Abstract: A structural polymeric composite includes a stiffening layer. The composite is made in a continuous extrusion process in which the stiffening layer is pulled through a cross-head die as a polymer is extruded over it. The layer includes a film or textile carrier, a filler of carbon fibers, fiberglass, organic fibers or minerals forming a mat. A binder may be dispersed over the mat and a second carrier applied. The mat is subjected to heat and pressure to soften the carriers and binder so they penetrate into the interstices of the filler and binds mechanically with them and the carriers and binder bind chemically with each other to form the stiffening layer. A polymer is then extruded over the stiffening layer, which may be used flat, provided with holes or punches for composite action with the polymer, formed into a profile, or segmented to provide spaced-apart stiffening layers.

Abstract: A structural polymeric composite includes a stiffening layer. The composite is made in a continuous extrusion process in which the stiffening layer is pulled through a cross-head die as a polymer is extruded over it. The layer includes a film or textile carrier, a filler of carbon fibers, fiberglass, organic fibers or minerals forming a mat. A binder may be dispersed over the mat and a second carrier applied. The mat is subjected to heat and pressure to soften the carriers and binder so they penetrate into the interstices of the filler and binds mechanically with them and the carriers and binder bind chemically with each other to form the stiffening layer. A polymer is then extruded over the stiffening layer, which may be used flat, provided with holes or punches for composite action with the polymer, formed into a profile, or segmented to provide spaced-apart stiffening layers.

Abstract: A structural polymeric composite includes a stiffening layer. The composite is made in a continuous extrusion process in which the stiffening layer is pulled through a cross-head die as a polymer is extruded over it. The layer includes a film or textile carrier, a filler of carbon fibers, fiberglass, organic fibers or minerals forming a mat. A binder may be dispersed over the mat and a second carrier applied. The mat is subjected to heat and pressure to soften the carriers and binder so they penetrate into the interstices of the filler and binds mechanically with them and the carriers and binder bind chemically with each other to form the stiffening layer. A polymer is then extruded over the stiffening layer, which may be used flat, provided with holes or punches for composite action with the polymer, formed into a profile, or segmented to provide spaced-apart stiffening layers.

Abstract: A safety barrier is formed of framing, including a guard rail that defines the infill below the rail without the use of pickets. The infill is covered with mesh screen, which may be made of nylon which has greater tensile strength than conventional fiberglass. The mesh screen is held to the framing by an extruded base. The base has a central channel between two flat spline grooves. Flat splines hold mesh screen in their respective grooves more securely than conventional friction-based channel splines. A metal plate is positioned in the central channel to enables screws that secure the base to be tightened to hold it to the framing better. The elimination of pickets in the infill leaves the view unobstructed and allows other treatments of that portion of a deck or porch that are more aesthetically pleasing without compromising safety.

Abstract: A screen door made of foamed polymer with heat welded joins between rails and stiles and a flat spline groove. The rails and stiles are extruded with the flat spline groove. Prior to joining the rails and stiles, a thin notch is made to remove the smooth skin of the extruded stiles before being joined to the cut ends of the rails. The heat welded joint between the notched stile and cut end of the rail is ten times stronger than conventional polymer door joints. A flat spline is used to insert the marginal portion of the screen into the flat spline groove, which is wider in the interior than at its entrance and resists the pull from normal forces on the screen much more effectively than a round spline in a rectangular groove.

Abstract: A lineal retainer kit for facilitating the covering of openings defined by porch framing with mesh screening and a second material. The primary components of the kit are a lineal retainer, two splines for the two opposing grooves in the lineal retainers, a cap, and fasteners to hold the lineal retainers to the framing, and possibly also including mesh screening material. The lineal retainers use opposing grooves and splines to hold two different coverings, such as mesh screening and plastic film or a fabric, at the same time. In particular, the kit enables homeowners or contractors to tailor the environment of a porch to better meet the homeowner's needs by providing an easy way to add shade, privacy, ultraviolet light protection, or a different aspect of the porch decor.

Abstract: A retainer strip assembly for securing screening and screen covering and the like to a framing member comprises a base strip, cover strip and cap strip fastened to the framing member, the cap strip covering the base strip and holding in place the screening and screen covering, and the cover strip contained within the base strip for avoiding the tearing or fraying of screen covers when the cap strip is placed on or removed from the base strip while installing or removing screen covers.

Abstract: An enclosure, such as a column for supporting a roof, is defined by plural, adjacent, beveled segments, including two outermost segments, folded and joined. An adhesive is used on the beveled edges to help hold the shape of the enclosure. In addition, the edges of the outermost segments are configured to interlock so that, with manual force and no tools, the outermost segments can be snapped together, thereby holding the enclosure while the adhesive cures. The configurations on the outermost edges are preferably made of interlocking projections and recesses, at least one of which projections is displaced slightly when the outermost segments are joined. The segments may be formed by milling a single panel while applying tape to the joints between segments to hold them in adjacent relationship. The tape may then be removed after the enclosure is formed. The preferred material for the enclosure is foamed plastic.

Abstract: A framing system for mounting flexible sheets of material, such as screening in an opening in a wall or porch includes U-shaped channels, or lineals, having at least one external built-in groove for receiving a spline strip for holding an edge of the sheet in place in the groove. Four lineals define a rectangular opening over which the sheet is stretched and then secured in place by jamming its edges into the external spline grooves of the surrounding four lineals with the spline strips to hold the sheet in place. Universal fasteners hold the lineals to the porch walls. The universal fasteners also have alignment grooves on their upper surface, lower surface or both of these surfaces that are useful for receiving an alignment string or wire to align a series of the fasteners across a surface so that they are in line to receive and accurately align a single lineal or multiple lineals arranged end to end.