and final stringent
inspection will it be cleared for use in the Northerm Window.
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hardware
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| Just prior to the installation of the operating
hardware, each window is fitted with the special rubber seals that will
give the window its trademark Northerm seal.
All operating windows (openers) are assembled with Truth Hardware.
Hardware that is designed to operate correctly with the window's
dimensions and weight is installed, and the window sash and frame are
mated for the first time. Great care is taken during this process to
facilitate an exact fit to create that famous Northerm seal. The
assembled frames are inspected and tested, then passed on to have the
interior and exterior trims fitted and attached.
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Accessories
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The Northerm Window can be accessorized with a
number of different trims, both interior and exterior, that make the
installation and final finishing of the window much easier and cost
effective for the customer.
During the manufacturing process, these are assembled and
attached last, just before the glazing of the insulated glass unit and
final inspection. The Northerm vinyl profiles are engineered with slots
and arrowheads, which facilitate the easy installation of these trims
during manufacture, or even after the window is completed.
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hardware
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| Once all assembly work has been completed and any accessories have been
fitted to the window, the Insul-Therm insulated glass unit is installed
in the window. The glazing process finalizes the assembly of the
Northerm Window, but finished product won't be declared finished until
it passes a 46 point inspection process and is prepped for delivery. |
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Summary
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The finished Northerm Window takes approximately 2
to 6 man hours to manufacture (depending on configuration) and is
inspected 8 times (not counting the inspections during the manufacture
of the Insul-Therm insulated glass unit). When we promise quality we deliver quality! This description of our
manufacturing processes should display the care we take to ensure that each
window we manufacture is of the same high quality as the windows in our
showroom.
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