Description:TECHNICAL FIELD
[0001] The present disclosure relates to the field of fabrications and assembly of doors, windows. More particularly, the present disclosure relates to a seamless weld joint system and method for aluminium doors and windows such as sliding windows and casement windows.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed disclosure, or that any publication specifically or implicitly referenced is prior art.
[0003] Traditional methods for joining aluminium profiles in door and window frames have long relied on mechanical joints, fasteners, and adhesives. While the existing techniques are widely used, and often lead to visible corner joints that interrupt the frame’s aesthetic continuity. In some cases, mechanical joints may also compromise the structural integrity of the frame, leading to issues such as leakage and deterioration of joint. Furthermore, the existing methods require precise alignment during assembly, and even slight deviations can result in defects like uneven surfaces, cracking, or warping. The challenges in existing methods collectively diminish the overall quality of the finished product.
[0004] In modern architectural designs, there is a growing demand for window and door frames that exhibit seamless finishes and robust construction. Clients and designers alike prioritize visual appeal and structural reliability, particularly in high-end projects where flawless aesthetics and long-lasting performance are critical. Unfortunately, traditional joining methods fall short of achieving these goals, especially in terms of delivering uniformity and a seamless appearance. The limitations of mechanical joints and adhesives are particularly apparent in achieving strong and visually integrated corner joints.
[0005] One of the primary disadvantages of the traditional joining methods include lack of seamlessness in the corner joints, which negatively impacts the visual uniformity of the frame. The exposed joints are not only unsightly but also prone to collecting dirt and moisture, leading to long-term issues like corrosion and weakening of the structure. Additionally, the reliance on fasteners and adhesives can introduce inconsistencies in joint strength and alignment. This can result in defects such as warping under load or uneven frame surfaces, reducing the overall reliability of the frame.
[0006] Moreover, the existing methods are less suited to meet the demands of advanced architectural designs, where precision and durability are paramount. Mechanical joints may loosen over time due to temperature fluctuations or vibration, while adhesive joints may degrade when exposed to harsh environmental conditions. The said limitations highlight the need for an advanced approach that addresses both structural and aesthetic shortcomings, such as the innovative seamless weld joint system.
[0007] There is, therefore, a need to overcome the above drawback, limitations, and shortcomings associated with the existing practices, which include a seamless weld joint system for aluminium doors and windows, and method thereof.

OBJECTS OF THE PRESENT DISCLOSURE
[0008] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.
[0009] It is an object of the present disclosure to overcome the above drawback, limitations, and shortcomings associated with the existing mechanisms, and provide a seamless weld joint system and method for aluminium doors and windows such as sliding windows and casement windows.
[0010] It is an object of the present disclosure to provide a seamless weld joint system and method for aluminium doors and windows such as sliding windows and casement windows, which simplifies operations and an installation process, eliminating visible joints and enhancing the structural strength of a frame and paving the way for superior aluminium door and window frames.
[0011] It is an object of the present disclosure to provide a seamless weld joint system and method, which ensures uniformity between a welded joint and adjacent surfaces through sanding, buffing, and surface levelling.
[0012] It is an object of the present disclosure to provide a seamless weld joint system and method, which streamlines an installation process to be labour-efficient and time-effective, enhance durability, aesthetics, and corrosion resistance of the frames using powder coating.

SUMMARY
[0013] The present disclosure relates to the field of fabrications and assembly of doors, windows. More particularly, the present disclosure relates to a seamless weld joint system and method for aluminium doors and windows such as sliding windows and casement windows.
[0014] In an aspect, the present disclosure discloses a method for creating seamless weld joints in aluminium doors and windows. The method may include the step of preassembling and aligning a plurality of aluminium frame profiles comprising at least one of an outer frame and a sash frame, forming pre-assembled weld surfaces using one or more corner connection elements. The method may include the step of cleaning and preparing the pre-assembled weld surfaces. The method may include the step of executing a welding process at the pre-assembled weld surfaces to fuse the outer frame, the sash frame, and a glazing bead frame coupled with the corner connection elements. The method may include the step of attaching the glazing bead frame to the sash frame or the outer frame by mechanical fastening for securing one or more glass panels. The method may include the step of sanding and buffing the one or more welded corner joints to obtain seamless transitions between adjacent surfaces.
[0015] In an embodiment, the one or more corner connection elements may include one or more corner cleats, and one or more corner aligners.
[0016] In an embodiment, the method may include operating the welding process at a pre-defined temperature range.
[0017] In an embodiment, the method may include applying a powder coating layer at a pre-defined thickness range for providing a uniform finishing and corrosion resistance.
[0018] In an embodiment, the method may include facilitating a seamless transition between one or more welded corner joints and one or more adjacent outer frame surfaces through sanding and buffing, resulting in a polished and uniform appearance.
[0019] In an embodiment, the method may include pre-aligning the glazing bead frame with the one or more corner aligners, welded to form a seamless glazing bead frame, and screwed laterally to the sash frame or outer frame for providing retention of glass.
[0020] In an embodiment, the method may include incorporating the one or more corner cleats with one or more precision groove features to interlock with the plurality of aluminium profiles, facilitating mechanical stability and accurate alignment during welding.
[0021] In an embodiment, the method may include preheating a welding electrode to a pre-defined temperature range to reduce thermal stresses and improve weld quality as part of the welding process.
[0022] In an embodiment, the method may include incorporating precision torque-controlled mechanical fastening in the glazing bead frame to prevent deformation or over-tightening of the sash frame, while maintaining its structural and aesthetic integrity.
[0023] In an aspect, the present disclosure discloses a seamless weld joint system for aluminium doors and windows. The seamless weld joint system may include a plurality of aluminium frame profiles configured to form at least one of an outer frame and a sash frame. The system may include one or more corner connection elements that includes one or more corner cleats coupled to the plurality of aluminium frame profiles, and configured with one or more corner aligners to align and reinforce one or more corners during a pre-assembly state. The system may include a glazing bead frame pre-aligned with the one or more corner aligners, welded to form a bead frame coupled to the sash frame, and configured to secure one or more glass panels. The system may include one or more welded corner joints are welded to form the sash frame using a welding process to obtain a unified connections of the one or more welded corner joints. The seamless weld joint system may provide the one or more unified welded corner joints upon obtaining post-welding finishing, comprising at least one of sanding, buffing, and powder coating processes.
[0024] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF DRAWINGS
[0025] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in, and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure, and together with the description, serve to explain the principles of the present disclosure.
[0026] In the figures, similar components, and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label with a second label that distinguishes among the similar components. If only the first reference label is used in the specification, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.
[0027] FIG. 1 illustrates architecture of the proposed modular window and door system assembly of a seamless outer frame and a sash frame, in accordance with an embodiment of the present disclosure.
[0028] FIG. 2 illustrates an exemplary architecture of a window with all visible joints, in accordance with an embodiment of the present disclosure.
[0029] FIG. 3 illustrates architecture of the proposed modular window and door system, featuring a glazing bead frame, a sash frame, and an outer frame, in accordance with an embodiment of the present disclosure.
[0030] FIG. 4 illustrates a flow chart of a method for creating seamless weld joints in aluminium doors and windows, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0031] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit, and scope of the present disclosure as defined by the appended claims.
[0032] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details. Embodiments of this disclosure relate to avatar-based gaming scheme system and method.
[0033] The present disclosure relates to the field of fabrications and assembly of doors, windows. More particularly, the present disclosure relates to a seamless weld joint system and method for aluminium doors and windows such as sliding windows and casement windows.
[0034] In an aspect, the present disclosure discloses a seamless weld joint system for aluminium doors and windows such as sliding windows and casement windows. The system may include a plurality of aluminium frame profiles configured to form at least one of an outer frame and a sash frame. The system may include one or more corner cleats coupled to the plurality of aluminium frame profiles, and configured with corner aligners to align and reinforce one or more corner during a pre-assembly state. The system may include a glazing bead frame pre-aligned with the corner aligners, welded to form a bead frame coupled to the sash frame, and configured to secure one or more glass panels. The system may include one or more welded corner joints are welded to form the sash frame using a welding process to obtain a unified connections of the one or more welded corner joints. The seamless weld joint system may provide the one or more unified welded corner joints upon obtaining post-welding finishing comprising at least one of sanding, buffing, and powder coating processes.
[0035] FIG. 1 illustrates architecture of the proposed modular window and door system assembly of a seamless outer frame 102 and a sash frame (104) after corner welding followed by powder coating, in accordance with an embodiment of the present disclosure.
[0036] Referring to FIG. 1, the seamless weld joint system 100 (also referred as “seamless corner weld joint system 100” or “the system 100”, herein) for aluminium doors and windows of an outer frame 102 and a sash frame 104. The seamless weld joint system 100 may include the outer frame 102, the sash frame 104, and welded corner joints 106. The outer frame 102 may be configured to form the stationary or fixed portion of the window or door, which is typically secured to the building structure. The outer frame 102 may be configured to serves as the primary structural element that houses the sash frame 104. The sash frame 104 may be the movable portion within the outer frame 102 and is designed to hold the glass panel 108. Both the outer frame 102 and the sash frame 104 are fabricated using aluminium profiles that are preassembled and precisely aligned to ensure uniformity in dimensions and strength before welding.
[0037] In an embodiment, the seamless weld joint system 100 may include a plurality of aluminium frame profiles configured to form either or both then outer frame 102 and the sash frame 104. The aluminium profiles serve as the primary structural components of the window or door frame. The system 100 may incorporate one or more corner connection elements that may include one or more corner cleats which may be pre-coupled to the frame profiles during the pre-assembly stage. Further, the one or more corner cleats may be configured with one or more corner aligners to align and reinforce one or more corners during the pre-assembly state. In an embodiment, the one or more corner connection elements may include the one or more corner cleats and the one or more corner aligners. The corner cleats may be incorporated with precision groove features that interlock with the aluminium profiles, providing mechanical stability and ensuring precise alignment prior to welding. The design of the system 100 minimizes misalignment and improves the overall strength of the joint.
[0038] In an embodiment, the system 100 may include a glazing bead frame 302 (refer FIG. 3) which may be coupled to the sash frame 104 to secure glass panels 108. The glazing bead frame 302 may be pre-aligned with the corner aligners and later welded to form a seamless beading frame. After welding, the glazing beads 302 may be fastened to the sash frame 104 using a precision torque-controlled screws 304, which may prevent deformation or over-tightening, preserving the structural and aesthetic integrity of the frame.
[0039] In an embodiment, the system 100 may further include a welding process, specifically Tungsten Inert Gas (TIG) welding, is employed to weld the corner joints 106. The TIG process operates within a pre-defined temperature range of 600°C to 660°C, ensuring precision, preventing warping, and forming uniform, defect-free bonds. A pre-heating step may also be employed, wherein the aluminium profiles are heated to a temperature range of 150°C to 200°C to reduce thermal stresses and enhance weld quality. The TIG welding process may utilize a shielding gas, such as argon or argon-helium mixtures, to prevent oxidation during welding, ensuring superior weld quality and high-strength corner joints 106.
[0040] In an embodiment, post-welding, the system 100 may undergo finishing processes such as sanding, buffing, and powder coating to ensure a seamless transition between the welded joints and adjacent frame surfaces, resulting in a polished, uniform appearance. A powder coating layer, applied at a pre-defined thickness of 60 to 80 microns, provides a durable finish with enhanced corrosion resistance, making the system 100 suitable for various environmental conditions.
[0041] FIG. 2 illustrates an exemplary architecture a seamless weld joint system 200 (e.g., 100 as represented in the FIG.1) for aluminium doors and windows of the outer frame 102 and the sash frame 104 before welding, in accordance with an embodiment of the present disclosure. In an embodiment, the system 200 creates a seamless appearance at the corner of the aluminium doors and windows such as sliding windows and casement windows.
[0042] In an embodiment, referring FIG. 2, the seamless weld joint system 200 to the corner joints, represented as 202-1 and 202-2, are critical to the seamless weld joint system 100. The corner joints 106 may involve the precise alignment of adjoining frame profiles using corner cleats and corner alignment mechanisms to ensure a perfect fit before the welding process. During preassembly, the aluminium profiles of the outer frame 102 and the sash frame 104 may be connected at their corners using temporary mechanical aids such as corner cleats and alignment tools. Thus, the system 100 ensures proper alignment and eliminates gaps or misalignments at the corners before the welding step. Once the alignment is confirmed, the welding process (e.g., the TIG welding) is performed at the joints to fuse the profiles seamlessly. The welded joints form a strong, robust connection, and any unevenness is further addressed using sanding and buffing to achieve a flawless transition between the welded corners and adjacent surfaces.
[0043] In an embodiment, the system 100 may integrate the outer frame 102, the sash frame 104, and preassembled corner joints 106 to deliver a highly durable and aesthetically superior window and door system 100. By ensuring precise alignment and seamless welds at the corners, the system 100 may overcome traditional limitations of mechanical joints, resulting in a polished, continuous finish that enhances both structural performance and visual appeal.
[0044] FIG. 3 illustrates architecture 300 of the proposed modular window and door system 100 with glazing bead, sash frame, and outer frame, in accordance with an embodiment of the present disclosure.
[0045] In an embodiment, the assembly of the glazing bead 302, the sash frame 104, and outer frame involves a meticulous process to ensure a seamless finish and robust structural integrity. Initially, the glazing bead 302 may be pre-aligned with the sash frame 104 using corner alignment tools to guarantee precise positioning. The corners of the glazing bead 302 are then welded together to form a continuous bead frame, ensuring a seamless connection. The welded glazing bead frame is subsequently aligned with the sash frame 104 and securely attached by screwing (e.g., mechanical fastening) it laterally into the sash profile. The dual attachment welding for a seamless appearance and screwing 304 for forming a mechanical joint which ensures that the glazing bead 302 not only provides a flawless finish but also firmly retains the glass within the sash. The combined process enhances both the aesthetic uniformity and functional reliability of the window or door assembly.
[0046] FIG. 4 illustrates a flow chart of a method 400 for creating seamless weld joints in aluminium doors and windows such as sliding windows and casement windows, in accordance with an embodiment of the present disclosure.
[0047] In an embodiment, the method 400 includes the step 402, preassembling and aligning a plurality of aluminium frame profiles comprising at least one of an outer frame 102 (as represented in FIG. 1 and FIG. 2) and a sash frame 104 (as represented in FIG. 1, FIG. 2, and FIG. 3), forming pre-assembled weld surfaces using one or more corner connection elements.
[0048] In an embodiment, the method 400 includes the step 404, cleaning and preparing the pre-assembled weld surfaces.
[0049] In an embodiment, the method 400 includes the step 406, executing a welding process at the pre-assembled weld surfaces to fuse the outer frame 102, the sash frame 104, and the glazing bead frame 302 coupled with the one or more corner connection elements. In an embodiment, the one or more corner connection elements may include one or more corner cleats, and one or more corner aligners.
[0050] In an embodiment, the method 400 includes the step 408, attaching the glazing bead frame 302 (as represented in FIG. 3) to the sash frame 104 or the outer frame (102) by welding and screwing (e.g., the mechanical fastening) for secure glass panels 108 (as represented in FIG. 1 and FIG. 2).
[0051] In an embodiment, the method 400 includes the step 410, sanding and buffing the one or more welded corner joints to achieve seamless transitions with adjacent surfaces for creating seamless weld joints in aluminium doors and windows such as sliding windows and casement windows.
[0052] In an embodiment, the method 400 may include operating the welding process at a pre-defined temperature range. In an embodiment, the method 400 may include applying a powder coating layer at a pre-defined thickness range for providing a uniform finishing and corrosion resistance. In an embodiment, the method 400 may include facilitating a seamless transition between one or more welded corner joints 106 and one or more adjacent outer frame surfaces through sanding and buffing, resulting in a polished and uniform appearance. In an embodiment, the method 400 may include pre-aligning the glazing bead frame 302 with the corner aligners, welded to form a seamless glazing bead frame, and screwed laterally to the sash frame 104 or outer frame 102 for providing retention of glass. In an embodiment, the method 400 may include incorporating the one or more corner cleats with one or more precision groove features to interlock with the plurality of aluminium profiles, facilitating mechanical stability and accurate alignment during welding. In an embodiment, the method 400 may include preheating a welding electrode to a pre-defined temperature range to reduce thermal stresses and improve weld quality as part of the welding process. In an embodiment, the method 400 may include incorporating precision torque-controlled mechanical fastening in the glazing bead frame 302 to prevent deformation or over-tightening of the sash frame 104, while maintaining its structural and aesthetic integrity.
[0053] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0054] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0055] It is to be appreciated by a person skilled in the art that while various embodiments of the present disclosure have been elaborated with the seamless weld joint system for aluminium doors and windows such as sliding windows and casement windows. However, the teachings of the present disclosure are also applicable for other types of applications as well, and all such embodiments are well within the scope of the present disclosure. However, the seamless weld joint system for aluminium doors and windows is also equally implementable in other industries as well, and all such embodiments are well within the scope of the present disclosure without any limitation.
[0056] Accordingly, the present disclosure provides the seamless weld joint system for aluminium doors and windows such as sliding windows and casement windows.
[0057] Moreover, in interpreting the specification, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refer to at least one of something selected from the group consisting of A, B, C….and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
[0058] While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The scope of the disclosure is determined by the claims that follow. The disclosure is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the disclosure when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0059] The present invention provides a seamless weld joint system and method for aluminium doors and windows such as sliding windows and casement windows.
[0060] The present disclosure simplifies operations and the installation process, eliminating visible joints and enhancing the structural strength of the frame and paving the way for superior aluminium door and window frames.
[0061] The present disclosure ensures uniformity between the welded joint and adjacent surfaces through sanding, buffing, and surface levelling.
[0062] The present disclosure streamlines the installation process to be labour-efficient and time-effective, enhance durability, aesthetics, and corrosion resistance of the frames using powder coating.
, Claims:1. A method (400) for creating seamless weld joints in aluminium doors and windows, wherein the method (400) comprises:
preassembling and aligning (402) a plurality of aluminium frame profiles comprising at least one of an outer frame (102) and a sash frame (104), forming pre-assembled weld surfaces using one or more corner connection elements;
cleaning and preparing (404) the pre-assembled weld surfaces;
executing (406) a welding process at the pre-assembled weld surfaces to fuse the outer frame (102), the sash frame (104), and a glazing bead frame (302) coupled with the corner connection elements;
attaching (408) the glazing bead frame (302) to the sash frame (104) or the outer frame (102) by mechanical fastening for securing one or more glass panels (108); and
sanding and buffing (410) the one or more welded corner joints (106) to obtain seamless transitions between adjacent surfaces.
2. The method (400) as claimed in claim 1, wherein the one or more corner connection elements comprise one or more corner cleats, and one or more corner aligners.
3. The method (400) as claimed in claim 1, the method (400) comprising:
operating the welding process at a pre-defined temperature range.
4. The method (400) as claimed in claim 1, the method (400) comprising:
applying a powder coating layer at a pre-defined thickness range for providing a uniform finishing and corrosion resistance.
5. The method (400) as claimed in claim 1, the method (400) comprising:
facilitating a seamless transition between one or more welded corner joints (106) and one or more adjacent outer frame surfaces through sanding and buffing, resulting in a polished and uniform appearance.
6. The method (400) as claimed in claim 2, the method (400) comprising:
pre-aligning the glazing bead frame (302) with the one or more corner aligners, welded to form a seamless glazing bead frame, and screwed laterally to the sash frame (104) or outer frame (102) for providing retention of glass.
7. The method (400) as claimed in claim 2, the method (400) comprising:
integrating the one or more corner cleats with one or more precision groove features to interlock with the plurality of aluminium profiles, facilitating mechanical stability and accurate alignment during welding.
8. The method (400) as claimed in claim 1, the method (400) comprising:
preheating a welding electrode to a pre-defined temperature range to reduce thermal stresses and improve weld quality as part of the welding process.
9. The method (400) as claimed in claim 1, the method (400) comprising:
incorporating precision torque-controlled mechanical fastening in the glazing bead frame (302) to prevent deformation or over-tightening of the sash frame (104), while maintaining its structural and aesthetic integrity.
10. A seamless weld joint system (100) for aluminium doors and windows, the seamless weld joint system (100) comprising:
a plurality of aluminium frame profiles configured to form at least one of an outer frame (102) and a sash frame (104);
one or more corner connection elements comprising one or more corner cleats coupled to the plurality of aluminium frame profiles, and configured with one or more corner aligners to align and reinforce one or more corners during a pre-assembly state;
a glazing bead frame (302) pre-aligned with the one or more corner aligners, welded to form a bead frame coupled to the sash frame (104), and configured to secure one or more glass panels (108); and
one or more welded corner joints (106) are welded to form the sash frame (104) using a welding process to obtain a unified connections of one or more welded corner joints (106),
wherein the seamless weld joint system (100) provides the one or more welded corner joints (106) upon obtaining post-welding finishing, comprising at least one of sanding, buffing, and powder coating processes.