[0001] The present teachings relate generally to fenestration assemblies. More particularly, the present teachings relate to systems and methods for assembling fenestration assemblies that effectively secure substrates, such as energy-efficient window films.

BACKGROUND

[0002] Fenestration refers to products that fill openings in a building envelope, such as windows, doors, skylights, curtain walls, etc., and are designed to permit the passage of air, light, vehicles or people through the building envelope. A building envelope, in turn, generally refers to the separation between the interior and the exterior environments of a building. It serves as the outer shell that protects the indoor environment, as well as facilitates climate control of the indoor environment.

[0003] In order to increase a building's energy efficiency, and to decrease the loads on a building's air conditioning and heating systems, fenestration assemblies are used to cover the interior of a building's window with a transparent window film. A combination of the window and the film is referred to herein as a "window/film combination." By way of example, using such a window/film combination in the winter season causes interior light to reflect back inside, trapping a relatively greater amount of heat inside the building envelope. Conversely, in the summer season, a relatively large amount of exterior light is reflected back to the exterior of the building, allowing cooler temperatures to prevail inside the building envelope.

[0004] What is therefore needed are systems and methods of assembling energy-efficient fenestration assemblies that reduce the load on air conditioning units regulating the temperature inside the building envelope in an economical, time-efficient and effective manner.

SUMMARY OF THE INVENTION

[0005] In one aspect, the present teachings disclose a system for building a fenestration assembly. The system include: (i) a table having at least one raised edge that is raised from a table surface of the table and that facilitates decambering of one or more cambered sides of a frame to form one or more decambered sides of the frame; and (ii) one or more presser subassemblies arranged along at least one of the raised edges such that when a sufficient amount of force is received by one or more of the presser sub-assemblies, the force is transferred from one or more of the presser sub-assemblies to a segment for engaging and/or mating the segment with one of the decambered sides of the frame to form one side of the fenestration assembly.

[0006] In another aspect, the present teachings disclose a system for building a fenestration assembly. The system includes: (i) a table including a table surface that secures a frame; (ii) one or more presser sub-assemblies arranged along or on the table surface, one or more of the presser sub-assemblies including a decambering component that secures and decambers a segment having a cambered profile to form a decambered segment; and wherein when a sufficient amount of force is received by one or more of the presser sub-assemblies, the force is transferred from the presser sub-assemblies to the decambered segment for engaging and/or mating the decambered segment with one side of the frame to form a decambered, engaged and/or mated arrangement of the fenestration assembly.

[0007] In yet another aspect, the present teachings disclose a process for building a fenestration assembly. The process includes: (i) obtaining a frame including one or more sides, each side having a cambered profile along at least one plane; (ii) obtaining one or more segments, each of which includes a cambered profile along a plane that is substantially similar or parallel to at least one of the planes of the sides of the frame; (iii) positioning a substrate between the frame and one or more of the segments; (iv) decambering at least one side of the frame to form at least one decambered side of the frame; (v) decambering one or more of the segments to form one or more decambered segments; and (vi) engaging and/or mating one or more of the decambered segments with at least one of the decambered sides of the frame to secure the substrate between one or more of the decambered segments and at least one of the decambered sides of the frame such that the substrate extends along a plane that is substantially similar or parallel to at least one of the planes of the sides of the frame and forms at least one decambered, engaged and/or mated side of the fenestration assembly.

[0008] In yet another aspect, the present teachings disclose another process for building a fenestration assembly. The process includes: (i) obtaining a frame including one or more sides; (ii) obtaining one or more segments, at least one of which includes a cambered profile along a plane; (iii) positioning a substrate between the frame and one or more of the segments; (iv) decambering one or more of the segments to form one or more decambered segments; and (v) engaging and/or mating one or more decambered segments with at least one of the sides of the frame to secure the substrate between one or more decambered segments and at least one of the sides of the frame such that the substrate extends along a plane that is substantially similar or parallel to the plane of the frame and forms a decambered, engaged and/or mated side of the fenestration assembly.

[0009] In yet another aspect, the present teachings disclose another process for building a fenestration assembly. The process includes: (i) obtaining a frame including one or more sides, each side having a cambered profile along at least one plane; (ii) obtaining one or more segments; (iii) positioning a substrate between the frame and one or more of the segments; (iv) decambering one or more sides of the frame to form one or more decambered sides of the frame; and (v) engaging and/or mating one or more of the segments with one or more of the decambered sides of the frame to secure the substrate between one or more of the segments and one or more decambered sides of the frame such that the substrate extends along a plane that is substantially similar or parallel to the plane of the frame and forms a decambered, engaged and/or mated side of the fenestration assembly.

[0010] In yet another aspect, the present teachings disclose another process for building a fenestration assembly. The process includes: (i) obtaining a frame including one or more sides, at least one of which includes a cambered profile along a plane; (ii) decambering at least one of the sides of the frame to form at least one decambered side of the frame; and (iii) securing a substrate on at least one decambered side of the frame such that the substrate contacts and/or adheres to at least one decambered side of the frame and extends along a plane that is substantially similar or parallel to the plane of the frame and forms a decambered, engaged and/or mated side of the fenestration assembly.

[0011] In yet another aspect, the present teachings disclose a fenestration assembly. The fenestration assembly includes: (i) a frame including one or more sides that are capable of engaging and/or mating; (ii) one or more segments engaging and/or mating with one or more sides of the frame to form one or more sides of the fenestration assembly in a tensioned state such that a tension is directed along a plane that extends along a length of one or more sides of the fenestration assembly; and (iii) a substrate disposed between the frame and one or more of the segments in a tensioned state, such that a tension in the substrate extends along a plane that is parallel or at an angle that is less than 25° relative to a plane of the side of the fenestration assembly, as one or more of the segments engage and/or mate with one or more of the sides of the frame.

[0012] In yet another aspect, the present teachings disclose another fenestration assembly. The fenestration assembly includes: (i) a frame including one or more sides, at least one of which includes a cambered profile along a plane; and (ii) a substrate disposed on the frame such that the substrate contacts and/or adheres to at least one cambered side of the frame and extends along a plane that is substantially parallel to or at an angle that is less than 25° relative to the plane of the cambered side of the frame.

[0013] In yet another aspect, the present teachings disclose another fenestration assembly. The fenestration assembly includes: (i) a frame including frame features and/or components that are capable of engaging and/or mating; (ii) one or more segments including segment features and/or components engaging and/or mating with the features and/or the components of the frame to form an engaged and/or mated frame and segment arrangement; (iii) a substrate disposed inside the engaged and/or mated frame and segment arrangement, which has defined therein an off-center serpentine substrate path that is positioned a certain distance away from an approximate midpoint between a non-mating edge of the frame and a non-mating edge of the segment.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 shows a side-sectional view of a tensioner segment, according to one embodiment of the present arrangements and that is used to grip and apply tension to a substrate.

[0015] Figure 2 shows a side-sectional view of a base frame, according to one embodiment of the present arrangements and that is used to secure a substrate when one example of a present fenestration assembly is in an assembled state.

[0016] Figure 3 shows a side-sectional view of a fenestration assembly, according to one embodiment of the present arrangements, in an assembled state and having secured thereon a substrate.

[0017] Figure 4 shows a top view of a fenestration assembly table, according to one embodiment of the present arrangements, for engaging and/or mating a segment (e.g. , a tensioner segment or a segment of a base frame) to a frame (e.g. , a base frame or a tensioner frame) to form the present fenestration assemblies.

[0018] Figure 5 shows a side view of another fenestration assembly table, according to another embodiment of the present arrangements, for engaging and/or mating a segment to a frame to form the present fenestration assemblies.

[0019] Figure 6 shows a detailed side view of the fenestration assembly table of Figure 5 and that has secured thereon a base frame and a tensioner segment in accordance with one embodiment of the present arrangements.

[0020] Figure 7A shows a side- sectional view of a presser sub-assembly, according to one embodiment of the present arrangements and that includes a beam having a tray region in an orientation that faces away from a fenestration assembly table (e.g. , fenestration assembly table of Figure 6).

[0021] Figure 7B shows a side-sectional view of a presser sub-assembly, according to one embodiment of the present arrangements and that includes the tray region as shown in Figure 7A, but in an orientation that faces towards the fenestration assembly table (e.g. , fenestration assembly table of Figure 6).

[0022] Figure 8 shows a top view of a yet another fenestration assembly table, according to one embodiment of the present arrangements, for engaging and/or mating a segment to a portion of a frame.

[0023] Figure 9 shows a top view of another fenestration assembly table, according to one embodiment of the present arrangements, for engaging a tensioner segment to a portion of a base frame. [0024] Figure 10A shows a top view of a cambered frame, according to one embodiment of the present arrangements.

[0025] Figure 10B shows a top view of cambered segments, according to one embodiment of the present arrangements and that engage and/or mate with the cambered frame of Figure 10A.

[0026] Figure 11 shows an exemplar fenestration assembly of Figure 10B, according to one embodiment of the present arrangements, having secured therein a window film and in a tensioned state.

[0027] Figure 12A shows a side-sectional view of a fenestration assembly, according to one embodiment of the present arrangements, in a tensioned state and including a substrate disposed parallel to a plane that extends a length of two opposite sides of the fenestration assembly.

[0028] Figure 12B shows a side-sectional view of a fenestration assembly, according to another embodiment of the present arrangements, in a tensioned state and including a substrate disposed along a plane that is positioned at an angle relative to a plane that extends a length of at least one side of the fenestration assembly.

[0029] Figure 13 is a flowchart showing a process, according to one embodiment of the present teachings, for assembling a fenestration assembly (e.g. , using and without using any one of the present fenestration assembly tables).

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0030] In the following description numerous specific details are set forth in order to provide a thorough understanding of the present teachings. It will be apparent, however, to one skilled in the art that the present teachings may be practiced without limitation to some or all of these specific details. In other instances, well known process steps have not been described in detail in order to not unnecessarily obscure the present teachings.

[0031] The present teachings provide novel fenestration assembly designs. The present teachings further provide novel methods of making fenestration assemblies. Further still, the present teachings provide fenestration assembly tables for simultaneously assembling one or more of the present fenestration assemblies, each including substrates, such as a window film. The present fenestration assemblies may be used in connection with a building envelope for energy efficiency applications. When installed, certain embodiments of the present fenestration assemblies provide significant reduction in transmission of heat through a building's opening or a window frame cavity during different seasons. These embodiments therefore provide the advantage of increased energy efficiency and decreased loads on a building's heating and air conditioning systems.

[0032] As mentioned above, the present teachings also offer processes for assembling such fenestration assemblies using fenestration assembly tables, according to the present arrangements. In certain embodiments of the present teachings, fenestration assembly tables are used to facilitate engaging and/or mating of a segment (e.g. , a tensioner segment (sometimes herein referred to as a "tensioner")) into a corresponding receiving side of a frame (e.g. , a base frame). In an engaged and/or mating configuration, a substrate, disposed between the segment and the frame, is firmly secured therebetween. In one embodiment of the present arrangements, a window film serves as the substrate, and in these embodiments, the window film may be sufficiently taut, as well as wrinkle-free near the corners of a fenestration assembly. As a result, the fenestration assemblies according to the present arrangement give an appearance that resembles a glass window, and not a plastic substrate.

[0033] The fenestration assemblies, according to one embodiment of the present teachings, include a substrate and a frame (e.g. , a base frame as described in Figure 2 or a tensioner frame as described in Figure 1). In accordance with certain embodiments of the present teachings, fenestrations assemblies include a tensioner, a substrate and a base frame. In this embodiment, the substrate is positioned between the tensioner and the base frame as shown in Figure 3.

Furthermore, the substrate is positioned along a plane (e.g. , a "viewing area" plane that is visible to an observer when the present fenestration assemblies are in an assembled and installed state) that is the same as or substantially parallel to a plane of the fenestration assembly, as explained below.

[0034] Figure 1 shows a side-sectional view of a tensioner 100, according to one embodiment of the present arrangements. In the present fenestration assemblies, tensioner 100 is designed for gripping and applying tension to a substrate (denoted by reference numeral 316 in Figure 3).

[0035] Tensioner 100 includes a first endcap 102 disposed at a first end and a second endcap 108 disposed at a second end, which is opposite the first end. A first nipple 104b represents a protruding portion of tensioner 100 and is located proximate to a middle region of the tensioner. A second nipple 104a represents another protruding portion of tensioner 100 and is located between first nipple 104b and first endcap 102. At the other end of tensioner 100, a protruding male member 106 is disposed adjacent to second endcap 108. Like nipples 104a and 104b, male member 106 may also be a protruding portion of the tensioner, except it may protrude to a greater extent than nipples 104a and 104b. In one embodiment of the present arrangements, male member 106 protrudes from about two times to about three times the distance nipples 104a and/or 104b protrude from a mating edge of tensioner 100 (e.g. , mating edge 324 of Figure 3 below). The mating edge, as the term is used herein, refers to the edge that is proximate to the mating configuration inside the present fenestration assemblies. [0036] Endcaps 102 and 108 are designed to cap tensioner 100 at each end. The function of first endcap 102 and second endcap 108, in certain embodiments of the present arrangements, is aesthetic, i.e. , providing smooth sides that are more pleasing to a viewer when the present fenestration assemblies are installed to cover an opening or a window frame cavity.

[0037] As will be explained below, tensioner components, such as nipples 104a and 104b and male member 106, form parts of a serpentine path. In one embodiment of the present arrangements, base frame components, such as a tension enhancer portion and a female region, both of which are described in greater detail in connection with Figure 2, engage and/or mate with components of tensioner 100 to define a serpentine path inside the present fenestration assemblies. Tensioner 100 need not include any specific number of nipples and male members; rather, the present teachings contemplate use of an appropriate number of these components to adjust a tension in the substrate to desired levels.

[0038] Although the embodiment of Figure 1 shows nipples 104a and 104b and male member 106 each extending at an approximately 90 angle from the mating edge of tensioner 100, the present teachings recognize that these components may extend from the mating edge of tensioner 100 at any angle, including an angle that is not 90 .

[0039] As shown below with reference to the embodiment of Figure 3, in an engaged state of the present fenestration assemblies, at least a portion of protruding male member 106 locks a substrate into a corresponding female cavity region (e.g. , denoted by reference numeral 208 in Figure 2). To facilitate an effective engaged configuration of the present fenestration assemblies, male member 106, as shown in Figure 1, may include indentations on at least one edge that engage with a serrated surface of the female region. In certain embodiments of the present teachings, the indentations so formed are jagged edges that are angled at approximately 45 . In other embodiments of the present arrangements, male member 106 is fabricated without indentations.

[0040] Figure 2 shows a side-sectional view of a base frame 200, according to one embodiment of the present arrangements, which engages with a corresponding tensioner (e.g. , tensioner 100 of Figure 1). Base frame 200 includes an endcap 202 disposed at a first end and includes a compressible material track 210 at the opposite end. On a first side of base frame 200, a viewing area 206 is disposed. A "viewing area," as the term is used herein, refers to a viewable area of the fenestration assembly on the room side when the present fenestration assemblies are installed to cover an opening or a window frame cavity. On an opposite area of base frame 200 that is across from viewing area 206, a female region 208, a slope region 204 and a tension enhancer 210 are provided to engage and/or mate with corresponding features of tensioner 100 of Figure 1. [0041] Female region 208 comprises a cavity that may be thought of as a "valley" and that is capable of receiving at least a portion of a male member of a tensioner (e.g. , male member 106 of tensioner 100 of Figure 1). As mentioned above, at least one side of the inner surface of female region 208 is serrated.

[0042] In an assembled state of the present fenestration assemblies, tension enhancer 210 pushes a portion of a secured substrate toward a portion of tensioner 100 that is between nipples 104a and 104b, creating additional tension in the substrate. Although Figure 2 shows one tension enhancer 210, the present teachings contemplate use of any number of tension enhancers to increase window film tension to desired levels. In an alternate embodiment of the present teachings, however, a tension enhancer 210 is not used.

[0043] A slope region 204 is a sloping portion of base frame 200 that slopes inwardly, and towards viewing area 206 at an angle that is approximately 45 relative to a plane that intersects and extends a length of tape bed area 205. In an assembled state of the present fenestration assemblies, nipple 104b is positioned at a location proximate to an end of slope region 204 that is closer to viewing area 206. Nipple 104b may protrude outwardly from the mating edge of tensioner 100 at a distance that is slightly larger than the distance sloping region 204 slopes inwardly towards viewing area 206. As a result, a substrate positioned between nipple 104b and an area on the base frame defined by sloping region 204 is effectively locked into place.

[0044] As shown in Figure 2, viewing area 206 spans a certain length between two ends of base frame 200. In an assembled and installed configuration of the present fenestration assemblies, viewing area 206 may be visible to a building occupant. In an alternate embodiment of the present arrangements, however, a backside of the tensioner is a portion of a fenestration assembly that is visible to the building occupant and therefore, may be thought of as the viewing area.

[0045] Endcap 202 is designed to cap base frame 200 at a first end. Though the embodiment of Figure 2 shows endcap 202 with an L-shaped configuration, alternate embodiments of the present arrangements use varying shapes of endcap 202. By way of example endcap 202 may be configured as a straight edge.

[0046] Compressible material track 210 is designed to house a compressible material therein. The presence of this material allows the present fenestration assemblies to be effectively installed and removed. Consequently, the present teachings provide a high-throughput installation process for easy maintenance of the present fenestration assemblies.

[0047] Tensioner 100 of Figure 1 and base frame 200 of Figure 2 are composed of a rigid material capable of stabilizing a substrate that is being installed in a window frame cavity as part of the present fenestration assemblies. Representative materials to make tensioner 100 and base frame 200 include at least one member chosen from a group comprising aluminum, steel, graphite, plastic, glass, wood and composites.

[0048] According to one embodiment of the present arrangements, each of tensioner 100 and base frame 200 are fabricated as contiguous structures. In an alternate embodiment of the present arrangements, however, one or more parts, regions or portions of tensioner 100 or base frame 200 are fabricated separately as components and then attached to the tensioner or base frame structure. By way of example, a male member (e.g. , male member 106 of Figure 1) may be fabricated separately from the other component parts of tensioner 100 of Figure 1, and is then connected to tensioner 100 by any method known to those skilled in the art. In such

embodiments, separate parts may be fabricated using different materials.

[0049] Figure 3 shows a side-sectional view of one side of a fenestration assembly 300, according to one embodiment of the present arrangements. Fenestration assembly 300 includes a tensioner 100' that is engaged or in a mating position with a base frame 200' such that a substrate 316 is disposed therebetween. Tensioner 100', base frame 200', male member 306, nipples 304a and 304b, female region 308 and tension enhancer 310 are substantially similar to their counterparts, tensioner 100 of Figure 1, base frame 200 of Figure 2, male member 206 and nipples 104a and 104b of Figure 1, and female region 208 and tension enhancer 210 of Figure 2, respectively. Figure 3 also shows a non-mating edge 320 and a mating edge 324 of tensioner 100', and a non-mating edge 326 and a mating edge 328 of base frame 200'.

[0050] Figure 3 shows that nipples 304a and 304b are separated by a distance, "d," along mating edge 324 of tensioner 100'. In an engaged and/or mated state of the present fenestration assemblies, tension enhancer 310 pushes substrate 316 towards a region on tensioner 100' that is relatively equidistant between nipples 304a and 304b (i.e. , at a location that is about ½ of distance, d, between each nipple). In this state, male member 306 also occupies a female region 308. Figure 3 shows that various engaging and/or mating locations, inside one side of the present fenestration assemblies, define a serpentine pathway of the substrate in this state. In accordance with one embodiment of the present arrangements, substrate locations in and around where male member 306 mates with female region 308, substrate locations where tension enhancer 310 engages with nipples 304a and 304b, and substrate locations near the slope region of base frame 200', define the serpentine path.

[0051] When engaging and/or mating one segment and/or one side of a base frame to form a first side of a fenestration assembly, male member 306 completely mates with female region 308. During such a mating step, male member 306 forces substrate 316 into female region 308 from locking points 312 and 318 to a completely mated state. At locking points 312 and 318, male member 306 is able to effectively grab substrate 316, preventing substrate 316 from slipping along the male member's surface (as male member 306 drives substrate 316 into female region 308). During the same mating step, the engaging and/or mating force that drives tensioner 100' towards base frame 200', coupled with the relatively short distance, about d/2, between tensioner enhancer 310 and each of nipples 304a and 304b, effectively introduce crimps or creases on a substrate surface. As the present fenestration assembly process moves to engaging and/or mating another segment and/or an opposite side of the base frame to form a second side of the fenestration assembly, locking points 312 and 318 of the first side and the opposite side of the fenestration assembly serve to introduce a certain level of tension within substrate 316. Crimps or creases produced at nipples 304a and 304b and tension enhancer 310 of the first side and the opposite side of the fenestration assembly provide an enhanced level of tension within substrate 316. The enhanced level of tension introduced by virtue of nipples 304a and 304b and tension enhancer 310 is a greater level of tension than that produced by mating of male member 306 and female region 308. The present teachings recognize that in this manner, other similar features may be introduced along the serpentine pathway to engineer the tension in the substrate to desired levels that are even higher.

[0052] Substrate 316 used in fenestration assembly 300 may be glass or film. In one embodiment of the present teachings, substrate 316 is a window film, and more preferably, transparent window film, that increases a window's energy-efficiency and is capable of being secured by the present fenestration assemblies. By way of example, Silver 35, which is commercially available from 3M Corporation of Minneapolis, Minnesota, may be used. In alternate embodiments of the present arrangements, substrate 306 may be a translucent window film or an opaque window film that increases a window's energy-efficiency and is capable of being secured by the present fenestration assemblies. To the extent transparent window films and/or glass are used as substrates in the present fenestration assemblies, those with low emissivity coatings represent a preferred embodiment of the present teachings. By way of example, emissivity values (i.e. , a ratio of heat emitted compared to a blackbody) for these coatings are typically between about 0.02 and about 0.98.

[0053] In one embodiment of the present arrangements, substrate 316 may be any thickness so long as it can be secured inside a frame or a present fenestration assembly and it is not too flimsy. In certain embodiments of the present arrangements, the thickness of substrate 316 depends on the dimensions of the window that is ultimately covered by a frame or a present fenestration assembly. In one embodiment of the present arrangements, however, substrate 316 is between about 1 mm and about 30 mm in thickness. In a preferred embodiment of the present arrangements, substrate 316 is between about 6 mm and about 12 mm in thickness, and in an even more preferred embodiment of the present arrangements, substrate 316 is between about 8 mm and about 10 mm in thickness.

[0054] In certain embodiments of the present teachings, d (a distance between two nipples 304a and 304b) scales with a thickness of substrate 316. In other words, a relatively thicker substrate requires a relatively longer distance, d, to fit a substrate along a serpentine path defined by nipples and/or a tensioner enhancer. By way of example, d equals about ¼ inch for a film that is about 9 mm thick.

[0055] In one embodiment of the present arrangements, a fully mated position of male member 306 within female region 308 requires a head portion (shown to be protruding by a distance, "1") to be forced proximate to the end of female region 308. In this position, nipples 304a and 304b and tension enhancer 310 are also fully engaged, as shown in Figure 3. In this embodiment, however, when the head portion is not proximate to the end of female region 308, nipples 304a and 304b and tension enhancer 310 are also not fully engaged. In this partial mating stage, the serpentine pathway is not yet defined. In an alternate embodiment of the completely mated stage of the present teachings, the serpentine pathway is defined when nipples 304a and 304b and tension enhancer 310 are fully engaged and protrude a distance, 1, from mating edge 324 of tensioner 100'.

[0056] In certain embodiments of the present arrangements, nipples, tension enhancers and other such features on the tensioner and base frame are not necessary. In fact, the present teachings provide fenestration assembly designs that have features other than nipples and a tension enhancer. To this end, in accordance with certain embodiments of the present arrangements, a fenestration assembly includes: (i) a frame (e.g. , base frame or tensioner frame) having frame components; (ii) a segment (e.g. , tensioner or segment of base frame) having segment components that engage and/or mate with the frame components to define an off-center serpentine channel that is disposed a certain distance away from a centerline (e.g. , denoted by reference numerals 1208 and 1210 in Figures 12A and 12B, respectively). The centerline, as the term is used herein, refers to a line that represents a midpoint between a distance between a non- mating edge of the frame (e.g. , non-mating edge 326 of Figure 3) and a non-mating edge of the segment (e.g. , non-mating edge 320 of Figure 3) in an assembled configuration of the present fenestration assemblies. According to the present teachings, it is believed that an off-center serpentine path configuration inside the present fenestration assemblies (e.g. , fenestration assembly 300 of Figure 3) strengthens it, allowing it to withstand a greater amount of tension than if it had a serpentine path that was disposed along its centerline.

[0057] Although Figure 3 shows tensioner 100', in the form of a segment, engaging and/or mating with one side of base frame 200', the present fenestration assemblies are not so limited. In those embodiments of the present fenestration assemblies where a tensioner is used, it may be in the shape of a frame (i.e. , a tensioner frame). Furthermore, in this embodiment, a segment of a base frame may engage and/or mate with one side of the tensioner frame. As a result, a frame, as the term is used herein, refers to either a base frame or a tensioner frame, and a segment, as the term is used herein, refers to either a tensioner (in segment form) or a segment of a base frame. Moreover, a frame may be fabricated in the shape of a closed frame (e.g. , in the shape of a square, rectangle, or the like), and a segment may be fabricated in complementary fashion such that one segment engages and/or mates with one side of the base frame.

[0058] Regardless of the mating configuration, other optional features, such as a cambered profile described below, allow the present fenestration assemblies to withstand a relatively significant amount of tension in the substrate surface. In an unassembled state of one embodiment of the present fenestration assemblies, at least one or each of a frame and a segment has a cambered profile that extends along a plane that is substantially similar or parallel to a plane along which substrate 316 extends inside fenestration assembly 300 of Figure 3. In one embodiment of the present arrangements, a cambered profile is non-linear (i.e. , not 180°) along a length of at least one side of the frame or a length of one or more of the segments. In another embodiment of the present arrangements, the cambered profile includes a bend in one direction. In yet another embodiment of the present arrangements, the cambered profile includes a curvature in one direction.

[0059] A process of building a fenestration assembly may include decambering the frame and/or the segment, as the case may be. Accordingly, decambering refers to removing or reducing a cambered profile of the frame and/or the segment. By way of example, one step of the present teachings includes decambering tensioner 100' and/or base frame 200' along a plane that is substantially similar or parallel to a plane along which substrate 316 extends inside fenestration assembly 300. After decambering of the frame and/or the segment, substrate 316 is applied to one or both of the frame and/or segment. In one embodiment of the present teachings, substrate 316 is applied to a decambered frame, and the frame is released so that it may go back to a cambered state. In another embodiment of the present teachings, if the substrate is secured between the segment and the frame, as shown in Figure 3, the decambered frame and/or decambered segment may engage and/or mate with each other. In certain preferred embodiments of the present teachings, engaging and/or mating of frame and segment features and/or components occur in a direction that is perpendicular to the direction of camber. In a next step, releasing tensioner 100' and base frame 200' from their decambered states after they are in an engaged and/or mating position produces additional tension in the substrate. This is due to tensioner 100' and base frame 200', or the entire assembled structure of the tensioner and base frame, gripping and pulling the substrate in different directions, as the tensioner and base frame resist being maintained in their decambered states. This is referred to as a "tensioned state" of a fenestration assembly, and this "tensioned state" may be thought of as producing a tension in the gripped substrate that is along the same plane as the cambered profiles of the sides of a frame and/or of one or more segments. Accordingly, this "tensioned state" associated with fenestration assemblies of the present teachings provides systems and methods that produce a more taut and glare-free substrate, secured by the component parts of a fenestration assembly, due to the additional tension generated thereon.

[0060] In certain embodiments of the present arrangements, a tensioned state of a fenestration assembly produces a slight camber in one or more sides of a fenestration assembly that is less than a cambered profile of the frame side and/or the segment prior to engaging and/or mating. According to such embodiments, forces associated with a frame and segment resisting being maintained in their decambered states are sufficient to cause a slight bend in a side or sides of a fenestration assembly. In other words, after a force causing decambering of a frame or a segment is removed after engaging and/or mating with a corresponding frame or segment, a slight camber returns to the component parts of a fenestration assembly (e.g. , a frame and one or more segments). According to one embodiment of the present arrangements, a segment is rotatably coupled to a side of a base frame using a hinge connection.

[0061] According to certain embodiments of the present arrangements, a frame and segments are configured as discrete structures prior to engaging and/or mating. According to an alternate embodiment of the present arrangements, however, a frame and one or more segments are fabricated such that one or more segments is rotatably coupled to one or more sides of a frame. According to such embodiments, a segment is rotated relative to the side of the frame until the segment is placed in a mated and/or engaged configuration with the side of the frame.

[0062] Length and thickness of various regions of a side of frame and a segment may vary according to such parameters as degree of camber and strength of materials used. In one embodiment of the present arrangements, a length of a tape bed area (e.g. , tape bed area 205 of Figure 2) and/or a substrate bed (i.e. , a serrated region along tensioner 100' in Figure 3 that extends between male member 306 and nipple 304b) scales with an extent of camber and depends on the strength of materials used to make a base frame and tensioner segments. In another embodiment of the present teachings, a thickness associated with a base frame and/or tensioner segments scales with a degree of camber and the thickness of the substrate used.

[0063] Figure 4 shows a top view of a fenestration assembly table 400, according to one embodiment of the present arrangements, for assembling one or more sides of a fenestration assembly (e.g. , fenestration assembly 300 of Figure 3). According to certain embodiments of the present teachings, table 400 may be used to decamber a frame (e.g. , base frame 200 of Figure 2) and/or one or more segments (e.g. , tensioner 100 of Figure 1) along a plane that is substantially similar or parallel to a plane along which the substrate extends inside the present fenestration assemblies. As explained in further detail below, a segment is engaged and/or mated to one side of a base frame to form one side of a fenestration assembly.

[0064] Table 400 includes a table surface 404 with a first raised edge 402a on one side (shown in an X-direction) and a second raised edge 402b on another side shown (shown in a Y- direction). Table surface 404 provides a sufficiently large area, adjacent to and perpendicular to raised edges 402a and/or 402b, to immobilize a side of a frame (e.g. , a base frame or a tensioner frame) that will be mated and/or engaged to a segment (e.g. , a base segment or a tensioner segment).

[0065] In the configuration of Figure 4, raised edges 402a and 402b are substantially perpendicular to each other. One or more presser sub-assemblies 406 are shown disposed along raised edge 402a. In another embodiment of the present arrangements, one or more presser sub- assemblies 406 are disposed along raised edge 402b. Regardless of whether they are disposed along one raised edge or more than one raised edge, presser sub-assemblies 406 may be designed for pressing the segment to one side of the frame. "Pressing," as the term is used herein, conveys the concept of supplying a sufficiently large amount of force to engage and/or mate a segment to a side of a frame.

[0066] Raised edges 402a and 402b are portions of assembly table 400 that may extend perpendicularly upward from table surface 404. Raised edges 402a and 402b provide stable edges, each of which may receive a side of a base frame or a tensioner for securing and/or decambering. Raised edges 402a and 402b may be thought as components that facilitate squaring, or decambering in one direction, the sides of a frame or a segment during a process of assembling the fenestration assemblies of the present teachings.

[0067] During an assembly process of a fenestration assembly, in accordance with one embodiment of the present teachings, a pressure sufficient to decamber a side of a frame is applied. An amount of a pressure sufficient to decamber a frame side is relative to certain factors, including but not limited to component materials of a frame, an amount of camber with which a frame side is configured, and the length and/or width of a frame side.

[0068] In the context of Figure 4, a frame may horizontally rest on table surface 404 of table 400. Two of the frame sides may be decambered, i.e. , forced to be substantially linear or not cambered to an original extent, by pushing one side of the frame against raised edge 402a, which facilitates decambering in a Y-direction, and pushing an adjacent or opposite side of the frame against raised edge 402b, which facilitates decambering in an X-direction. The decambering force may be applied to one side of the frame for a sufficiently long period of time until that side engages and/or mates with the segment. Next, the frame and the segments in their engaged and/or mated state are released from the pressure of the decambering forces, producing a fenestration assembly in a tensioned state.

[0069] In certain embodiments of the present arrangements, raised edges 402a and 402b may be disposed adjacent to a recessed region. One or both of raised edges 402a and 402b may function in conjunction with the recessed region to secure and/or decamber one or more sides of the fenestration assemblies. Although the embodiment of Figure 4 shows two raised edges 402a and 402b, in alternate embodiments of the present arrangements, any number of raised edges is used.

[0070] Table surface 404 is made from a material (e.g. , metal and wood) that ensures the stability of table 400 when a sufficient amount of force is delivered on the sides of the frame to mate and/or engage with the corresponding segment. In certain embodiments of the present arrangements, table surface 404 does not span an entire length and/or an entire width of table 400. In other embodiments of the present arrangements, however, table surface 404 includes a platform region that extends from a bottom region of a raised edge toward a center region of table 400. This platform region may extend a distance sufficient to support a side of a frame when table 400 is being used to assemble a fenestration assembly according to the present teachings, and in such manner, may be thought of as the entire table surface. Preferably, the platform region extends to a distance that abuts a rail that may also secure a portion of a frame (e.g. , as shown below with respect to a platform region of table surface 604, rail 624 and base frame 604 of Figure 6).

[0071] As shown in the embodiment of Figure 4, raised edges 402a and 402b are perpendicular with respect to each other and intersect at a corner of table surface 404. When such embodiments are being used to assemble the present fenestration assemblies, two corner sides of a frame may be simultaneously decambered using raised edges 402a and 402b in the same manner as described above. Likewise, in those embodiments where more than two raised edges are disposed on the perimeter of a table surface, the same number of sides of the frame and/or the same number of segments may be simultaneously decambered. In certain embodiments of the present arrangements, prior to engaging and/or mating with the corresponding segments, each side of the frame is decambered along a plane that is substantially similar or parallel to a plane associated with a cambered state of each side of the base frame.

[0072] Presser sub-assemblies 406 comprise a system of subcomponents (explained in further detail below with respect to Figure 6). According to one embodiment of the present arrangements, the system of subcomponents are used for securing and decambering the segment, aligning the segment with the corresponding side of the frame, and providing a force that is delivered to the aligned segment for engaging and/or mating with the corresponding side of the frame. Although the embodiment of Figure 4 shows three presser sub-assemblies 406 disposed on raised edge 402a, any number of presser sub-assemblies may be used. Likewise, although the embodiment of Figure 4 shows presser sub-assemblies 406 disposed only on raised edge 402a, one or more presser sub-assemblies may be disposed on any raised edge of table surface 404 (e.g. , raised edge 402b). Because presser sub-assemblies 506 are shown disposed on raised edge 402a, they may also be thought of as "edge pressers."

[0073] Figure 5 shows a side view of a table 500, according to one embodiment of the present arrangements, for assembling a fenestration assembly. Table 500 includes, among other things, a table surface 504, one or more presser sub-assemblies 506 located on opposite sides of table surface 504, and a table support 508 disposed below table surface 504. Table surface 504 and presser sub-assemblies 506 are substantially similar to their counterparts of Figure 4, i.e. , table surface 404 and presser sub-assemblies 406, respectively. Table support 508 is a structure that supports and stabilizes table 500 and the components of the present fenestration assembly during fabrication.

[0074] According to the embodiment of Figure 5, two presser sub-assemblies 506 are shown on opposite sides of table 500. In such a configuration, the present table may be used to engage and/or mate sides of separate frames, or opposite sides of a single frame, with segments that may be secured and, if necessary, decambered by each of presser sub-assemblies 506. In such manner, table 500 may be configured to facilitate a high throughput, i.e. , fabricating a large number of fenestration assemblies per unit time.

[0075] Figure 6 shows a detailed side view of a presser system 600, according to one embodiment of the present arrangements and for pressing the frame and the corresponding segment to secure a substrate therebetween and to at least partially or completely fabricate a fenestration assembly of the present teachings. System 600 includes one or more presser subassemblies 606 that are coupled to a table 500'. Presser sub-assembly 606 has a primary function of pressing the frame with the segment such that the two are in an engaged and/or mating configuration. Presser sub-assembly 606, table 500', base frame 200', tensioner 100' and substrate 624 are substantially similar to their counterparts, i.e. , presser sub-assembly 406 and table 400 of Figure 4, base frame 200 of Figure 2, tensioner segment 100 of Figure 1 and substrate 316 of Figure 3, as shown above.

[0076] Table 500' includes a cylinder 616 that is coupled at a bottom end to a mounting bracket 620 and at a top end to one end of a ram 608, which is retractable inside cylinder 616. A top end of ram 608 is coupled to a bottom end of a clamp 607. Clamp 607 is coupled via a hinge 612 to a punch 610. A beam 630 is coupled to a bottom side of punch 610. As shown in the embodiment of Figure 6, beam 630 includes a tray portion that secures tensioner segment 100'.

[0077] Hinge 612 is an optional feature of table 500'. In fact, in preferred embodiments of the present arrangements, clamp 607 and punch 610 form a single unitary structure and hinge 612 is absent.

[0078] Cylinder 616 and ram 608 are components of a hydraulic system that generates a force sufficient for presser system 600 to engage and/or mate the segment, e.g. , tensioner 100', with the frame, e.g. , base frame 200'. Accordingly, ram 608 and cylinder 616 may be any ram and cylinder well-known to those of skill in the art and are capable of being coupled to other components of a hydraulic system, and to table 500'. In one embodiment of the present arrangements, ram 608 and cylinder 616 operate to provide a unidirectional force to the segment to mate and/or engage with the frame. As shown in Figure 6, such unidirectional force will transfer from ram 608 to clamp 607 to punch 610 and, via beam 630, ultimately to tensioner segment 100', such that a protruding region of tensioner 100' (e.g. , male member 106 of Figure 1) will press, relatively perpendicularly, through an extending plane of substrate 624 and into a valley portion of base frame 200' (e.g. , female region 208 of Figure 2).

[0079] Although in the embodiment of Figure 6, cylinder 616 and ram 608 are shown positioned adjacent to table surface 604, in other embodiments of the present arrangements, ram 608 and cylinder 616 are disposed above a table surface 604. In some of these embodiments of the present arrangements, cylinder 616 is disposed above ram 608.

[0080] While use of cylinder 616 and ram 608 in a hydraulic system to generate an engaging and/or mating force that is transferred to tensioner segment 100' represents a preferred embodiment of the present arrangements, the present teachings contemplate use of any means of generating such force. By way of example, the engaging and/or mating force may be generated by one apparatus chosen from a group comprising presser, roller and hammer.

[0081] Beam 630 may be in a shape of an I-beam. A bottom end of beam 630 includes a tray region that secures the segment. According to one embodiment of the present teachings, securing the segment in beam 630 facilitates decambering of that segment in one direction. In other words, the tray region of beam 630 is strong enough for the segment to be secured and maintained therein and in a decambered state. In accordance with an alternate embodiment of the present teachings, a surface of the tray region (that is proximate to the segment during an operative state of table 500') has defined therein one or more apertures for creating suction so that the segment adheres to the tray region. In these embodiments, these apertures may be coupled to a vacuum source to produce the requisite amount of suction to produce effective adhesion. [0082] A single beam 630, as shown and discussed in greater detail in connection with Figure 9, is coupled to the punches of one or more presser sub-assemblies disposed along an edge of table 500'. In other words, more than one presser sub-assembly may be coupled to the same beam 630. In this configuration, a single or multiple forces are distributed by multiple presser sub-assemblies, along beam 630, for providing the engaging and/or mating force to a tensioner.

[0083] Table 500' includes certain features for effective decambering of a frame (e.g. , a base or a tensioner frame). As shown in Figure 6, table surface 604 includes a raised edge (e.g. , raised edge 402a or 402b of Figure 4) on one end and a block 626, which slidably engages with a rail 624, on the other end. During a process of assembly of the present fenestration assemblies, base frame 200' is positioned between the raised edge of table surface 604 and block 626. In this configuration, rail 624 may be thought of as an adjoining portion of table surface 604. Forcing the frame against the raised edges and using the blocks to keep the frame in place accomplish decambering of the frame in one direction.

[0084] In accordance with one embodiment of the present arrangements, rail 624 includes a slot (e.g. , a T-slot, as shown in Figure 6) that movably engages certain table components along rail 624. By way of example, Figure 6 shows block 626 secured within a T-slot of rail 624. As another example, a carriage movably engages with rail 624, as explained below with reference to Figure 9, and which includes one or more presser sub-assemblies disposed thereon. According to certain embodiments of the present arrangements, rail 624 extends along the length and/or width of table surface 604, providing the advantage of mobility of components (e.g. , blocks 926 and carriage 914 shown in Figure 9) to different desired locations on table surface 604.

[0085] In Figure 6, one or more blocks 626 may be used to secure and facilitate decambering of one or more sides of a frame. Because one or more blocks 626 are capable of movement along rail 624, they may be positioned to accommodate decambering sides of frames of varying dimensions. Blocks 626 are also useful in simultaneously decambering multiple sides of the frame.

[0086] According to one embodiment of the present arrangements, support frame 618 is disposed beneath the region of table surface 604 where base frame 604 is disposed. In this configuration, support frame 618 provides stable, rigid support to counteract the force generated by presser sub-assemblies 606 that engages and/or mates frame 200' and segment 100'. Likewise, support frame 618 facilitates maintaining the integrity of assembly table 606 over time and with repeated generation of such force. According to one embodiment of the present arrangements, support frame 618 extends along a length and/or width of assembly table 500'. [0087] A mounting bracket 628 is disposed beneath rail 624 to support the rail. Likewise, a support bracket 620 is disposed beneath cylinder 616 to support the cylinder. In the configuration shown in Figure 6, support frame 618 is supported on one side by mounting bracket 628 and on the other side by support bracket 620. In this manner, support brackets 620 and 628 provide additional stability to components of system 600. The various components used to assemble presser sub-assemblies 606 and table 500' may be comprised of any rigid material sufficient to provide stability to the components when the present systems are operational. Representative materials to make these components include at least one material chosen from a group comprising aluminum, steel, graphite, plastic, glass, wood and composites.

[0088] Figure 7A shows certain components of a presser sub-assembly (e.g. , presser subassembly 606 of Figure 6), according to certain embodiments of the present teachings, in a non- engaged state, i.e. , prior to securing a segment 100" in the tray region of beam 730. Clamp 707, punch 710, beam 730, and tensioner segment 100" are substantially similar to their counterparts, clamp 607, punch 610, beam 630 and tensioner segment 100' of Figure 6.

[0089] In one embodiment of the present teachings, prior to pressing the frame and the segment into a mating and/or engaged position, the present arrangement provides an effective way of loading the segment. To this end, Figure 7 A shows hinge 712 connecting clamp 707 to punch 710. In this configuration, hinge 712 facilitates rotation of punch 710 approximately 180° out from its operative position (i.e., a position at which the frame and segment are set in place for engaging and/or mating). In this non-operative position, the tray portion of beam 730 faces upwards, and away from where the underlying frame would be located during the operative state. Moreover, a high throughput of fabrication of the present fenestration assemblies is realized as the position of beam 730 of Figure 7A shows that a tensioner segment 100" is relatively easily secured therein.

[0090] Figure 7B shows the same components as shown in Figure 7 A, but in an operative position. Clamp 707, hinge 712, punch 710', beam 730' and tensioner segment 100" are substantially similar to their counterparts, clamp 707, hinge 712, punch 710, beam 730 and tensioner segment 100" of Figure 7B. As shown in Figure 7B, after tensioner segment 100" is loaded and secured inside the tray portion of beam 730', hinge 712 rotates punch 710' and beam 730' into an operative position, such that tensioner segment 100" is disposed above and faces a base frame (e.g., base frame 200'of Figure 6) so that mating and/or engaging may commence. In one embodiment of the present arrangements, in an engaged state, hinge 712 is locked or secured such that the relatively straight connection between clamp 707 and punch 710' is maintained when force is delivered to tensioner segment 100" for effective engaging and/or mating with the base frame. [0091] In alternate embodiments of the present arrangements, a unitary structure, which represents a combination of clamp 607 and punch 610, as shown in Figure 6, is implemented instead of using hinge 612. During a segment loading operation, the unitary clamp/punch structure retracts away from table 500', creating sufficient space around beam 630 so that the segment is easily loaded onto the beam. If required, the segment undergoes decambering inside beam 630, as mentioned above, before effective mating and/or engaging commence.

[0092] Figure 8 shows a top view of a fenestration assembly table 800, according to one embodiment of the present arrangements. Table 800 includes rails 808 in the X-direction (hereinafter "X-rails") and rails 810 in the Y-direction (hereinafter "Y-rails"). X-rails and Y-rails are substantially similar to rail 624 of Figure 6 and are disposed on table surface 804 in a gridlike formation. Other features of table 800, such as table surface 804, blocks 826 and presser sub-assemblies 806 are substantially similar to their counterparts, i.e. , table surface 604, block 626 and presser sub-assembly 606 of Figure 6, respectively. Figure 8 also shows a raised edge 802a in an X-direction (hereinafter "X-raised edges") and a raised edge 802b in a Y-direction (hereinafter "Y-raised edges") perpendicular to each other and substantially similar to their counterparts, raised edges 402a and 402b of Figure 4. Raised edges 802a and 802b are arranged to receive two perpendicular sides of a frame (e.g. , a tensioner frame or a base frame).

[0093] Blocks 826 may be disposed along one of many Y-rails 810 and also along one of many X-rails 808. Blocks 826 on X-rails 808 and Y-rails 810, and raised edges 802a and 802b, define an outer boundary of a region where a frame is secured. In some instances, the boundary of the region is the same as or substantially similar to the boundary of the frame. In accordance with one embodiment of the present arrangement, one or more blocks 826 slidably engage with at least one of X-rails 808 and at least one of Y-rails 810. In this embodiment, blocks 826 are moved to different locations along these rails to accommodate frames of varying dimensions. As mentioned before, raised edges and blocks are features of a table that may be used to effectively decamber sides of a frame. By way of example, blocks 806 disposed on Y-rail 810 may be used to decamber a side of a frame that is secured against these blocks. In such manner, a side of a base frame is decambered along a plane that extends in the X-direction, as shown on Figure 8. As a result, table 800 is an exemplar design of the present tables that may be adapted for building fenestration assemblies of different dimensions and/or shapes using a single table.

[0094] In such embodiments, as explained in further detail below with reference to Figure 9, one or more rails span an entire length and/or an entire width of table 400, providing a support structure on which blocks are immobilized. One or more of raised edges 402a and 402b function in conjunction with the blocks such that the segment and/or the frame are decambered, and then in a subsequent step, allowed to effectively mate and/or engage with each other. [0095] Figure 9 shows a top view of a table 900, according to one embodiment of the present arrangements, used to assemble the present fenestration assemblies. Table 900 includes raised edges 902a and 902b, table surface 904, X-rails 908, Y-rails 910, and one or more blocks 912, each of which is substantially similar to its counterpart, i.e. , raised edges 802a and 802b, table surface 804, X-rails 808, Y-rails 810, and one or more blocks 826 of Figure 8. A base frame 918 is substantially similar to its counterpart, base frame 200', and each of beams 920a and 920b are substantially similar to beam 630, of Figure 6. Figure 9 also shows a carriage 914 disposed along at least one of X-rail 908 and/or Y-rail 910. As shown in Figure 9, raised edges 902a and 902b define the outer boundaries of two perpendicular sides of base frame 918 when the base frame is forced into and maintained in a decambered state. In the decambered state, blocks 926, which are slidably disposed on X- and Y-rails 908 and 910, define the boundary of two opposite and perpendicular sides of base frame 918. As a result, raised edges 902a and 902b and blocks 926 may define the boundary of a frame (e.g. , a base frame and a tensioner frame) when the frame is in a decambered state.

[0096] Figure 9 also shows, disposed on raised edge 902a, two presser sub-assemblies 906 coupled to beam 920a. Similarly, on the opposite side of frame 918, carriage 914 has coupled thereto three presser sub-assemblies 916, which in turn are coupled to beam 920b. Because presser assemblies 916 are coupled to a carriage and not a raised edge, they may be thought of as "carriage pressers." In one embodiment of the present teachings, carriage pressers 916 are used in a manner that is similar to that described with respect to Figures 7A and 7B to load and secure a tensioner segment. In an alternate embodiment of the present teachings, carriage 914 retracts away from frame 918 and/or from table surface 904 so that a segment is easily loaded onto beam 920b. Though not shown in Figure 9, beams 920a and 920b each include a tray region that secures a tensioner segment in a decambered state.

[0097] According to one embodiment of the present teachings, carriage 914 is a movable sub-system that provides a movable structure (i.e., movable along one or more rails) with one or more presser sub-assemblies attached thereto. In other words, carriage 914 may be thought of as analogous to a movable raised edge that is fitted with presser sub-assemblies. Although not shown in Figure 9, a carriage may include one or more components that allow for slidably engaging with rails 908 and/or 910.

[0098] As shown in Figure 9, presser sub-assemblies may be disposed along one or more raised edges and along one or more carriages to effectively simultaneously engage and/or mate a frame with multiple segments, providing a high-throughput assembly apparatus and process.

[0099] According to one embodiment of the present teachings, a rectangular-shaped fenestration assembly is fabricated stepwise, as opposed to simultaneously fitting each side of the frame with its corresponding segment. In this embodiment, a first segment is engaged and/or mated with a shorter side of the frame, and a second segment is next engaged and/or mated with the opposite shorter side of the frame. Once the sides of the frame of relatively shorter length have been engaged and/or mated with their corresponding segments, the frame may be realigned such that the relatively longer sides of the frame that are to undergo mating and/or engaging are disposed below presser sub-assemblies. At this stage of the assembly process, the segments corresponding to the relatively longer sides of the frame may have already been loaded onto the beam of the presser sub- assemblies. To position the long side of the frame, blocks 926 may be redistributed and/or positioned along one of X-rails 908 and/or one of Y-rails 910 to provide boundary supports, against which the frame sides are secured and decambered.

[00100] Figure 10A shows a top view of a base frame 1002 having four sides 1002a, 1002b, 1002c and 1002d. Figure 10B shows a top view of a tensioner- segment arrangement 1500. Arrangement 1500 includes four tensioner segments 1502a, 1502b, 1502c and 1502d. Tensioner segment 1502a corresponds to base frame side 1002a. As shown in Figures 10A and 10B, base frame 1002 and tensioner segments 1502a, 1502b, 1502c and 1502d are in a cambered state prior to engaging and/or mating. The cambered profiles of base frame 1002 and tensioner segments 1502a, 1502b, 1502c and 1502d extend along a substantially similar plane or parallel planes. Prior to assembling, a substrate (e.g. , denoted by reference numeral 1106 in Figure 11), according to one embodiment of the present arrangements, is disposed between base frame 1002 and one or more of tensioner segments 1502a, 1502b, 1502c and 1502d. In an assembled state of a fenestration assembly that includes base frame 1002 and tensioner segments of arrangement 1500, tensioner segment 1502a engages and/or mates with side 1002a of base frame 1002. In a similar fashion, segments 1502b, 1502c and 1502d engage and/or mate with sides 1002b, 1002c and 1002d, respectively, of base frame 1002. It is noteworthy that although Figure 10A shows a base frame and Figure 10B shows tensioner segments, the present teachings contemplate that instead of a base frame, a tensioner frame is used to engage and/or mate with one or more base frame segments. Regardless of whether a base frame or a tensioner frame is used, engaging and/or mating the frame with the segments effectively secures the substrate between the frame and the segments. It important to note that it is not necessary that both a frame and tensioner segments include a cambered profile or that all segments or all sides of a frame include a cambered profile. In certain embodiments of the present arrangements, one or more of base frame 1002, tensioner segments 1502a, 1502b, 1502c and 1502d are cambered. Moreover, at least some of base frame 1002, tensioner segments 1502a, 1502b, 1502c and 1502d are not cambered. [00101] Although the embodiments of Figures 10A and 10B show a frame and corresponding segments that are configured with a cambered profile that is concave and/or extends away from a center region of the ultimately fabricated fenestration assembly, in other embodiments of the present arrangements, a frame and corresponding segments are configured with a cambered profile that is convex and/or extends towards a center region of the ultimately fabricated fenestration assembly. Fenestration assemblies that engage and/or mate a frame and segments that have cambered profiles that are relatively convex may use substrates that are substantially rigid, e.g. , hard acrylic films.

[00102] Figure 11 shows a fenestration assembly 1100, according to one embodiment of the present arrangements, in a tensioned state. A tensioned state of fenestration assembly 1100 results after a substrate is secured between an engaged and/or mated frame (e.g. , base frame 1002) and segments (e.g. , tensioner segments 1502a, 1502b, 1502c and 1502d), and after the engaged and/or mated frame and segment configuration is released from the decambering forces (e.g. , decambering forces applied using raised edges 802a and 802b and blocks 826 of Figure 8). The initial cambered profile of the components (e.g. , frame and segments shown in Figures 10A and 10B) produces tension in resulting fenestration assembly 1100, and at least a portion of that tension is transferred to substrate 1106 (secured within fenestration assembly 1100). As a result, the tendency of the fenestration assembly to resist being maintained in a decambered state, or a tendency of the fenestration assembly to return to its original cambered state, produces a relatively taut substrate, akin to a drumhead mounted on a drum. The tensioned substrate is gripped by the mated and/or engaged frame and segment configuration adjacent to a "viewing area" plane that is substantially similar or parallel to a plane in which sides of the frame and/or segments are cambered. In other words, a viewing area plane of the extending substrate is substantially similar or parallel to a plane associated with the cambering and decambering of the present fenestration assembly and its components parts (e.g. , frame or segments). If the substrate selected is a glare-free and/or energy-efficient window film, then fenestration assembly 1100 may provide the advantage of an energy-efficient fenestration assembly.

[00103] Figure 12A shows a side-sectional view of a fenestration assembly 1200, according to one embodiment of the present arrangements, in a tensioned state and having sides that intersect a plane that is substantially similar or parallel to the viewing area plane of a substrate 1206.

Fenestration assembly 1200 includes tensioner segments 1204a and 1204b engaged and/or mated to opposite sides of a base frame 1202. The engaged and/or mated sides of the fenestration assembly secure a substrate 1206. A centerline 1208 defines a plane that extends along a center region of each side of fenestration assembly 1200. The centerline may be thought of as an approximate midpoint between a non-mating edge of one side of the frame (e.g. , non- mating edge 326 of Figure 3) and a non-mating edge of the corresponding segment (e.g. , non-mating edge 320 of Figure 3). As shown in the embodiment of Figure 12A, a viewing area plane of substrate 1206 is substantially similar or parallel to centerline 1208. Thus, tension in substrate 1206 lies along a plane that is substantially similar or parallel to a plane of the fenestration assembly. Accordingly, Figure 12A shows a fenestration assembly that is relatively straight and/or flat.

[00104] In other embodiments of the present teachings, however, a tensioned state of a fenestration assembly produces a fenestration assembly having sides that intersect a plane that is at angle that is less than 25° relative to the viewing area plane of substrate 1206'. As explained above with reference to Figure 3, an "off-center" substrate path inside the present fenestration assemblies supports the relatively high level of tension present in substrate 1206'. To this end, Figure 12B shows a side-sectional view of a fenestration assembly 1200', according to an alternate embodiment of the present teachings and that has sides that lie in a plane that is at an angle relative to the viewing area plane of substrate 1206'. Base frame 1202', tensioner segments 1204a' and 1204b', substrate 1206' and centerline 1208', are substantially similar to their counterparts, base frame 1202, tensioners 1204a and 1204b, substrate 1206 and centerline 1208, of Figure 12 A. Unlike the embodiment of Figure 12A, Figure 12B shows outside edges of opposite sides protruding slightly outward, and inside edges of the same sides protruding slightly inward, with a slight bend introduced at outer regions of the viewing area surface of substrate 1206'. The substrate bends produce "tray-like" fenestration assemblies, with a relatively flat viewing area of substrate 1206' that is slightly curved around the sides of the present fenestration assemblies.

[00105] A centerline 1210 extends along a plane that intersects each side of fenestration assembly 1200', but is at an angle, Θ, relative to line 1208', which lies in a viewing area plane of substrate 1206'. According to one embodiment of the present arrangements, Θ, has a value that is less than about 25°. According to another embodiment of the present arrangements, Θ has a value that is less than about 5°. According to yet another embodiment of the present arrangements, Θ has a value that is about 0° (e.g. , as shown in the relatively straight and/or flat configuration of fenestration assembly 1200 of Figure 12A).

[00106] Figure 12B shows an off-center substrate path (shown by an interface of tensioner 1204a' with base frame 1202' above centerline 1210) that is positioned above a centerline of a fenestration assembly side. Further as explained above, this off-center configuration produces a positive value for Θ. In an alternate embodiment of the present arrangements, however, an off- center substrate path that is positioned below the centerline of the fenestration assembly side produces a negative value for Θ. [00107] The present teachings recognize that a substrate path extending along the centerline inside the sides of the present fenestration assemblies, and that does not extend in an off-center fashion, may provide corner substrate regions that are not sufficiently tensioned. According to the present teachings, such fenestration assemblies suffer from the "corner problem."

Conventional wisdom would propose that the corner problem, as recognized by the present teachings, may be solved by, among other things, using frames and segments of significantly larger dimensions and/or using heavier materials to fabricate the frames and segments. These solutions suffer from drawbacks. For example, larger and/or heavier fenestration assemblies are more expensive and difficult to build. Further, larger fenestration assemblies have relatively wider sides and therefore obscure a good portion of a window's viewing area. To this end, the present teachings propose an inexpensive and relatively easy-to-build design that also preserves the viewing area of the window or cavity receiving the present fenestration assemblies.

Specifically, the "off-center" substrate path inside the sides of the present fenestration assemblies produces the "traying" effect that causes opposite sides to bend slightly upward (as shown below with reference to Figure 12B), introducing a requisite amount of tension in the substrate at the corner regions of the viewing area to effectively solve the "corner problem." Thus, the present teachings recognize that it is not necessary to rely upon the cambered profile of a frame and/or tensioner to introduce a requisite amount of tension in the substrate. However, use of cambered profiles in the frame and/or the segment represents a preferred embodiment of the present arrangements.

[00108] Figure 13 is a flowchart showing a process 1300, according to one embodiment of the present teachings, for fabricating one side of a fenestration assembly (e.g. , fenestration assembly 1100 of Figure 11). Process 1300 begins with a step 1302, which includes obtaining a frame (e.g. , base frame 200 of Figure 2) including one or more sides, each side having a cambered profile along at least one plane. Although it is not necessary that each side of the frame include a cambered profile, it represents a preferred embodiment of the present teachings. In certain embodiments of the present teachings, however, each side of a frame has a non-cambered profile, i.e., the frame comprises relatively straight sides.

[00109] Next, a step 1304 includes obtaining one or more segments (e.g. , tensioner 100 of Figure 1), each of which includes a cambered profile along a plane that is substantially similar or parallel to at least one of the planes of the sides of the frame obtained in step 1302. In those embodiments where sides of the frame are not cambered, at least one of the segments is cambered along a plane that is ultimately the plane along which the present fenestration assemblies are in a tensioned state. In certain embodiments of the present teachings, however, each segment obtained in step 1304 has a non-cambered profile and one or more sides of the base frame may be cambered.

[00110] Next, a step 1306 includes positioning a substrate between the frame and one of the segments obtained in step 1304. In certain embodiments of the present teachings, positioning the substrate includes temporarily stabilizing the substrate on the frame or the segment so that the substrate remains relatively secure, prior to commencing mating and/or engaging of the segment with the frame. By way of example, two-sided tape (e.g. , adhered to a tape bed area on a base frame) may be used to stabilize the substrate on the frame or on one or more segments.

[00111] Next, a step 1308 includes decambering at least one side of the frame to form at least one decambered side of the frame. According to one embodiment of the present teachings, decambering includes removing or reducing a bend or a curvature, from a side of the frame, that ranges from about 1/32 inch per foot of the frame to about 2.5 inches per foot of the frame. Each side of the frame may be decambered prior to engagement and/or mating of a particular side to the corresponding segment. By way of example, decambering is facilitated by securing one or more sides of a base frame against one or more raised edges of a table (e.g. , raised edges 902a and 902b on table surface 904 of Figure 9). As another example, decambering is facilitated by securing one or more sides of a frame against one or more blocks or carriages that are disposed on a rail of a table (e.g. , blocks 926 on rails 908 and 910 in Figure 9). The present teachings recognize that any combination of these may be used to carry out step 1308. In those embodiments in which a frame having a non-cambered profile is obtained (e.g. , in step 1302), a step 1308 is not needed.

[00112] Next, a step 1310 includes decambering at least one of the segments (e.g. , tensioner 100 of Figure 1) to form at least one decambered segment. According to one embodiment of the present teachings, decambering includes removing or reducing a bend or a curvature, from one or more segments, that ranges from about 1/32 inch per foot of a segment to about 2.5 inches per foot of the segment. A segment may decambered by securing the segment to a tray region of a beam (e.g. , tray region of beam 630 of Figure 6). In certain embodiments of the present teachings, a beam is coupled to one or more presser sub-assemblies, as shown in Figure 6. In other embodiments of the present teachings, a beam is coupled to a carriage presser, as shown in Figure 9. In yet other embodiments of the present arrangements, any means of decambering a tensioner segment is used so long as the segment is secured in a decambered state for engagement and/or mating with the corresponding side of the frame. In those embodiments where each segment has a non-cambered profile, a step 1310 is not needed.

[00113] Next, a step 1312 includes engaging and/or mating at least one of the decambered segments with at least one of the decambered sides of the frame to secure the substrate between at least one of the decambered segments and at least one decambered side of the frame.

According to certain embodiments of the present arrangements, a requisite engaging and/or mating force is generated by one or more presser sub-assemblies (e.g. , presser sub-assembly 606 of Figure 6).

[00114] Any combination of steps 1304 through 1312 may be used or repeated one or more times to engage and/or mate multiple decambered segments with multiple decambered sides of a frame, until all sides of the fenestration assembly are built. Further, a sequence of various steps may vary to produce different types of fenestration assemblies according to the present teachings. In one embodiment of the present teachings, each side of a frame may be decambered prior to engaging and/or mating. For example, each decambered segment may undergo sequential decambering and then engaging and/or mating one at a time until an entire, exemplar fenestration assembly is assembled. As another example, all decambered segments

contemporaneously undergo decambering and then engaging and/or mating to form an exemplar fenestration assembly. As yet another example, each decambered segment may engage and/or mate in any fashion (e.g. , sequentially or substantially contemporaneously) to the decambered sides of a frame.

[00115] After step 1312 has concluded or all sides of the present fenestration assemblies are fabricated, a releasing step is carried out. In this step, the fenestration assemblies are in a tensioned state and the decambering forces are released. Depending on factors, such as the amount of camber in the frame and/or the segment, a tensioned substrate is produced. Segments and frames inside the present fenestration assemblies may be tensioned along a plane that is substantially similar or parallel to (e.g. , as shown in Figure 12A), or at an angle that is less than 25° (e.g. , as shown in Figure 12B) relative to, the viewing area plane of the extending substrate.

[00116] Although illustrative embodiments of these arrangements and teachings have been shown and described, other modifications, changes, and substitutions are intended. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure, as set forth in the following claims.