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This application claims the benefit of No. 60/180,650 filed Feb. 7, 2000. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to shutter assemblies for mounting on exterior walls of buildings, adjacent to windows. More specifically, the invention relates to a multi-component shutter assembly that provides a wide variety of shutter configurations that can be assembled from a few basic components. 
     BACKGROUND OF THE INVENTION 
     Simulated window shutters are often used on residential and commercial buildings for aesthetic purposes. Most of these shutters are made of thermoformed or injection molded plastic. Shutters can be produced in a variety of different styles, the most popular of which is the louvered shutter. A louvered shutter has a relatively narrow frame and horizontal slats over most of its length. Sometimes a horizontal mullion is positioned at or near the vertical midpoint of the shutter to divide it into upper and lower louvered sections. A mullion generally has the same width as, and appearance of, the frame. 
     The raised panel shutter is less popular than the louvered shutter, but is also sold in significant quantities. A raised panel shutter has a perimeter frame and at least one generally flat central panel spaced from the frame by a recessed channel. As with the louvered shutter, a horizontal mullion sometimes divides the central panel into upper and lower sections. 
     Another shutter design is the “combination” shutter having both louvered and raised panel sections on a single shutter. A combination shutter can have more than one raised panel section, and/or more than one louvered panel section if desired. The louvered sections and panel sections can be positioned at any location along the length of the shutter to achieve the desired appearance. 
     An infinite variety of shutters can be conceived. However, prior to the current invention, the variations of shutters manufactured was limited due to high tooling costs. Typically, each shutter requires the construction of specialized tooling. Now, the present invention provides a solution to this problem. The present invention provides a shutter assembly made of multiple, interchangeable components that can produce an infinite variety of shutter assemblies. 
     SUMMARY OF THE INVENTION 
     The present invention provides a shutter assembly having at least one louvered section and at least one raised panel section. The shutter assembly includes two components, the base shutter and a panel element. The base shutter, in turn, includes two components, a frame and louvers. A plurality of louvers are positioned along the length of the frame, each louver extending transversely across the width of the frame. The second component of the shutter assembly is a panel element that is securable to the base shutter. After securing, the panel element is thus the raised panel section. The present invention can be practiced with a panel element that is substantially longer than the width of the frame. Such a panel element is noticeably different from a mullion. The present invention can be practiced with a base shutter that is integrally molded. In such a base shutter, the louvers and the frame are formed together as a single unitary piece, preferably by a plastic injection molding process. The plastic molded, unitary base shutter is suitable for use with, or without, one or more of the panel elements. 
     The securing of the panel element on the base shutter can be accomplished through the use of a projection extending from the panel element. The projection will engage the base shutter in any one of several ways. The projection can fit between the louvers during the securing of the panel element and create a snap fit on a louver. The present invention can also be practiced wherein the projection is cylindrical shaped. In such an embodiment, the frame of the base shutter includes at least one aperture. The panel element is secured to the base shutter when the projection is inserted into the aperture. The insertion of the projection can create a snap fit or, alternatively, the projection can be thermally deformed or engaged with a separate fastener. 
     In another embodiment of the present invention, louvers can be removed from the base shutter to facilitate the securing of the panel element. Removal of a quantity of louvers will create a gap in the base shutter. The panel element is inserted in this gap from the rear side of the base shutter. Securing of the panel element can be accomplished by several alternative means. In one embodiment, the frame includes at least one stake extending from the rear side of the frame. In this embodiment, the panel element includes at least one aperture. The stake located on the frame is inserted into the aperture located on the panel element. The insertion can form a snap fit or the stake can be thermally deformed after insertion or a separate fastener can be provided. Another embodiment of the invention requires that the panel element include a lip. The lip can extend a sufficient distance from the panel element to ensure that the panel element will not be capable of insertion completely through the gap in the base shutter. In such an embodiment the panel element can be secured to the base shutter by a snap fit or by adhesive placed along the lip of the panel element and then mating the panel element with the front or rear side of the frame, or by ultrasonic spot welding of the panel to the base shutter. The present invention can also be practiced with a panel element that includes a lip. Further, the panel element can be secured to the front or rear of the base shutter with the use of adhesives placed on the lip, or by ultrasonic spot welding of the panel to the base shutter. The present invention also teaches a method of constructing a shutter assembly. A base shutter having a frame and louvers is provided. Also, a set of panel elements of different sizes and appearances from the base shutter is provided. At least one panel element of the set can be selected for attachment to the base shutter. Finally, the selected element is secured to the base shutter at a desired location. This method is capable of producing an infinite variety of shutter assemblies. The method taught by the present invention can be practiced with a panel element that is substantially longer than the width of the frame. The method of the present invention can also be practiced with a panel element including at least one projection extending from a rear surface. The panel element can be secured by the projection. The method of the present invention can also be practiced by forming a gap in the base shutter and inserting the panel element through the gap. This method allows production of one plastic molded, louvered base shutter, which can be modified as required to produce different external appearances to meet current consumer demands without extensive retooling of production equipment. 
     Other objects, advantages and applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein: 
     FIG. 1 is an exploded view of a shutter assembly according to a first embodiment of the present invention wherein elements are attached over louvers of a base shutter; 
     FIG. 2 is an assembly view of the shutter assembly of FIG. 1; 
     FIG. 3 is a cross-sectional view taken along line  3 — 3  of FIG. 2; 
     FIG. 4 is an exploded view of a second embodiment of the invention wherein elements are inserted through an aperture cut in the base shutter; 
     FIG. 5 is a cross-sectional view of the shutter assembly of FIG. 4; 
     FIG. 6 is an exploded view of an embodiment of the invention wherein a full-length panel element is attached to the base shutter by stakes formed on the frame; 
     FIG. 7 is a cross-sectional view of the shutter assembly of FIG. 6; 
     FIG. 8 is an exploded view of an embodiment of the invention wherein a combination louver/panel element is attached to the base shutter by stakes formed on the element; 
     FIG. 9 is a cross-sectional view of the shutter assembly of FIG. 8; 
     FIG. 10 is a cross-sectional view of the shutter assembly showing the engagement of the panel element and the base shutter with a heat stake; 
     FIG. 11 is a cross-sectional view of the shutter assembly showing the engagement of the panel element and the base shutter with a fastener; 
     FIG. 12 is a cross-sectional view of the shutter assembly showing the engagement of the panel element and the base shutter with adhesive or ultrasonic spot weld; and 
     FIG. 13 is a cross-sectional view of the shutter assembly showing the engagement of the panel element and the base shutter with a snap fit arrangement. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention provides a shutter assembly  10  having at least one louvered section  12  and at least one raised panel section  14 . As used herein, a “louvered section” refers to an area of the shutter assembly where the space between two lengths of the frame is occupied by one or more louvers  16 . In FIGS. 1 and 2, a louvered section  12  is shown with one or more louvers  16 . As used herein, a “raised panel section” refers to an area of the shutter assembly where the space between two lengths of frame is occupied by a panel element. A raised panel section  14  is shown in FIGS. 1 and 2 with at least one panel element  18 . 
     The shutter assembly  10  includes a base shutter  20  and a panel element  18 . As shown in FIG. 1, base shutter  20  includes a frame  22  having longitudinally extending elongated frame portions and transversely extending frame portions forming a peripheral portion of the assembly, and a plurality of transversely extending louvers  16 . Preferably, the base shutter  20  is formed of plastic by an injection molding process. The frame  22  and louvers  16  are preferably integrally molded into a single unitary piece. Base shutter  20  can be produced in different lengths and widths, sizes and shapes, to suite a wide variety of window sizes and a wide variety of colors, and preferably is suitable for use independent of the panel elements. 
     FIG. 1 shows a rectangular shaped base shutter  20 . However, shutters having half round or quarter round upper sections are well known in the art and are within the scope of the present invention. Furthermore, it is well known in the art to produce shutters that incorporate mullions that function to divide the shutter into two or more sections. Mullions are typically the same width as the frame  22 . Shutters incorporating mullions are within the scope of the present invention. 
     The shutter assembly of the present invention also incorporates a panel element  18 . Panel element  18  is preferably made of plastic and can be formed by injection molding or thermal forming. One or more panel elements  18  can be attached to base shutter  20  at desired locations along the length of the frame  22 . Ideally, panel element  18  can be manufactured in a variety of lengths and widths, sizes and shapes, styles and colors so that an infinite variety of shutter assemblies can be constructed. 
     The panel element  18  is secured to the base shutter  20  to form the shutter assembly  10 . The securing of the panel element  18  can be accomplished in several ways. Creating a shutter assembly  10  in this manner allows for maximum flexibility in creating a great variety of shutters, while, at the same time, limiting tooling expense in the production of shutter assemblies  10 . In one embodiment of the present invention, the panel element  18  is secured to the base shutter  20  through the use of a projection  24 . FIG. 3 shows one example of a projection  24  that is within the scope of the present invention. The projection  24  extends from a rear surface of the panel element  18 . As used herein, “rear surface” refers to the side of the panel element  18  that is hidden from view when the shutter assembly  10  is mounted next to a window. In FIG. 3 the projection  24  takes the form of a retainer  26 . The retainer  26  extends from the rear surface of panel element  18  in between louvers  16  and connects to at least one louver  16 . A snap fit edge  27  can be formed on the retainer  26  to operably engage a rear surface of the louver  16  to hold the panel element  18  securely to the frame  22 . 
     In FIG. 9 an alternative form of projection  24  is shown. The projection  24  takes the form of a stake  28 . In this embodiment of the present invention, frame  22  includes an aperture  30 . Aperture  30  is best shown in FIG.  8 . In this embodiment of the present invention, the securing of the panel element  18  is accomplished when stake  28  is inserted into aperture  30 . Securing of panel element  18  can be accomplished during the insertion by a snap fit arrangement as shown in FIG. 13, or by use of a separate fastener  46  engageable with the stake  28  as shown in FIG. 11, or by thermally deforming stake  28  after insertion as shown in FIG.  10 . If thermal deformation is the method chosen, stake  28  is known in the art as a “heat stake”. 
     The shutter assembly  10  can also be assembled by removing a quantity of louvers  16  from the base shutter  20 . Preferably, the louvers  16  are removed from the base shutter  20  by cutting a portion of the louvers  16  out of the frame  22 . When the louvers  16  are removed, a gap  32  is created in the base shutter  20 , as best illustrated in FIG. 4,  6 , or  8 . Once the gap  32  has been formed, the panel element  18  is inserted into the base shutter  20  from a rear or front side of the base shutter  20 . As used herein, the “rear side of the base shutter” is the side that is hidden from view when the shutter assembly  10  is mounted next to a window. As used herein the “front side of the base shutter” is the side that is visible when the shutter assembly  10  is mounted next to a window. 
     In embodiments of the present invention wherein one or more louvers  16  are removed to form gap  32 , the panel element  18  can be secured to the base shutter  20  in several alternative ways. Preferably, panel element  18  includes a projection  24 . Furthermore, the projection  24  can take the form of a lip  34 . The lip  34  can extend from the panel element  18  in a generally tangential direction as best seen in FIG.  5 . FIGS. 7 and 9 show an alternative variation on lip  34 . The lip  34  can support an aperture  30 , or a stake  28 , or any combination thereof for connecting with complementary structure on the frame  22 . 
     FIG. 5 shows one embodiment of the present invention incorporating a gap  32  between the frame  22  and a panel element  18  including a lip  34 . In this variation of the present invention, panel element  18  is inserted through gap  32  and, preferably, is slightly deformed. This deformation creates a resiliency force in the direction of arrow  36  and a snap fit between panel element  18  and frame  22  is achieved. Lip  34  acts to prevent panel element  18  from completely passing through frame  22 . 
     The panel element  18  can be formed such that a snap fit with frame  22  is not achieved. Specifically, the panel element will be formed such that its width, excluding the lip  34 , is equal to or less than the width of gap  32 . In such an embodiment, the panel element  18  can be secured to the frame  22  through the use of ultrasonic spot welding or adhesive  38  as best seen in the detail of FIG.  12 . 
     In another embodiment of the present invention employing a gap  32 , the frame  22  can include a stake  28 . Furthermore, in such an embodiment the lip  34  of the panel element  18  can include an aperture  30 . The securing of the panel element  18  to the frame  22  is functionally identical to the method described above. The stake  28  is inserted into aperture  30 , aperture  30  now being part of panel element  18 . The insertion can create a snap fit arrangement for stake  28 , as shown in FIG.  13 . In addition, or alternatively, the stake  28  can be thermally deformed as shown in FIG.  10 . The present invention can also be practiced in a third embodiment. The panel element  18  can include a lip  34 . The base shutter  20  can be unmodified (i.e., no gap  32 ). In such an embodiment, the panel element  18  is secured to the front of the base shutter  20  through the use of ultrasonic spot welding or adhesive  38  as shown in the detail of FIG.  12 . The panel element  18  is positioned at a desired location along the frame  22 , spot welding is performed or adhesive  38  is positioned on one side, front or rear, of the lip  34 , and the panel element  18  is pressed against the frame  22 . The securing of the panel element  18  to the frame  22  through the use of a stake  28  and aperture  30  can also be accomplished wherein a separate fastener  46  is used, as best shown in FIG.  11 . 
     The shutter assembly  10  of the present invention can be practiced with a combination element  40 , as best seen in FIG.  8 . The combination element  40  is a variant of the standard panel element  18 . In FIG. 8, a combination element  40  having a flat planer section  42  and a louvered section  44  is shown. All of the securing methods detailed above are generally applicable to the combination element  40 . Combination element  40  can include a projection  24 , or a retainer  26 , or a lip  34  or any combination thereof for attaching to the base shutter  20 . Projection  24  can extend from combination element  40  at the flat planar section thereof. 
     The present invention also teaches a method of constructing a shutter assembly  10 . A base shutter  20  is provided, having a frame  22  and a plurality of transversely extending louvers  16 . A set of panel elements  18  of different sizes and appearances are provided. At least one panel element  18  of the set is selected, and secured to the base shutter  20 . The panel element  18  can be secured at any position along the frame  22  of the base shutter  20 . The method taught by the present invention can be practiced wherein the panel element  18  is substantially longer than the width of the frame  22 . This arrangement is shown in FIG. 2, wherein panel element  18  is clearly longer than a cross-section of frame  22  is wide. The method of the present invention can be practiced wherein the panel element  18  includes at least one projection  24  extending from a surface thereof, such as stake  28  extending from the rear surface of the panel  18 , or alternatively from the rear surface of the base shutter  20 . In this embodiment of the invention, the panel element  18  covers a plurality of louvers  16 . 
     Alternatively, the present invention can be practiced wherein louvers  16  are removed from the base shutter  20  and the panel element  18  is inserted through the gap  32  created therein. FIG. 6 shows one example, albeit an extreme example, of the present invention. All the louvers  16  have been removed from the base shutter  20  leaving essentially only a frame  22 . The panel element  18  is inserted into frame  22  and completely occupies the space between the sides of the frame  22 . 
     The flexibility in the manufacture of shutter assemblies provided by the present invention allows for an infinite variety of shutters to be produced. Certainly, all of the possible variations are not detailed in this specification. 
     While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.

Summary:
A multi-component shutter assembly for the production of decorative shutters having a nearly infinite variety of different combinations of louvered sections and raised panel sections with a greatly reduced tooling cost. The shutter system includes a base shutter having a perimeter frame and transverse louvers along its length, and a set of elements which are attachable to the base shutter. The elements are manufactured in a wide variety of different sizes, styles, and colors, and any one or more of the elements can be attached to the base shutter at any desired location along its length to produce a shutter assembly of the desired appearance. The elements can be fastened to the front of the base shutter to cover the louvers at that location, or some or all of the louvers of the base shutter can be cut away and removed to form an aperture and the element fastened to the base shutter to cover the aperture.