Screen door

摘要

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.

主权项

1. A process for making a screen door comprising the steps of:
(a) extruding two stiles of foamed vinyl, each stile of said two stiles having a spline groove, said spline groove having an entrance and an interior, said two stiles having a skin exterior and a porous interior, and wherein said entrance to said spline groove is narrower than said interior of said groove, wherein said each stile has a top end and an opposing bottom end; (b) cutting said top end and said bottom end of said each stile of said two stiles to expose said porous interior; (c) extruding two rails of foamed vinyl, each rail of said two rails having a spline groove, each rail of said two rails having a skin exterior and a porous interior, said spline groove in said each rail having an entrance and an interior, and wherein said entrance to said spline groove is narrower than said interior of said groove, wherein said each rail of said two rails has a left end and a right end; (d) cutting said left end and said right end of said each rail to expose said porous interior; (e) securing said porous interior of said left end and said right end of a first rail of said two rails to said porous interior of said top ends, respectively, of said two stiles, and said porous interior of said left end and said right end of a second rail of said two rails to said porous interior of said bottom ends, respectively, of said two stiles to form joints for a rectangular frame resistant to moisture and having an opening within said frame bordered by said two rails and said two stiles; (f) covering said opening of said two stiles and two rails with screen mesh; and (g) inserting a spline over said mesh and into said spline grooves of said two stiles and two rails to hold said screen mesh in said spline grooves of said two stiles and said two rails, said spline having a major dimension and two minor dimensions, wherein one minor dimension of said two minor dimensions is larger than said other minor dimension of said two minor dimensions.