Methods and Systems for Manufacture of a Rot-Resistant Shutter

Abstract

A rot-resistant window shutter and method of manufacture therefor, wherein the shutter is manufactured as a one-piece construction from a suitable cellular polyvinyl chloride substrate, and may be selectively structural and/or aesthetically manipulated without concern of degradation of structural integrity of the shutter, and thus without concern of jeopardizing the rot-resistivity thereof.

1 . A system for making a rot-resistant product comprising;
 a table;   a motorized cutting element;   a jig; and   a rot-resistant material;   whereby a pattern is formed on at least a forward surface of said rot-resistant material by said motorized cutting element and wherein said pattern is formed according to a configuration of said jig.   
   
   
       2 . The system for making a rot-resistant product of  claim 1 , wherein said motorized cutting element comprises a router. 
   
   
       3 . The system for making a rot-resistant product of  claim 2 , wherein said router comprises a guide in the shape of a disc disposed concentrically about an axis of rotation of said motorized cutting element. 
   
   
       4 . The system for making a rot-resistant product of  claim 3 , wherein said guide comprises at least one rolling element operatively connected thereto for reducing a frictional force acting on said guide when said router is in operation. 
   
   
       5 . The system for making a rot-resistant product of  claim 3 , wherein said jig comprises a plurality of adjustable members, forming an interior perimeter of said jig. 
   
   
       6 . The system for making a rot-resistant product of  claim 5 , wherein an exterior side surface of said guide is maintained in contact with said interior perimeter during a time when said pattern in formed. 
   
   
       7 . The system for making a rot-resistant product of  claim 5 , wherein said plurality of adjustable members comprise at least one of a plurality of tracks and a quick lock mechanism. 
   
   
       8 . The system for making a rot-resistant product of  claim 1 , wherein said motorized cutting element comprises a milling machine. 
   
   
       9 . The system for making a rot-resistant product of  claim 1 , wherein said motorized cutting element comprises a single blade comprising a plurality of sharp teeth disposed along a length thereof. 
   
   
       10 . The system for making a rot-resistant product of  claim 8 , wherein said jig comprises a linear member disposed along an edge of said table along an axis generally perpendicular to a major axis of said motorized cutting element. 
   
   
       11 . The system for making a rot-resistant product of  claim 1 , wherein said table comprises a material having surface having a low coefficient of friction. 
   
   
       12 . The system for making a rot-resistant product of  claim 1 , wherein said jig comprises at least one of a linear member disposed along an edge of said table along an axis generally perpendicular to a major axis of said motorized cutting element and a plurality of adjustable members, forming an interior perimeter of said jig. 
   
   
       13 . A method for making a rot-resistant product comprising the steps of:
 a. providing a rot-resistant workpiece; and   b. contacting at least a forward surface of said rot-resistant workpiece with a rotary cutting element to form a rot-resistant product including at least one pattern in at least said forward surface.   
   
   
       14 . The method for making a rot-resistant product of  claim 13 , wherein said rotary cutting element comprises a milling machine, and wherein said contacting step comprises passing said workpiece through said milling machine to form a linear pattern. 
   
   
       15 . The method for making a rot-resistant product of  claim 13 , wherein said rotary cutting element comprises at least one single blade comprising a plurality of sharp teeth disposed along a length thereof. 
   
   
       16 . The method for making a rot-resistant product of  claim 13 , wherein said rotary cutting element comprises a router. 
   
   
       17 . The method for making a rot-resistant product of  claim 13 , further comprising the step of guiding at least one of said workpiece and said rotary cutting element using a jig system. 
   
   
       18 . A method for making a rot-resistant product comprising the steps of:
 providing a rot-resistant workpiece;   forming a plurality of patterns in at least a forward surface of said workpiece; and   separating at least a portion of said workpiece, said portion including at least one pattern formed in said forward surface to form a rot-resistant product.   
   
   
       19 . The method for making a rot-resistant product of  claim 18 , wherein the step of forming further includes contacting a rotary cutting element with at least a portion of said forward surface. 
   
   
       20 . The method for making a rot-resistant product of  claim 18 , wherein the step of forming further includes guiding at least one of said workpiece and a tool using a jig system.