Abstract:
A shutter is manufactured by laminating top and bottom surfaces of a substrate material. The substrate material is then cut in bulk, forming strips that are shaped, sanded, edge-laminated and cut to length so as to create prefinished shutter components. These components are then assembled into a completed shutter. The laminates provide a high gloss, piano finish that is more scratch resistant and easier to clean, dust and maintain than spray-painted coatings used on conventional shutters. Tongue and groove joint construction reduces component chipping and cracking and provides significantly more surface glue space than conventional doweled joints. Also, louver tension control anchors prevent warping and bowing of the shutter frame and will not strip out of the louvers as would conventional tension controllers using “screw into wood” construction. The louver to tilt bar links are glued within predrilled holes in the louvers to reduce the cracking and splitting caused by conventional staple gun insertion of links. These techniques also allow shutter components to be thinner and composed of medium density fiberboard (MDF), which would be especially prone to damage with conventional construction methods. The combination prefinished, MDF substrate shutter components and associated construction methods achieve a high-quality shutter at a much reduced cost over conventional shutters constructed entirely of indigenous wood that is spray-painted after assembly.

Description:
[0001]    This application claims the benefit of provisional patent application No. 60/233,307 entitled Pre-Coated Medium Density Fiberboard Shutter, filed Sep. 15, 2000. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    Shutters are a high quality interior window treatment, having a combination of style, functionality and elegance that sets them apart from other window coverings. Shutters provide warmth in the winter and protect from damaging heat and sunlight in the summer. Shutters also provide complete control of view, privacy and light. Conventional shutters are made of an indigenous wood such as popular, oak or ash. The shutter components are typically assembled using doweling, screws and staples. After assembly, the shutters are stained or painted.  
         SUMMARY OF THE INVENTION  
         [0003]    The basic shutter manufacturing process described above may have been in use for hundreds of years or more. This process, however, has various disadvantages. Shutters manufactured using a “coat after assembly” method are costly to produce, and conventional finishes used in the shutter industry, such as spray paint, can scratch, mar, and smudge during the assembly process, rendering pre-coating impractical. Further, indigenous woods are relatively expensive, and shutters manufactured from indigenous woods are costly to prepare for assembly and are not amenable to modern coating processes. In addition, conventional coatings on indigenous wood are easily damaged during installation and use and are difficult to clean.  
           [0004]    To overcome some of these disadvantages of conventional shutters, a shutter according to the present invention is finished before assembly. This prefinishing process uses laminates that resist damage during and after assembly and that are easy to clean using standard household products. The lamination processes are largely automated and performed in bulk, reducing manufacturing time and costs. The shutter according to the present invention also utilizes a composite, manufactured wood made of medium density fiberboard (MDF) material. MDF is a less expensive material than indigenous wood and less costly to prepare. MDF has a suitable surface for modern laminates and is durable enough during assembly to allow prefinishing.  
           [0005]    Attempting to assemble shutters from MDF utilizing conventional attachment techniques, such as dowels, screws and staples, however, is problematic due to the tendency of MDF to crack and split. Further, MDF warps and bows with a degree of deflection dependent on the size of the material used. As a result, large, unsightly gaps can develop in installed shutters made from MDF. These inherent problems with MDF have been a barrier to the use of MDF in the shutter industry.  
           [0006]    To overcome the disadvantages of MDF shutter construction, a shutter according to the present invention utilizes tongue and groove construction for assembly of shutter components, significantly reducing the cracking and splitting of the MDF material. Further, the shutter is constructed with a louver tension control that also functions as a frame stabilizer, significantly reducing the warping and bowing of the MDF material. Advantageously, the tongue and groove assembly and the frame stabilizer allow shutters to be constructed with thinner than conventional material, further reducing costs. In addition, links for attaching a tilt bar with louvers are inserted using predrilled holes and glue rather than a conventional staple gun, also reducing the cracking and splitting of the MDF material. These assembly techniques allow MDF to be used as the primary material, overcoming inherent problems to achieve the end result of a quality shutter.  
           [0007]    One aspect of the present invention is a shutter manufacturing method comprising the steps of applying a first laminate to a surface of a substrate to form a laminated sheet and cutting the laminated sheet to a predetermined width to form a laminated board. Further steps are milling an edge of the laminated board to form a milled edge and applying a second laminate to the milled edge. Additional steps are cutting the laminated board to a predetermined length to form a prefinished shutter component and assembling the prefinished shutter component into a shutter. In one embodiment the prefinished shutter component is a louver, and the method comprises the further steps of drilling a link hole into the milled edge and gluing a link into the link hole. In another embodiment the prefinished shutter component is a louver, and the method comprises the further steps of drilling a pin hole in an end of the prefinished shutter component and applying the second laminate to the end over the pin hole. An additional step may be press fitting a pin into the pin hole through the second laminate. An alternative additional step may be threading an anchor into the pin hole. In yet another embodiment the substrate is medium density fiberboard (MDF), the first laminate is a hot roll laminate of decorative paper, and the second laminate is a heat transfer foil.  
           [0008]    Another aspect of the present invention is a shutter comprising a pair of stiles each having a pair of opposite stile faces, a pair of opposite stile edges and a pair of opposite stile ends. The shutter also comprises a pair of spreaders each having a pair of opposite spreader faces, a pair of opposite spreader edges, and a pair of opposite spreader ends, the spreaders each fixedly attached between the stiles so as to form a frame. The shutter further comprises a plurality of louvers each having a pair of opposite louver faces, a pair of opposite louver edges, and a pair of opposite louver ends, the louver ends rotatably mounted to inside ones of the stile edges so that the louvers are within the rectangular opening. The stile faces, the spreader faces and the louver faces have a first laminate and at least one each of the stile edges, the spreader edges and the louver edges have a second laminate.  
           [0009]    In one embodiment, the shutter further comprises a plurality of frame stabilizers located at a predetermined spacing along the stiles. In a particular embodiment, the spacing is no greater than about 24 inches. Each of the frame stabilizers may comprise a selected louver, a pin hole drilled within one of the selected louver ends, an anchor fixedly mounted within the pin hole; and a tensioning screw adjustably retained within one of the stiles and threaded into the anchor so as to control the rotation of the louvers and stabilize the frame. The anchor may comprise a plurality of coarse threads adapted to grip within the pin hole. In a particular embodiment the number of the threads is at least about 9.  
           [0010]    The shutter may also comprise a drilled link hole located along a leading edge of the louvers and a link glued with the link hole. The spreaders and the louvers may each have a medium density fiberboard (MDF) core wherein the first laminate is a hot roll paper laminate and the second laminate is a heat transfer foil. In a particular embodiment the stiles have a thickness in the range of about ¾ to 1¼ inches, and the spreaders have a thickness in the range of about ⅝ to 1¼ inches.  
           [0011]    A further aspect of the present invention is a shutter manufacturing method comprising the steps of coating a plurality of attached shutter components, separating the attached shutter components into a plurality of prefinished shutter components, and incorporating the prefinished shutter components into a shutter assembly. In one embodiment, the attached shutter components comprise a board and the separating step comprises the step of cutting along end portions of the attached shutter components. In another embodiment, the attached shutter components comprise a sheet and the separating step comprises the step of cutting along edge portions of the attached shutter components. The method may further comprise the step of coating a cut edge portion of the attached shutter components. Also, the method may further comprise the step of cutting attached end portions of the attached shutter components. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    [0012]FIG. 1 is a perspective view of a prefinished, medium density fiberboard (MDF) shutter according to the present invention;  
         [0013]    [0013]FIG. 2 is an exploded perspective view of a prefinished MDF shutter;  
         [0014]    [0014]FIG. 3 is a front perspective view of a prefinished MDF shutter mounted within a window frame;  
         [0015]    [0015]FIG. 4 is a back perspective view of a finger-jointed, natural wood window frame, such as shown in FIG. 3;  
         [0016]    FIGS.  5 A-D are end, outside edge, front and inside edge views, respectively, of a partial groove stile;  
         [0017]    FIGS.  6 A-E are outside edge, perspective, front, and end views of a top spreader, and a perspective view of a bottom spreader, respectively;  
         [0018]    FIGS.  7 A-D are leading edge, perspective, top and end views of a louver;  
         [0019]    FIGS.  8 A-D are end, perspective, front edge and side views of a tilt bar;  
         [0020]    FIGS.  9 A-B are front-end and back-end perspective views, respectively, of a threaded anchor for louver tension control and frame stabilization;  
         [0021]    FIGS.  10 A-B are flowcharts of a shutter component prefinishing process and a prefinished shutter assembly process, respectively, according to the present invention;  
         [0022]    [0022]FIG. 11 is a perspective view of a laminated and cut substrate sheet;  
         [0023]    [0023]FIG. 12 is a perspective view of a laminated and cut substrate board;  
         [0024]    [0024]FIG. 13 is a perspective view of a laminated component;  
         [0025]    FIGS.  14 A-G are end, front, inside edge, perspective, exploded inside edge perspective, exploded outside edge perspective and detailed end views, respectively, of a full groove stile;  
         [0026]    FIGS.  15 A-D are end, outside edge, front and inside edge views, respectively, of a full groove stile base;  
         [0027]    FIGS.  16 A-E are front, side, end and detailed end views, respectively, of a groove insert;  
         [0028]    FIGS.  17 A-B are exploded perspective and perspective views, respectively, of a capped louver;  
         [0029]    FIGS.  18 A-C are inside face perspective, outside face perspective, and alternative embodiment outside face perspective views, respectively, of a louver end cap; and  
         [0030]    [0030]FIG. 19 is an exploded perspective view of an alternative embodiment prefinished MDF shutter. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0031]    Shutter Overview  
         [0032]    [0032]FIG. 1 illustrates an assembled, prefinished, medium density fiberboard (MDF) shutter  100  according to the present invention. The shutter  100  is installable within a window opening and operable to control the amount of light entering a building interior and to maintain the privacy of the building occupants, in a manner that is well known in the art. The shutter  100  has stiles  500 , spreaders  600 , louvers  700  and a tilt bar  800 . In the embodiment shown, the stiles  500  are fixedly attached to the spreaders  600  so as to form a shutter frame  102  having a generally rectangular opening  104 . One of ordinary skill in the art will recognize that shutter embodiments having non-rectangular openings to accommodate windows of various sizes and shapes can be constructed using the materials and processes described herein and are contemplated to be within the scope of the present invention.  
         [0033]    As shown in FIG. 1, the louvers  700  are rotatably mounted to the stiles  500  within the frame  102 . The tilt bar  800  is linked to the leading edges of the louvers  700  and operable up and down so as to rotate the louvers to various positions. The shutter  100  has a closed position (shown) with the tilt bar  800  in a fully up position and the louvers  700  overlapping along the edges so as to block light from passing through the opening  102 . The shutter  100  also has various open positions (not shown) with the tilt bar  800  positioned away from the fully up position and the louvers  700  rotated away from the plane of the opening  102  so as to allow light to pass.  
         [0034]    [0034]FIG. 2 shows a shutter  100  in exploded perspective view, further illustrating the various shutter components. A pair of stiles  500 , a top spreader  600  and a bottom spreader  650  are mutually attached using tongue and groove construction to form a shutter frame  102  (FIG. 1). The stiles  500  are described in detail with respect to FIGS.  5 A-D, below. The spreaders  600 ,  650  are described in detail with respect to FIG. 6A-E, below. The louvers  700  are rotatably mounted to the stiles  500  using standard louver pins  210 , such as Sullivan part #F9020W, which is a 1″ plastic pin with a ⅛″ dia.×⅝″ portion including a {fraction (1/32)}″ spacer that is press-fit into a louver  700  and a ¼″ dia.×⅜″ cylindrical portion that rotates within a stile  500 .  
         [0035]    As shown in FIG. 2, one or more selected louvers  700  receive an anchor  900  instead of a louver pin  210 . Each louver  700  having anchors  900  is rotatably mounted to the stiles  500  with a pair of standard 8-32×2″ roundhead screws  230 . The anchors  900  and screws  230  advantageously function both as an adjustable louver tension control and a frame stabilizer. The anchors  900  and the associated tension control and frame stabilization mechanisms are described in detail with respect to FIGS.  9 A-B, below. The tilt bar  800  is attached to an edge of each of the louvers  700  with an interlocked tilt bar link  240  and louver link  250 , such as a 1″×¼″×{fraction (1/16)}″ dia. wire staple and a ¾″×¼″×{fraction (1/16)}″ dia. wire staple. Prefinishing and construction of the shutter components is described in detail with respect to FIG. 10A, below. Assembly of the shutter components is described in detail with respect to FIG. 10B, below.  
         [0036]    FIGS.  3 - 4  illustrate a window frame  400 . FIG. 3 is a front, perspective view illustrating a shutter  100  mounted within a window frame  400 . FIG. 4 is a back, perspective view illustrating one embodiment of a prefinished window frame  400  utilizing finger-jointed, natural wood. As shown in FIG. 3, a shutter  100  is attached to a window frame  400  with hinges  310  mounted to the window frame  400  and one of the stiles  500 , allowing the shutter  100  to swing open or closed. As shown in FIG. 4, the window frame  400  has a finger-jointed, natural wood core  410  such as formed from 2′, 3′ or 4′ pieces of poplar. The wood core  410  is partially finished with a profile wrap  420 . The wrapped sections of the window frame  400  are attached at the corners with screws, nails or staples, as is well-known in the art.  
         [0037]    Shutter Component Details  
         [0038]    Stiles  
         [0039]    FIGS.  5 A-D illustrate a partial groove stile embodiment  500 . A full groove stile embodiment  1400  (FIGS.  14 A-G) is described with respect to FIGS.  14 - 16 , below. A stile  500  is a generally elongated, planar shutter component having first and second faces  501 , first and second ends  503 , an outside edge  505  and an inside edge  507 . A pair of stiles  500  form the sides to an assembled shutter frame  102  (FIG. 1), as described above, and extend vertically when a shutter  100  (FIG. 1) is installed in a conventional window. Stiles  500  provide mounts for the shutter louvers  700  (FIG. 1), as described with respect to FIGS.  1 - 2 , above, and a structure for hinge attachment to a window frame  400  (FIG. 3), as described with respect to FIG. 3, above.  
         [0040]    In one embodiment, a stile  500  is prefinished, having a substrate material with a first laminate applied to the stile faces  501  and a second laminate applied to the stile edges  505 ,  507 . In a particular embodiment, the core material is medium density fiberboard (MDF), the first laminate is a decorative paper, such as US Coatings High Gloss OSS White, and the second laminate is a heat transfer foil, such as Kurtz part #C87046SR. The lamination process is described with respect to FIGS.  10 - 13 , below.  
         [0041]    Also shown in FIGS.  5 A-D, a stile  500  has partial grooves  510  extending within each end  503  toward the opposite end  503  along the inside edge  507 . The grooves  510  are configured to receive the spreader tongues  610  (FIGS.  6 A-E). Also, a stile  500  has a number of pin holes  530  extending into the stile  500  perpendicularly from the inside edge  507  and spaced at regular intervals along the inside edge  507 . The pin holes  530  are configured to receive a louver pin  210  (FIG. 2) for rotatably mounting a louver  700  (FIG. 2), as described with respect to FIGS.  1 - 2 , above and FIG. 10B, below. Further, the stile  500  has one or more tension adjustment holes  550  extending into the stile  500  at a predetermined spacing along the outside edge  505 . The adjustment holes  550  are configured to accept a tensioning screw  230  (FIG. 2) threaded into an adjustment hole  550 , out a corresponding pin hole  530  and into an anchor  900  (FIG. 2), so that the head of the screw  230  (FIG. 2) is retained within the stile  500 .  
         [0042]    As shown in FIGS.  5 A-D, the stile length is window frame dependent, which is a custom measurement for each installation. In a particular MDF embodiment, a stile width, i.e. across a face  501 , is 2″-4″ and a stile thickness, i.e. across an edge  505 ,  507 , is ¾″. A standard wood shutter typically is constructed with 1¼″ thickness boards for both stiles and spreaders. The stile  500  of the present invention is advantageously constructed of thinner MDF, i.e. in the range of ¾″ to 1¼″, providing a shutter with comparable strength and less cost due to less material used. In this particular embodiment, a groove  510  is ¼″×¾″ and corresponds to a spreader width. A pin hole  530  is ¼ 41  dia.×⅜″, and a tension adjustment hole  550  is ⅜″ dia.  
         [0043]    Spreaders  
         [0044]    FIGS.  6 A-E illustrate a spreader  600 ,  650 . A spreader  600 ,  650  is a generally planar shutter component having first and second faces  601 , first and second ends  603 , a inside edge  605  and an outside edge  607 . A top spreader  600  and a bottom spreader  650  (FIG. 6E) form the top and bottom of an assembled shutter frame  102  (FIG. 1), as described above, and extend horizontally when a shutter  100  (FIG. 1) is installed in a conventional window. A spreader  600 ,  650  has a shaped cutout  620  along the length of the inside edge  605  configured to accommodate a louver edge  705 ,  707  (FIGS.  7 A-D) when the shutter  100  (FIG. 1) is closed. As shown in FIGS.  6 A-D, a top spreader  600  has a notch  630  in one face  601  at the inside edge  605  generally centered between the ends  603 . As shown in FIG. 6E, a bottom spreader  650  is identical to a top spreader  600  except that it does not have the notch  630  (FIGS.  6 B-C). A top spreader  600  is installed in the shutter frame  102  (FIG. 1) with the cutout  620  proximate the tilt bar  800  (FIG. 1). The bottom spreader  650  (FIG. 6E) is installed in the shutter frame  102  (FIG. 1) with the cutout  620  distal the tilt bar  800  (FIG. 1). A spreader  600 ,  650  also has tongues  610  extending away from each end  603 . The tongues  610  are configured to insert into the stile grooves  510  (FIGS.  5 A-D).  
         [0045]    In one embodiment, a spreader  600 ,  650  is prefinished, having a substrate material with a first laminate applied to the spreader faces  601  and a second laminate applied to the spreader inside edge  605 . In a particular embodiment, the substrate material is medium density fiberboard (MDF), the first laminate is a decorative paper, and the second laminate is a heat transfer foil, as described with respect to FIGS.  5 A-D, above. The lamination process is described with respect to FIGS.  10 - 13 , below.  
         [0046]    As shown in FIGS.  6 A-E, the spreader length is window frame dependent, which is a custom measurement for each installation but less than 30″ as determined by the louver length, as described with respect to FIGS.  7 A-D, below. In a particular MDF embodiment a spreader width, i.e. across a face  601 , is 2½″-5″ and a spreader thickness, i.e. across an edge  605 ,  607  is ⅝″. Like a stile  500  (FIGS.  5 A-D), in this particular embodiment a spreader  600 ,  650  is advantageously thinner, i.e. in the range of ⅝″ to 1 ¼″, than a standard wood shutter typically constructed with 1¼″ thickness, providing a shutter with comparable strength and less cost due to less material used. In this particular embodiment a spreader  600 ,  650  is thinner than a stile  500  (FIGS.  5 A-D), creating a ⅛″ step  108  (FIG. 1) that advantageously disguises a stile-spreader seam between these two components. Also in this particular embodiment, a tongue is ¼″×¾″ and extends most of the spreader width.  
         [0047]    Louvers  
         [0048]    FIGS.  7 A-D illustrate a louver  700 , which is a generally planar shutter component having first and second faces  701 , first and second ends  703 , a leading edge  705  and a trailing edge  707 . Multiple louvers  700  are rotatably mounted within an assembled shutter frame  102  (FIG. 1) and extend horizontally between stiles  500  (FIG. 1) when a shutter  100  (FIG. 1) is installed in a conventional window. A louver  700  has a pin hole  710  generally centered at each end  703  and extending partially into the louver  700  along an axis of rotation. The pin hole  710  is configured to accept either a press-fit louver pin  210  (FIG. 2) or a screwed-in anchor  900  (FIG. 2). A louver  700  also has predrilled link holes  720  centered between the ends  703  along the leading edge  705 . The link holes  720  are configured to accept a louver link  250  (FIG. 2). In one embodiment, a louver  700  is constructed of a substrate material with a first laminate applied to the louver faces  701  and a second laminate applied to the louver edges  705 ,  707 . The second laminate may also be applied to the louver ends  703 . In a particular embodiment, the substrate material is MDF, the first laminate is a decorative paper, and the second laminate is a heat transfer foil, as described with respect to FIGS.  5 A-D, above. The lamination process is described with respect to FIGS.  10 - 13 , below.  
         [0049]    As shown in FIGS.  7 A-D, the louver length is window frame dependent but less than about 30″ when using MDF so as to advantageously avoid louver instability and wobble. In a particular embodiment, a width, i.e. across a face  701  is 2½″, 3½″ or 4 ½″, and a louver thickness, i.e. across an edge  705 ,  707  is ⅜″. In this particular embodiment, a louver pin hole  710  is ⅛″ dia.×⅝″ and the link holes  720  are spaced ¼″ apart and are {fraction (5/64)}″ dia.×½″.  
         [0050]    Tilt Bar  
         [0051]    FIGS.  8 A-D illustrate a tilt bar  800 . A tilt bar  800  is an elongated rod having a generally rectangular cross-section with rounded corners on a front edge  810  and square corners on a back edge  820  and sides  830 . In one embodiment, the tilt bar  800  is constructed of 16′ standard tilt rod natural wood stock, which is milled, sanded and prefinished with a profile wrap, such as used on the wood frame  400  (FIG. 4). The prefinished stock is cut to length, which is window frame dependent. In a particular embodiment, the back edge  820  is ½″ and the side edges  830  are ⅝″.  
         [0052]    Frame Stabilizer  
         [0053]    FIGS.  9 A-B illustrate an anchor  900 . The anchor  900  is a generally hollow cylinder having a socket end  901 , a round end  902 , coarse outer threads  910  and fine inner threads  940 . The socket end  901  is utilized to drive the anchor  900  into a louver pin hole  710  (FIGS.  7 A-D), so that the outer threads  910  cut into the pin hole  710  (FIGS.  7 A-D). This, with the addition of glue, allows the anchor  900  to firmly grip inside the louver  700  (FIGS.  7 A-D). The fine threads  940  accommodate the threads of the tensioning screw  230  (FIG. 2). In one embodiment, the anchor  900  has 3 to 12 coarse threads  910  and, in a particularly advantageous embodiment, the number of coarse threads  910  is at least 9 so as to prevent the anchor  900  from stripping from MDF louvers  700  (FIGS.  7 A-D).  
         [0054]    The anchor  900  and tensioning screw  230  (FIG. 2) advantageously function as both a louver tension control and frame stabilizer. Louver tension control determines the force required for the tilt bar to rotate the louvers. Traditional shutters provide tensioning with screws threaded directly into a selected louver. The tension is adjusted high enough so that the louvers maintain a particular position set with the tilt bar and low enough so that the louvers are easily repositioned. Such screws will quickly strip out of MDF louvers when sufficient operational tension is applied. The anchors  900  advantageously prevent the tensioning screw  230  (FIG. 2) from stripping out of a louver  700  (FIG. 2). Further, a shutter frame made of MDF is unstable in that it bows and warps. The anchors  900  advantageously allow sufficient tension to be distributed along the stiles  500  (FIG. 2) to reduce bowing and warping. The anchors  900  are inserted into one or more selected louvers at a predetermined spacing along the stiles  500  (FIG. 2). In one embodiment, the anchored louver spacing is no greater than about every 24″ so as to advantageously provide sufficient and evenly distributed tension on the shutter frame  102  (FIG. 1).  
         [0055]    Shutter Component Prefinishing  
         [0056]    FIGS.  10 A-B illustrate a shutter component prefinishing process and a prefinished shutter assembly process, respectively. As shown in FIG. 10A, an initial processing step is selecting a shutter component type  1002 , which includes a stile  500  (FIG. 2), a spreader  600  (FIG. 2) and a louver  700  (FIG. 2), as described above. A next step is determining a substrate sheet size  1004 . Advantageously, a substrate sheet may comprise multiple, edge-to-edge shutter components that are laminated in bulk and separated by cutting along edge portions, saving manufacturing steps. In one embodiment, standard 4′×8′×⅜″ MDF sheets are used for louvers  700  (FIGS.  7 A-D), 4′×10′×¾″ MDF sheets are used for stiles  500  (FIGS.  5 A-D) and 4′×8′×⅝″ MDF sheets are used for spreaders  600  (FIGS.  6 A-E), advantageously reducing wastage. Further steps are applying a first laminate to the planar surfaces of each sheet  1008  and cutting a laminated sheet into laminated boards  1012 , as described in further detail with respect to FIG. 11, below.  
         [0057]    [0057]FIG. 11 illustrates sheet lamination and cutting, which yield a laminated board  1150 . An substrate  1100  is sandwiched between a first laminate  1110  to form a laminated sheet  1103 . This may be accomplished with a hot roll laminator, such as a TB-60 from Black Bros. Co., Mendota, Ill. Laminated boards  1150  are then cut from the laminated sheet  1103  at predetermined widths  1120  corresponding to a particular shutter component. In one embodiment, the predetermined widths  1120  produce boards  1150  that are ⅛″ wider than the final component width to allow for losses when the edges are milled and sanded, as described with respect to FIG. 12, below. For example, laminated boards  1150  of 2⅝″, 3⅝″ or 4⅝″ widths are cut for 2½″, 3½″ or 4½ louvers  700  (FIGS.  7 A-D), respectively.  
         [0058]    As shown in FIG. 10A, additional processing steps include milling, sanding and laminating board edges  1014  and cutting a laminated board into laminated shutter components  1016 , as described in further detail with respect to FIG. 12. Advantageously, a laminated board may comprise multiple, end-to-end shutter components that are laminated along previously cut edges in bulk and then separated by cutting along attached end portions, saving manufacturing steps. As shown in FIG. 12, a laminated board  1150  has edges  1151  (FIG. 11), one or both of which may be milled flat or to a particular shape to form a milled edge  1201  and then sanded accordingly. A second laminate  1210  is then applied to one or both milled edges  1201 . This may be accomplished with a Voorwood L110 Edge Foiler, available from X-Factory, Charlotte, N.C. Nominally, the foiler temperature and pressure parameters are 320° F. and 1000 psi. Temperature may vary ±10° F. depending on material temperature, material thickness and humidity. Prefinished shutter components  1230  are cut from a laminated board  1150  at predetermined lengths  1220  corresponding to the custom measured length for a particular shutter component.  
         [0059]    Also shown in FIG. 10A, additional steps are performed on a prefinished stile component. A cutting grooves at stile ends step  1022  forms the grooves  510  (FIGS.  5 AD) used for tongue and groove assembly of the shutter frame  102  (FIG. 1). A drilling pin  30  holes step  1024  forms the stile pin holes  530  (FIG. 5D) that retain louver pins  210  (FIG.  2 ) or tensioning screws  230  (FIG. 2), as described above. A drilling adjustment hole(s) step  1028  forms the tension adjustment hole(s)  550  (FIG. 5B) for inserting and adjusting the tensioning screws  230  (FIG. 2), as described above.  
         [0060]    Further shown in FIG. 10A, an additional step applied to a prefinished spreader component is cutting a tongue at the spreader ends  1032 . The cutting a tongue step  1032  creates a tongue  610  (FIGS.  6 A-E) for tongue and groove attachment of spreaders  600 ,  650  (FIG. 2) and stiles  500  (FIG. 2), as described with respect to FIG. 10B, below. Yet a further step applied to a top spreader  600  (FIGS.  6 A-D) is cutting a tilt bar notch  1034 . A tilt bar notch  630  (FIGS.  6 B-C) is described with respect to FIGS.  6 A-E, above. This step is eliminated for a bottom spreader  650  (FIG. 6E).  
         [0061]    Further shown in FIG. 10A, additional steps are performed on a prefinished louver component. A drilling pin holes step  1042  forms the louver pin holes  710  (FIGS. 7B, 7D) that retain louver pins  210  (FIG. 2) or anchors  900  (FIG. 2), as described above. A drilling link holes step  1044  forms the predrilled link holes  720  (FIGS.  7 A-B) that advantageously allow a louver link  250  (FIG. 2) to be inserted into a louver  700  (FIGS.  7 A-D) without splitting, as described above and further with respect to FIG. 10B, below. An installing anchors step  1048  inserts an anchor  900  (FIG. 2) into the pin holes  710  (FIGS. 7B, 7D) of selected louvers  700  (FIGS.  7 A-D), providing tension control and frame stabilization, as described with respect to FIGS.  9 A-B, above.  
         [0062]    A drilling jig (not shown) for pre-drilling the louver link holes  720  (FIGS.  7 -AD) can be used. The conventional method of attaching the tilt bar to each louver is to use a staple attached to both the tilt bar and the louver, each being placed only ¼″ or so out from the respective surfaces. The conventional method of staple attachment is to fire staples from a gun in rapid succession, which typically crack or split the louver. The louver is then patched and painted over during a post-finishing process. A barrier to the use of MDF for shutter construction has been the splitting of the louver when attaching the tilt bar to the louver using this conventional technique. A drilling jig is made of a hardened steel plate with guild holes pattered to copy the exact pattern of the staple holes in a stacked pattern of multiple louver units. This jig allows a simple “pre-drill” process followed by hand gluing of the staples into the louvers, as described below.  
         [0063]    As shown in FIG. 10A, yet a further processing step includes milling, sanding and laminating shutter component ends  1018 , described in further detail with respect to FIG. 13. As shown in FIG. 13, a prefinished component  1230  has cut ends  1301  with an exposed core  1100 . A second laminate  1310  is also applied to these ends  1301 . This step is advantageously applied to a louver  700  (FIGS.  7 A-D) after drilling so as to avoid damage to the finish. In an alternative embodiment, a louver end may be capped, as described with respect to FIGS.  17 - 18 , below.  
         [0064]    Shutter Assembly  
         [0065]    Conventionally, wood shutters are finished after they are assembled. The assembly process of the present invention advantageously utilizes modern laminating materials to finish the shutter components in bulk prior to shutter assembly, as described with respect to FIG. 10A, above.  
         [0066]    As shown in FIG. 10B, after shutter component prefinishing steps are completed, a shutter assembly process can be initiated. Shutter assembly includes the steps of installing anchors in selected louvers  1052 , installing louver pins  1054  and positioning the shutter components  1058 . During the installing anchors step  1052 , an anchor  900  (FIGS.  9 A-B) is installed into a louver pin hole  710  (FIG. 7B) by placing standard wood glue into the pin hole  710  (FIG. 7B) and threading the anchor  900  (FIGS.  9 A-B) into the pin hole  710  (FIG. 7B). The glue is then allowed to set for a period of 1 hour. During the installing louver pins step  1054 , ends of the louver pins  210  (FIG. 2) are press-fitted into the non-anchored louver pin holes  710  (FIG. 7B) prior to attachment of the stiles  500  (FIG. 2) to the spreaders  600  (FIG. 2). During the positioning shutter components step  1058 , stiles  500  (FIGS.  5 A-D) and spreaders  600  (FIGS.  6 A-E) are positioned for assembly of a shutter frame  102  (FIG. 1) and louvers  700  (FIGS.  7 A-D) are positioned between the stiles  500  (FIGS.  5 A-D), as described with respect to FIG. 2, above.  
         [0067]    Also shown in FIG. 10B, another assembly step is gluing and clamping a shutter frame around the positioned louver components  1062 . Conventional custom shutters are typically constructed with dowels and/or screws attaching the spreaders to the stiles. This convention shutter assembly method would cause MDF material to split. The shutter frame assembly step  1062  according to the present invention advantageously utilizes tongue and groove construction for assembly of the stiles  500  (FIGS.  5 A-D) and spreaders  600  (FIGS.  6 A-E), which avoids MDF material splitting. Spreader tongues  610  (FIGS.  6 A-E) are configured to insert into corresponding stile grooves  510  (FIGS.  5 A-D). Prior to stile-spreader attachment, standard wood glue is applied to the tongue outer surfaces and the groove inner surface. During attachment, the unattached ends of the louver pins  210  (FIG. 2) are placed into corresponding stile pin holes  530  (FIG. 5D). The shutter frame assembly is then pressed together and clamped, and the tongue-groove glue allowed to cure for a period of 1 hour.  
         [0068]    Further shown in FIG. 10B is an inserting tensioning screws step  1064 . Each louver  700  (FIGS.  7 A-D) having anchors  900  (FIGS.  9 A-B) is attached to the stiles  500  (FIGS.  5 A-D) with tensioning screws  230  (FIG. 2) inserted into the stile adjustment holes  550  (FIG. 5B), pushed through the corresponding stile pin holes  530  (FIG. 5D) and threaded into corresponding anchors  900  (FIGS.  9 A-B). In this manner, each louver  700  (FIGS.  7 A-D) is mounted between stiles  500  (FIGS.  5 A-D) with louver pins  210  (FIG. 2) retained in the louver pin holes  710  (FIG. 7B) and rotatably mounted within corresponding stile pin holes  530  (FIG. 5D). Selected louvers  700  (FIGS.  7 A-D) are instead mounted with tensioning screws  230  (FIG. 2) threaded into and retained by anchors  900  (FIGS.  9 A-B), as described with respect to FIG. 2.  
         [0069]    As shown in FIG. 10B, a tilt bar  800  (FIGS.  8 A-D) is attached to louvers  700  (FIGS.  7 A-D) during the steps of stapling links to a tilt bar  1068  and gluing louver links into link holes  1074 . During the stapling links step  1068 , tilt bar links  240  (FIG. 2) are inserted into a natural wood tilt bar  800  (FIGS.  8 A-D), such as with a conventional staple gun as is well-known in the art. Although links can be stapled directly into a natural wood tilt bar, this conventional attachment method would split an MDF louver. A gluing louver links step  1074  advantageously utilizes predrilled link holes  720  (FIGS.  7 A-B) and glue to avoid splitting MDF louvers. Standard wood glue is applied to louver links  250  (FIG. 2), which are manually threaded through the attached tilt bar links  240  and inserted into the link holes  720  (FIGS.  7 A-B).  
         [0070]    Additionally shown in FIG. 10B, the shutter assembly steps include assembling a window frame  1078  and mounting a shutter to a window frame  1084 . During the assembling window frame step  1078 , a window frame is assembled in a conventional manner using a partially wrapped, natural, finger-jointed wood, as described with respect to FIG. 4, above. During a mounting shutter to window frame step  1084 , hinges  310  (FIG. 3) are mounted to a stile edge and an inside edge of the assembled window frame, as shown in FIG. 3, above, and the assembled shutter  100  (FIG. 3) is attached to the assembled window frame  400  (FIG. 3).  
         [0071]    A hinging jig (not shown) is utilized to pre-drill pilot holes to permit screws to affix a hinge to MDF materials that otherwise could not be utilized due to the cracking and/or splitting characteristics found in the use of MDF. The jig allows the use of a thinner, less costly material for construction of the shutter than is considered standard in the industry. The jig also allows a pre-drilling of holes in an exact manner without drilling out through the sides of the material. The jig is made of a hardened steel plate with guild holes pattered to copy the exact pattern of the hinge screw holes. The jig is made with an oblong slotted hole to be used for alignment to a channel bar. The channel bar has pre-drilled/tapped holes each spaced by 1″, for a total length that permits multiple plates to be aligned along the bar. The pre-drilling plates are affixed to the channel bar using a wing nut bolt. In this manner, multiple shutter panels can be pre-drilled with identical settings.  
         [0072]    Additional Embodiments  
         [0073]    FIGS.  14 A-G illustrate a full groove stile embodiment  1400 , including a stile base  1500  (FIGS.  15 A-C) and a groove insert  1600  (FIGS.  16 A-C). An assembled full groove stile  1400  corresponds generally in configuration and function to the partial groove stile  500  (FIGS.  5 A-D), described above. A pair of stiles  1400  provide mounts for louvers  700  (FIG. 1), having a number of pin holes  1610  spaced at regular intervals along the inside edge  1507  and configured to receive louver pins  210  (FIG. 2). Also, the stile  1400  has one or more tension adjustment holes  1550  configured to accept a tensioning screw  230  (FIG. 2) for louver tension control and frame stabilization, as described above.  
         [0074]    As shown in FIGS.  14 A-G, the full groove stile  1400  differs from the partial groove stile  500  (FIGS.  5 A-D) in several respects. Advantageously, the full groove stile  1400  has two subcomponents, a stile base  1500  and a groove insert  1600 . The stile base  1500  has an end-to-end groove  1510  instead of end-proximate partial grooves  510  (FIGS.  5 A-D). This full groove  1510  can be cut in a single manufacturing step across several stiles  1400  instead of the two groove cuts required at each end for the partial groove stile  500  (FIGS.  5 A-D). Further, the pin holes  1610  are located on the groove insert  1600 , eliminating another manufacturing step required to drill pin holes  530  (FIG. 5D) in each stile  500  (FIGS.  5 A-D). The insert  1600  is sized and positioned within the groove  1510  so as to provide a groove portion at each end  1503  configured to receive the spreader tongues  610  (FIGS.  6 A-E), as described above. The stile base  1500  and groove insert  1600  are described in further detail with respect to FIGS.  15 - 16 , below.  
         [0075]    FIGS.  15 A-D illustrate a stile base  1500 , which is a generally elongated, planar shutter component having ends  1503 , an outside edge  1505  and an inside edge  1507 . A groove  1510  extends between the ends  1503  for the full length of the stile base  1500 . In a particular embodiment, the stile base  1500  is prefinished over an MDF core and dimensioned as to overall length, width and thickness; groove width and depth; and tensioning hole  1550  length and diameter as described with respect to the partial groove embodiment shown in FIGS.  5 A-D, above.  
         [0076]    FIGS.  16 A-D illustrate a groove insert  1600 , which is configured to fit within the stile base groove  1510  (FIGS.  14 E-G) generally midway between the stile base ends  1503  (FIGS. 14B). The insert  1600  is an elongated subcomponent having a shelf  1630  and legs  1640 . The installed insert  1600  is configured so that the shelf  1630  rests along the stile base inside edge  1507  (FIGS.  15 A-D) and the legs  1640  provide a friction fit along the inside of the stile base groove  1510  (FIG. 14G). The pin holes  1610  are dimensioned to accept louver pins  210  (FIG. 2) or a louver end cap  1800  (FIGS.  18 A-C), as described below. In one embodiment, the insert  1600  is a single section of extruded plastic or similar flexible material that is cut to length to accommodate a particular stile base  1500  (FIGS.  15 A-D). In another embodiment, the insert  1600  has multiple sections of extruded plastic that snap together or are otherwise fitted together to accommodate a particular stile base  1500  (FIGS.  15 A-D). One of ordinary skill in the art will recognize that various extruded cross-sections other than the cross-section  1620  shown in FIG. 14G may be utilized to press-fit into the stile base groove  1510  (FIG. 14G) and are contemplated to be within the scope of the present invention.  
         [0077]    FIGS.  17 A-B illustrate a capped louver embodiment  1700 , including a louver base  1750  and louver end-caps  1800 . An assembled capped louver  1700  (FIG. 17B) corresponds generally in function to an uncapped louver embodiment  700  (FIGS.  7 A-D), described above. Multiple capped louvers  1700  are rotatably mounted within an assembled shutter frame  102  (FIG. 1) and extend horizontally between stiles  500  (FIG. 1). A louver base  1750  corresponds to an uncapped louver  700  (FIG. 7A-D) in configuration and dimensions, as described above, except that it does not have pin holes  710  (FIG. 7B) and does not accept louver pins  210  (FIG. 2). In one embodiment, a louver base  1750  is constructed of a core material with a first laminate applied to the louver faces  1701  and a second laminate applied to the louver edges  1705 ,  1707 . No laminate is applied to the louver ends  1703 . Instead, the louver base  1750  is removably attached to louver end caps  1800  so that the ends  1703  are covered. In a particular embodiment, the core material is MDF, the first laminate is a decorative paper, and the second laminate is a heat transfer foil, as described with respect to FIGS.  5 A-D, above. In another embodiment (shown) the louver base  1750  does not have link holes  720  (FIGS.  7 A-B) for tilt bar attachment. Instead, the end caps  1800  are adapted to attach to a link bar  1900  (FIG. 19), as described below. The end caps  1800  are described in further detail with respect to FIGS.  18 A-C, below.  
         [0078]    As shown in FIGS.  17 A-B, a capped louver  1700  advantageously reduces manufacturing steps and parts by eliminating pin holes  710  (FIG. 7B) and louver pins  210  (FIG. 2), and, in one embodiment, link holes  720  (FIGS.  7 A-B) and associated links  240 ,  250  (FIG. 2). A further advantage is that the louver base  1750  can be removed from the end caps  1800 . Hence, an assembled shutter as described with respect to FIG. 19, below, allows louvers to be easily cleaned and damaged louvers to be replaced. Pin holes  710  (FIGS.  7 A-B) can be pre-drilled and anchors  900  (FIGS.  9 A-B) installed in one or more selected louver base(s)  1750  so as to provide louver tension control and frame stabilization, as described above. In that case, louver caps  1800  are installed with holes in place of the snap-fit buttons  1860  (FIG. 18B), as described below.  
         [0079]    FIGS.  18 A-C illustrate a louver end cap  1800 , which is adapted to removably attach to a louver base  1750  (FIGS.  17 A-B). The end cap  1800  has a cap body  1810 , side flaps  1820 , end flaps  1840 , a snap-fit stile button  1860  and an optional snap-fit link bar button  1880 . The cap body  1810  is generally planar with an inside face  1801  and an outside face  1802 . The cap body  1810  is adapted to cover a louver base end  1703  (FIG. 17A) so that the inside face  1801  is proximate the louver base  1703  and the outside face  1802  is distal the louver base  1703 . The side flaps  1820  and end flaps  1840  extend normal to the body  1810  from the inside face  1801  and are configured so that the side flaps  1820  grip the louver base faces  1701  (FIG. 17A) and the end flaps  1840  grip the louver base edges  1707  (FIG. 17A). Accordingly, an end cap  1800  is constructed of a material having some flexibility, such as a thin plastic, so that one or more of the side flaps  1820  and end flaps  1840  can be deflected for attachment or detachment to a louver base  1750 . In an alternative embodiment, not shown, the side flaps  1820  or end flaps  1840  or both are replaced by a wedge, prongs or similar structure extending from the center of the inside face  1801  and adapted to insert into, and fixedly attached to, a louver base edge  1703  (FIG. 17A).  
         [0080]    As shown in FIGS.  18 B-C, the snap-fit stile button  1860  is adapted to press fit into and lock inside a stile pin hole  1610  (FIG. 14C) so that a louver base  1750  (FIGS.  17 A-B) can be removably attached between stiles  1400  (FIGS.  14 A-D), as described with respect to FIG. 19, below. An optional snap-fit link bar button  1880  is adapted to press fit into and hold within a link bar hole  1910  (FIG. 19) so that a link bar  1900  can connect multiple louvers  1700  (FIGS.  17 A-B), as described with respect to FIG. 19, below. In one embodiment, the snap-fit buttons  1860 ,  1880  extend normally from the end cap outside face  1802  and have a catch that snaps and locks inside a pin hole  1610  or link bar hole  1910 , respectively.  
         [0081]    [0081]FIG. 19 illustrates a rear-linked shutter embodiment  150  utilizing full groove stiles  1400  and capped louvers  1700 . The rear-linked shutter  150  does not have a tilt bar  800  (FIG. 2), but instead has a link bar  1900 . The link bar  1900  has multiple link bar holes  1910  adapted to attach to each of multiple louvers  1700  via snap-fit buttons  1880  (FIG. 18C). In one embodiment, the link bar  1900  is constructed of a thin planar, elongated, flexible material, such as plastic, and adapted to fit in the space between the louvers  1700  and stiles  1400 . Advantageously, the view through the shutter  150  is not blocked by a tilt bar. Instead, the louvers  1700  are opened and closed by moving an individual louver  1700 , which moves all louvers via the link bar  1900 . Another advantage is that a tilt bar notch is eliminated in the top spreader, so that the spreaders  650  are the same part, reducing the number of parts and shutter manufacturing steps.  
         [0082]    Although a prefinished shutter has been described above in terms of an MDF substrate, one of ordinary skill in the art will recognize that the teachings disclosed herein may be applied to other substrates that have surfaces capable of taking modem finishes and that are sufficiently durable to be prefinished without surface damage during assembly. The use of any such substrates for a prefinished shutter are intended to fall within the scope of the present invention. Further, although a prefinished shutter has been described above in terms of laminate coatings, one of ordinary skill in the art will also recognize that other durable and maintainable coatings fall within the scope of the present invention.  
         [0083]    The prefinished medium density fiberboard shutter has been disclosed in detail in connection with various embodiments of the present invention. These embodiments are disclosed by way of examples only and are not to limit the scope of the present invention, which is defined by the claims that follow. One of ordinary skill in the art will appreciate many variations and modifications within the scope of this invention.