Abstract: The present invention relates to solid panel window shutters having both high strength and structural stability. More particularly, an exterior window shutter made of a solid panel of polyvinyl chloride with at least one support member affixed in the panel. The shutter includes a solid panel having front and back surfaces and side edges, support member, impact resistant member and slats having a channel to receive the support member; wherein the support member is embedded between the panel and the slats. Also contemplated by this invention are: a method to manufacture high strength and structurally stable exterior window shutters and a method to protect windows from extreme weather.

Abstract: The following disclosure describes a wood-product based door or window component including a wood-product based core having opposing first and second surfaces and at least a first side edge. Overlaying at least part of the first surface is a first overlay structure that includes a resin-impregnated paper, and overlaying at least part of the second surface is a second overlay structure that includes a resin-impregnated paper. The wood product based core has an edge band attached to the first side edge, and the edge band includes a resin-impregnated paper. The edge band is attached so that a portion of the wood-product based core is between the resin-impregnated paper of the edge band and the resin-impregnated paper overlaying the first and second surfaces.

Abstract: The present invention relates to veneered paneled elements such as doors. For example, a veneered raised panel door could include two vertically-oriented framing members (e.g., stiles) and two horizontally-oriented framing members (e.g., rails). These members are combined with a center panel to create a door frame. Each exposed edge of the door is layered with an edge banding. This edge banding (e.g., a wood or plastic veneer) covers any joints between the vertically-oriented and horizontally oriented framing members.

Abstract: A door member comprising a frame having a first side and a second side, opposite the first side, a core positioned within the frame, and a molded skin attached to the first side of the frame. The skin is prepared from a molding compound which, when molded, has a shrinkage of between about −0.0003 to about +0.0015. The molding compound comprises a resin system comprising a curable polyester resin, a co-curable unsaturated monomer, and at least two low profile additives. The molding compound also comprises at least about 30 percent by weight, based on the weight of the molding compound, of filler material, and fibrous reinforcement in an amount of less than about 35 weight percent, based on the weight of the molding compound.

Abstract: The present invention provides a building material derived from straw, such as rice straw, that has significantly improved fire-resistance properties over traditional cellulose-based materials. In one embodiment, the invention provides a method of fabricating a board from milled rice straw. The milled rice straw is blended with a binder to form a mixture. The mixture is then formed into a mat with sufficient size to achieve a predetermined board thickness and density. The mat is then pressed into the board. In another embodiment, the present invention provides a fire resistant board that includes milled rice straw, a resin binder, and a fire retardant material such as an organic phosphate, zinc borate, aluminum tribydrate, sodium silicate, or even rice hulls.

Abstract: A stain/topcoat system for non-porous thermoset and/or thermoplastic articles comprises a pigmented stain, and a topcoat comprising one or more non-siloxane film-forming polymers, an emulsion of one or more curable organopolysiloxanes, a weatherability agent having a functional group that is reactive with carboxylate functional sites and water. The topcoat displays exceptional adhesion and weatherability to pigmented stained surfaces.

Abstract: The present invention relates to solid panel window shutters having both high strength and structural stability. More particularly, an exterior window shutter made of a solid panel of polyvinyl chloride with at least one support member affixed in the panel. The shutter includes a solid panel having front and back surfaces and side edges, support member, impact resistant member and slats having a channel to receive the support member; wherein the support member is embedded between the panel and the slats. Also contemplated by this invention are: a method to manufacture high strength and structurally stable exterior window shutters and a method to protect windows from extreme weather.

Abstract: A method for fabricating a decorative window insert, and from the insert a decorative window, comprises the steps of producing a plurality of planar glass units each adapted by size and shape, for assembly together as a decorative insert master by assembling the planar glass units into a planar assembly wherein the planar glass units are joined by a came, producing a mold from the decorative insert master, the mold replicating the decorative insert master with a came mold portion and a planar glass units mold portion, filling the came mold portion of the mold with a dyed catalyzed resin and curing the resin as a simulated came portion of the insert, filling a planar glass units mold portion of the mold with a non-dyed catalyzed resin and curing it as a simulated glass portion of the insert followed by a post-curing of the simulated came portion and the simulated glass portion to produce the decorative window insert.

Abstract: A construction component for improved moisture, decay and insect resistance. The component preferably includes a plurality of members of which certain portions are comprised of materials resistant to moisture, decay and insects. The resistant member(s) are integrally connected to wood portion(s) to provide a single, low cost structure.

Abstract: A door or window unit adapted for use in a sliding or window assembly wherein said door or window unit includes an infill panel or panels (4) housed in a surrounding frame (3) characterised in that said panel is fined substantially flush to a face surface of said frame.

Abstract: The invention is directed to an insulated door and a method for manufacturing such have a glazing or window section installed therein. The frame of the window section is installed during manufacture and is flush with both faces of the door. The flush glazed door comprises a rigid wooden frame having an opening for mounting an insulated window therein, a metal sheathing secured on each side of the frame, a window frame unit mounted within the wooden frame within the opening and an insulated window positioned within the window frame unit. The window is retained within the frame in air-tight and weatherproof manner.

Abstract: A building panel formed by extruding a mixture of wooden and/or bamboo powder and a binding agent. Its panel body comprises (i) a door panel extending in the direction of extrusion, (ii) a pair of longitudinal frame members formed in the direction of extrusion on the right and left sides of the door panel, and (iii) a panel strip formed in the direction of extrusion at the center of the door panel. The door panel, the paired longitudinal frame members, and the panel strip are formed as a single piece. The door panel and the panel strip are cut short at their upper and lower ends so that the upper and lower ends of the longitudinal frame members stand out beyond the cut ends of the door panel and the panel strip, the standing-out portions constituting tenons.

Abstract: A method for fabricating muntin grid pieces includes steps that attach a pair of material strips to opposed edges of the muntin bar element. The material strips may be provided in side-by-side strips that may be separated an simultaneously applied to the opposite sides of the muntin bar element. The connection between the material strips and the muntin bar element may be made with an adhesive or a mechanical connection. The method allows the material strips to be connected to the muntin grid pieces before the muntin grid pieces are assembled into a muntin bar grid for a window.

Abstract: A storm door has first and second elongated, partly curved lock receiving openings formed in respective elongated edges. Each opening is filled in part with a molded hollow insert with an external periphery which matches a periphery of the respective opening. A lock mechanism has a housing with an external periphery that matches, at least in part, an internal periphery of a respective insert. An actuating port in the housing has a central axis, which extends parallel to the respective edge, through the door through which extends a rotatable actuating shaft. An external handle can be attached to the shaft. An unused insert can be closed with a slidably engaging cover.

Abstract: The present invention relates to a refined assembly structure of hubbed door leaf installed with glass, which comprises a first door skin with an opening, a second door skin with an opening, a top lacing material, a bottom lacing material, a left lacing material, a right lacing material, a handle reinforcement member and the ejected frame with multiplayer glass hold-down. The door skin with opening can be manufactured to be various shapes such as square, rectangular, circle, ellipse, and semicircle depending on different mold. When assembled, the lacing materials are mounted to the edges of the first door skin by the adhesive. The left and the right lacing materials are position-bonded, by ribs, to the flush-sided door skin. The top and the bottom lacing materials are positioned through the milled notches at the top and the bottom ends of the left and the right lacing materials. A reinforcement member is disposed at the handle position to enhance the mechanical strength of the handle while locked.

Abstract: A support brace is provided for structurally linking a sliding door to a surrounding structure. The support brace includes an elongate rail having a first end and a second end. The rail is fastened to a portion of the sliding door in spaced relation to the surrounding structure so that the first end is positioned adjacent to a top edge of the sliding door and the second end is positioned adjacent to a bottom edge of the sliding door. At least one bolt is slidingly secured to the rail, and includes a locking rod. The bolt is arranged so that it can be slid along the rail between a first position, where the locking rod projects beyond one of the first and second ends of the rail, and a second position where one of the first and second ends of the rail projects beyond the locking rod. At least one lock plate is also provided that includes an opening defined through a portion of the plate.

Abstract: A modular plastic shutter assembly that includes an injection molded panel that has been cut to length to accommodate the particular shutter assembly. A die cutter having an appropriately shaped cutting blade cuts an end of the panel to the desirable length. A separate injection molded panel end piece is secured to the cut end of the panel to form a complete panel.

Abstract: A panel for decorating a face of a conventional flat veneer plywood door to provide the door with a traditional rail-and stile appearance The panel has a decorative front surface, a back surface opposite the front surface adapted for attachment to the face of the door and a substantially uniform thickness separating the front and back surfaces. The front surface has a raised perimeter portion surrounding a central portion. The perimeter portion is spaced farther from the face of the door than the central portion when the back surface is attached to the face of the door. The back surface has an outer edge which contacts the face of the door when the back surface is attached to the face of the door.

Abstract: A door and method for fabrication of unitary six panel steel doors wherein frames members (stiles and rails or headers) are fabricated by forming metal stock into a cross-sectional channel configuration, cutting and swaging the channels into predetermined lengths. The stiles and rails of the frame members are swaged to provide frictional interconnection at the corners thereof upon assembly of the frame members (stiles and rails) into a rectangular frame configuration. Assembly of the frame is accomplished in a shuttle having two assembly jigs. Upon assembly, each frame is moved by the shuttle into a molding press wherein a panel of foam is molded within the frame. The shuttle moves back and forth through the molding press in a manner which provides for removal of a completed panel and assembly of an additional frame from one jig of the shuttle while the molding operation is accomplished within the molding press upon a frame retained within the other jig of the shuttle.

Abstract: A door comprising a laminated panel having a peripheral frame defining the peripheral edge thereof. The laminated panel comprises an outer skin of thermoplastic material impregnated with opaque pigmentation and an inner substrate intimately bonded with the outer skin. The inner substrate is formed of a relatively rigid thermoplastic material impregnated with a filler. The outer skin defines a three dimensional door surface which presents the texture and at least a part of the color of the exterior appearance of the door in use.

Abstract: A stain/topcoat system for non-porous thermoset and/or thermoplastic articles comprises a pigmented stain having substantially only a single binder resin which promotes adherence of a topcoat, and a topcoat which is an aqueous dispersion of a film forming polymer and a curable organopolysiloxane microemulsion. The topcoat displays exceptional adhesion and weatherability to pigmented stained surfaces.

Abstract: The plastic back-up shear plate is laterally disposed with generally a spring fit into the outwardly facing mouth of a metal window frame. The outwardly facing frame mouth is formed and defined by the window frame elongated hollow body and particularly by outer wall elements which face each other in an opposing manner. The plastic back-up shear plate has laterally disposed opposite outer edge portions which are interlockable on corresponding outer wall elements of hollow body metal window frame which wall elements define the mouth of the window frame. In a perpendicular direction, the back-up shear plate has a opposing edge portions with interlock on window frame mouths having a slightly different dimension. The plastic back-up shear plate lateral lips to lock onto lateral frame mouths having different dimensions for different sized frames. The shear plate is constructed and arranged to fit, with appropriate change in orientation, window frames of two different mouth openings.

Abstract: A prefabricated window fame with a decorative window subassembly within for use in a building having a window opening in a wall or a door with a rail about its perimeter. The window frame includes a first, or back, member and a second, or front, member overhanging the window subassembly therebetween and fastened together to form a window frame groove matching the window frame rail. The front frame member is mountable on the outside of the window opening and the back frame member is mountable on the inside of the window opening with the window subassembly therebetween. Frame members are identical, symmetric components with one when inverted matching another to comprise front and back frame members. The frame members are secured together by a plurality of fasteners secured to the frame members about their perimeters. The fasteners comprise matching latch hooks or posts with ridges matching frame holes with ridges.

Abstract: An adjustable shutter includes a substantially rectangular shutter frame having first and second pairs of opposed spaced apart frame members 3a, 3b defining a substantially rectangular opening between the frame members. A plurality of substantially parallel louvers 5 are operatively mounted within the shutter opening and extend between the opposed pair of first frame members. The louvers are capable of at least partially occluding the rectangular opening of the shutter frame. A respective frame cover 6a, 6b is operatively affixed to each one of the frame members. An adjustment mechanism is disposed between at least one frame member and its respective frame cover, and is operable to adjust a separation between the frame member and its respective same cover, such that a first overall dimension of the shutter can be adjusted. Finally, a respective corner cover member 7 is disposed in operative relation to each of the frame covers to visually occlude a gap between each adjacent frame cover.

Abstract: A floor tile or wall tile in the form of a panel has a frame and a filling. The frame and the filling are nondetachably connected in a utility state to form an integral part. The connection between frame and filling interlocks tongue and groovc-like. The frame extends beyond the filling in the plane of the tile at least the thickness of the frame. The filling is of the same thickness as the frame.

Abstract: A screen door made of foamed, closed-cell, solid-core polyvinyl chloride includes two rails and two stiles connected together to form a rectangular frame having an opening. A groove is milled into the frame around the opening. The screen that is to cover the opening is fastened to the frame by pressing it with a spline into the groove. The rails and stiles are connected using dowels in addition to adhesives, or, alternatively, using screws and traditional mortise and tenon joints. Holes are drilled into the stiles and then screws are driven into the rails from within the holes. The holes are then filled with foamed plastic plugs over the screws. The screen door can be cut and trimmed at the job site to fit it to the particular door frame, removing up to about an inch from each edge.

Abstract: Compression molded pigmented door skins fabricated by compression molding a pigmented, curable, unsaturated polyester sheet molding compound containing a co-curable unsaturated monomer, a low profile additive, and a microvoid-reducing thermoplastic polymer, exhibit uniform stainability while maintaining a low linear thermal coefficient of expansion. Such door skins are suitable for preparing wood grain textured exterior insulated doors which exhibit minimal thermal deflection when exposed to interior/exterior temperature differentials, even at eight foot door heights. The doors may be stained without first applying a seal coat.

Abstract: A frame for a cabinetry door and a facing for a dresser drawer are disclosed which utilize a log construction of sorts, and thus are particularly desirable for use with log homes. Each of the cabinetry door frame and the drawer facing utilize an at least generally convexly-shaped front surface so as to appear to be formed from a log. Further contributing to the log construction appearance of the cabinetry door frame and drawer facing is the use of larger dimensions for the cabinetry door frame and drawer facing. In this regard, the cabinetry door frame and drawer facing each may utilize piece of wood with is continuously arcuate extending between a pair of longitudinally extending sides, which in turn are spaced by a distance of at least about 3 inches.

Abstract: A technique for forming a contoured axially extending engineered moulding that has at least one axially extending exposed surface. The technique includes providing an elongated outer wood section. A substrate having at least one axially extending side is provided. The wood section is adhered to the axially extending side. The wood section is contoured uniformly in an axial direction to form the exposed surface. A preferred embodiment uses a reengineered rip saw to contour the piece of wood. It is also assumed that multiple moldings can be machined by the reengineered rip saw simultaneously. The simultaneous machining by the reengineered rip saw also permits simultaneous measurements and simultaneous cross cutting and dado cutting of the moldings.

Abstract: A door includes a first wood stile and a second wood stile. The door can also include a top rail and a bottom rail. The top rail has a first end attached to the first upper region of the first stile and a second end attached to the second upper region of the second stile. The bottom rail similarly has a first end attached to the first lower region of the first stile and a second end attached to the second lower region of the second stile. The door also includes at least a first moisture-resistant end-cap attached to the first lower end of the first stile and/or the second lower end of the second stile. The first end-cap, for example, can be a single component extending across the lower ends of the stiles and a bottom surface of the bottom rail. The door more preferably includes a first moisture-resistant end-cap attached to the first lower end of the first stile and a separate second moisture-resistant end-cap attached to the second lower end of the second stile.

Abstract: A sealed glazing unit simulating the appearance of a traditional divided-lite window has spaced apart parallel co-extensive glazing sheets interconnected by a peripheral seal. Muntin grid elements are located on at least two surfaces of the glazing sheets in mutually aligned registration, the elements being of a width sufficient to create a visual illusion of solid muntin bars within the glazing sheet cavity. Each of the muntin grid elements has on one side a relatively dark shade facing interiorly of the glazing unit and in the opposite side a relatively light shade facing exteriorly of the glazing unit, the combination of these shades creating the visual appearance of solid muntin bars within the cavity. Muntin grid elements within the glazing unit are preferably in the form of strips of plastic material adhered to the cavity glass surfaces, whereas muntin grid elements on the exterior surfaces of the unit can alternatively be formed as relatively thick members e.g.

Abstract: A multi-panel hollow door has a core made of corrugated paperboard. The core is formed from a stack of plies in which adjacent plies are adhered to one another in accordance with a predetermined pattern of adherence (e.g., a gluing pattern). The stack is expanded in a direction perpendicular to the plies to form an elongated series of cells disposed longitudinally between transversely spaced panel indentations of a door skin, at a central region of the door. Each cell has a pair of transversely spaced vertices, and juxtaposed end portions of vertex-forming plies form tabs. Each tab is preferably oriented to overlap an adjacent portion of a vertex-forming ply, the desired orientation being obtained by partial slitting of a single vertex-forming ply. Unexpanded end portions of a stack of plies may be broken off to form pads between corresponding portions of the skins.

Abstract: A modular plastic shutter assembly that includes an injection molded panel that has been cut to length to accommodate the particular shutter assembly. A die cutter having an appropriately shaped cutting blade cuts an end of the panel to the desirable length. A separate injection molded panel end piece is secured to the cut end of the panel to form a complete panel.

Abstract: A component shutter assembly and method of forming same. The assembly comprises a one-piece molded plastic, integrally formed shutter panel. The shutter panel may be molded in a small plurality of standard lengths and then one or both ends thereof cut to shorten the shutter panel to a specific, desired length once it is determined what-specific length of shutter is needed for a particular application. An independent, integrally formed end panel may then be secured to one or both ends of the cut shutter panel and ultrasonically welded thereto to form a finished component shutter assembly having a particular desired length and the appearance of a one-piece, integrally formed shutter. Embodiments directed to raised panel and louvered shutters are disclosed, as is a removable center panel section which may be used in connection with the louvered shutter panels if it is desired to provide a mid-panel section which is offset from the mid-point of the overall length of the shutter panel.

Abstract: A modular plastic shutter assembly that includes an injection molded panel that has been cut to length to accommodate the particular shutter assembly. A die cutter having an appropriately shaped cutting blade cuts an end of the panel to the desirable length. A separate injection molded panel end piece is secured to the cut end of the panel to form a complete panel.

Abstract: A vision frame assembly for use in fire-rated structures such as doors and alls. The frame assembly includes a pair of opposed frame members that snap-fit into a plurality of resilient latching clips mounted in the door or wall. The latching clips include mounting members to mount the clip to the door or wall and spring finger elements having differing lengths. The unique configuration of the spring finger elements makes the frame assembly adaptable to wide tolerance variations from different manufactures of doors, walls, and other fire-rated structures.

Abstract: A component shutter assembly and method of forming same. The assembly comprises a one-piece molded plastic, integrally formed shutter panel. The shutter panel may be molded in a small plurality of standard lengths and then one or both ends thereof cut to shorten the shutter panel to a specific, desired length once it is determined what-specific length of shutter is needed for a particular application. An independent, integrally formed end panel may then be secured to one or both ends of the cut shutter panel and ultrasonically welded thereto to form a finished component shutter assembly having a particular desired length and the appearance of a one-piece, integrally formed shutter. Embodiments directed to raised panel and louvered shutters are disclosed, as is a removable center panel section which may be used in connection with the louvered shutter panels if it is desired to provide a mid-panel section which is offset from the mid-point of the overall length of the shutter panel.

Abstract: A framing assembly for a door light which includes a first frame, a second frame, and a plurality of channel sections. The first and second frames are formed from a plurality of frame sections. The channel sections are disposed within the hollow space defined by the two skins of a door panel. The first frame sections are attached to the channel sections by any conventional fastening means. The first frame sections are provided with integral latch members and the second frames are provided with integral clip members which cooperate to retain the second frame member within the opening in a hollow door panel without the use of any visible external hardware. The framing assembly of the present invention may be provided with pre-finished surfaces and can be installed in pre-existing doors without the need for special welding equipment or extensive modification to the door panel prior to installation.

Abstract: A simulated panel door structure formed from a flat surface door utilizing an endless groove formed along the flat surface and etched to a uniform depth. The endless groove possesses a base surface and first and second side walls extending outwardly from the base surface. The second side wall of the groove is positioned outside the first side wall toward the periphery of the door. An insert having a lower surface and first and second side walls positions within the endless groove such that the lower surface of the insert lies adjacent the base surface of the groove. The first side wall of the insert lies adjacent a beveled surface of the veneer and extends no further outwardly than the flat surface of the door. The second side wall of the insert lies adjacent the second side wall of the groove. The insert further includes a lateral surface spanning the first and second side walls with a depression therealong.

Abstract: A recites full view door in which the frame portion is totally molded. It may be molded in a number of processes from polypropylene or other materials, with or without additives, and other plastics suitable for large molded frames. There is an outside section of the frame and an inside section which are modified for securement each to the other. Provision is made in the interior edges of the frame for receiving the pane of glass, and then a holding assembly is provided, primarily four pieces being top, bottom and the two sides which snap-fits into the inside portion of the frame and secures the window in removable engagement to the door. In the method, means are provided on the outer half and the inner half for snap-fittingly or press-fittingly engaging each other. In addition, sonic welding, gluing, and other means for securing the outer half and the inner half of the door are contemplated.

Abstract: A core component is shaped to compensate for varying widths and depths of the shell or framing of a building or structural member. The component includes two major surfaces defining respective front and rear sides of the component, and the rear side of the component is preferably the mirror image of the front side. The core component is preferably pre-formed and provided in a space or void on the interior of building or structural members, e.g., two prefabricated molded doorskins. The core component is preferably made from a composite soft board material. Processes for the production of a core component and a building member such as a composite door product are also disclosed.

Abstract: A synthetic door casement is composed of multiple panels of L-shaped compression molded skin panels, that can be embossed with a graining pattern on their outer surfaces, which are joined with batten means on their inner surfaces to form a pair of opposed rectangular casement skins which casement skins are then joined on opposite sides of an outer frame surrounding an inner frame to form a hollow rectangular casement which is then filled with a plastic foam, such as polyurethane foam, with the inner frame having an external recess to receive a glass pane along with cooperative retention moldings to hold the pane in place in the recess of the inner frame once the pane is inserted therein.

Abstract: A raised wall panel which includes a frame, a raised panel and a molding positioned between the two. The frame, having four frame members, is arranged in a "picture frame" configuration and attached to plywood fixed to a wall structure. The frame members are constructed of a base material, such as composition board or inexpensive plywood, which is covered by a decorative wood veneer. The raised panel is positioned within the frame using a spacing tool to ensure that the open area between the frame and the raised panel is uniform and the raised panel is attached to the plywood. The raised panel is also constructed of a base material which is covered by a decorative wood veneer. The molding has a built-up frame portion having a frame lip and a built-up panel portion having a panel lip. The molding is then positioned between the frame and the panel section such that the frame lip overlaps the frame member and the panel lip overlaps panel section.

Abstract: A door pressed from fiberboard opposing door forms to define elongate depressions of timber-like appearance disposed around the door or parts thereof within an elevated outer periphery portion of the door. Each of the depressed elongate timber-like panels surround a number of elevated door panels that are removed. The facing set of door forms have spacers and edging members, wherein the edges of the door forms from which the elevated panels are removed have plastic edging strips disposed on the opposing edges of each face of the door forms to support glazing therein.

Abstract: A mirrored door includes at least four interconnected members providing a frame. The frame has first and second oppositely disposed sides and an uninterrupted interior perimeter defining a cavity. A door skin is secured to one of the sides and closes the cavity. A mirror is positioned within the cavity and conforms to the perimeter. A molding element is disposed about the perimeter. The molding element bears upon the mirror and abuts the members. The molding section is mechanically secured to the members so that the mirror is thereby retained within the cavity.

Abstract: A wood wall structure has standard components arranged in such a way that strength and ductile capacity exceeds those in current standard wall arrangements. The structure has a top plate and a bottom plate that are substantially the same, each plate having a groove along the center face, a central sheath is positioned between the top and bottom plates fitting into each groove. Pairs of vertical framing elements extend between the top and bottom plates with the central sheath sandwiched therebetween and attachments between the pairs of framing elements retain the central sheath in position.

Abstract: A door structure for cabinets according to the invention is configured in a double structure wherein a front door 1 of a cabinet 5 comprises a main surface part 1A, which constitutes the external face, and a metallic meshed member 4, which constitutes the internal face. In the main surface part 1A and the top, bottom, right and left side members 1B through 1E of the door are bored pluralities of ventilation holes 2 and 3, respectively, so that air, entering through lower holes and warmed inside, is discharged through upper holes by such actions as conduction and stirring within the cabinet 5. This structure can enhance both the electromagnetic shielding performance and the cooling effect.

Abstract: A shutter assembly is provided which includes an integral shutter body portion having side rails and either slats or raised panels there between. The shutter assembly also includes separately molded end caps and one or more mullions. The shutter body is adjusted to its desired length by cutting the shutter at one or both ends. The end caps are snapped onto the shutter body and/or welded into place. The mullion is then snapped onto the body to produce a finished, balanced appearance for the overall shutter assembly.

Abstract: Door apparatus includes a perimeter frame and material inwardly from the perimeter frame has been removed from both sides of the door asymmetrically to allow the inner portion of the door to warp in response to temperature and/or humidity conditions without affecting the planar nature of the door perimeter frame. The perimeter frame remains in its original, planar, configuration so as to remain true regardless of the warping of the interior portion of the door due to temperature and/or humidity. The method of making the door includes the asymmetrical removal of the material from the inner portion of the door inwardly from the perimeter door frame on both sides of the door to provide relatively thin webs between relatively thick door portions.

Abstract: Durable, high strength entry systems and methods for their manufacture are provided. The entry systems are formed by assembling profiles produced by extruding and then machining and/or molding a composite material. The profiles are formed in a preferred embodiment by extruding a cellulose composite material to produce an extrusion which preferably contains hollow sections which reduce the weight and cost of the material. The extruded composite can be machined and/or molded after the extrusion process to provide means for securing the profiles to each other or to glass and panel inserts. Entry systems, such as sidelights, transoms and exterior doors, can be produced from the assembled profiles which are durable and strong and therefore resist corrosion, denting and decay. The entry systems can be produced from low cost wood substitutes and provide the appearance of real wood. The entry systems can be readily treated with paint or other finishing materials to provide the desired exterior finish.