Abstract: A method for making a decorative polymer panel assembly for insertion into an opening of a door or window. The method can include forming a polymer grille by cutting a design into a polymer with a low-moisture content of no more than five wt %. The polymer grille can have a frame portion and a design portion. A seal can be contiguously disposed about a perimeter of the frame portion. A grille assembly can be formed by disposing a translucent panel on each side of the seal, forming an air space with the polymer grille disposed within the air space. The grille assembly can be pressed and heated to form a heat formed seal between the seal, the polymer grille, and each translucent panel. The grille assembly can then be cooled to an ambient temperature, forming the decorative polymer panel assembly.

Abstract: A method for making a door with a decorative polymer panel assembly. The method can include forming a polymer grille by cutting a design into a polymer with a low-moisture content. The polymer grille can have a frame portion and a design portion. A seal can be contiguously disposed about a perimeter of the frame portion. A grille assembly can be formed by disposing a translucent panel on each side of the seal, forming an air space with the polymer grille disposed within the air space. The grille assembly can be pressed, heated and cooled, forming the decorative polymer panel assembly. The decorative polymer panel assembly can be disposed within an opening of a door, and the door can be disposed within an opening of a structure.

Abstract: An external grille assembly for a door. The external grille assembly can include a door insert. The insert can have a translucent panel, an exterior frame with screw bosses, an interior frame with screw bosses attached to the exterior frame, a connector hole formed in one of the screw bosses, and a connector engaged within the connector hole. The connector can provide attachment between the insert and an external grille. The external grille can be removably and pivotably mounted to the insert and connector with a pin. The connector can include a first plate connected to a second plate, a first tubular disposed within the connector hole, a fastener engaging the first tubular within the connector hole and attaching the connector to the insert, and a second tubular for receiving the pin. Also disclosed is a method a making the external grille assembly.

Abstract: A connector for connecting a grille to a door. The connector can include a first plate connected to a second plate at a right angle. A first tubular can extend at a right angle from the first plate for inserting into a door insert frame, such as in a screw boss. The first tubular can have a hole for receiving a fastener and fastening the connector to a door. A second tubular can be disposed proximate an intersection of the first plate and the second plate. The second tubular can have a hole extending at a right angle to the hole of the first tubular for receiving a pin that can be used to connect a grille to the connector.

Abstract: A method for making window with a decorative polymer panel assembly. The method can include forming a polymer grille by cutting a design into a polymer with a low-moisture content. The polymer grille can have a frame portion and a design portion. A seal can be contiguously disposed about a perimeter of the frame portion. A grille assembly can be formed by disposing a translucent panel on each side of the seal, forming an air space with the polymer grille disposed within the air space. The grille assembly can be pressed, heated and cooled, forming the decorative polymer panel assembly. The decorative polymer panel assembly can be disposed within a frame which can be disposed within an opening of a structure.

Abstract: A decorative security panel assembly for insertion into an opening of a door or an opening of a window. The assembly can include a polymer security with a low-moisture content of no more than five wt %, such that the polymer security grille does not produce condensation within the assembly. A seal can be disposed about the polymer security grille. A translucent panel can be disposed over each side of the polymer grille and engaged with the seal. An air space can be formed between the two translucent panels, with the polymer security grille disposed within the air space. A first frame can be engaged over one of the translucent panels, while a second frame is engaged over the second translucent panel, forming a frame assembly. The frame assembly can be inserted into an opening of a door or an opening in a structure.