Patent ID: 8171644

Claim:
A method for making a door with a decorative security panel assembly, the method comprising: a. storing a library of grille designs in a data storage of a computer numeric controlled machine having a processor in communication with the data storage, identifying a grille design from the library of grill designs, and forming a decorative security panel assembly by: (i) forming a polymer security grille by selecting the identified grille design and cutting the identified grille design into a polymer using a cutting means of the computer numeric controlled machine, wherein the polymer security grille has a melting point above one hundred forty degrees Fahrenheit and a low-moisture content of no more than five wt %, and wherein the polymer security grille further comprises: a grille front face and a grille back face, a grille first side formed between the grille front face and the grille back face, a grille second side formed between the grille front face and the grille back face, a grille top formed between the grille front face and the grille back face, and a grille bottom formed between the grille front face and the grille back face; (ii) contiguously disposing a seal about the grille first side, the grille top, the grille second side, and the grille bottom, wherein the seal has a seal first side and a seal second side; (iii) disposing a face of a first translucent panel over the seal first side; (iv) disposing a face of a second translucent panel over the seal second side, forming an air space enclosed between the first translucent panel and the second translucent panel, wherein the polymer security grille is disposed within the air space, wherein the polymer security grille, the seal, the first translucent panel, and the second translucent panel form a decorative security panel, and wherein the polymer security grille is spaced apart from the first translucent panel and the second translucent panel; (v) pressing the first translucent panel and the second translucent panel of the decorative security panel at a pressure up to one hundred twenty psi while simultaneously heating the decorative security panel at a low temperature up to one hundred twenty degrees Fahrenheit, forming a heat formed seal between the seal, the polymer security grille, and each translucent panel; and (vi) preventing fogging of the first translucent panel and the second translucent panel by preventing an introduction of condensation to the first translucent panel and the second translucent panel using the low-moisture content of the polymer security grille, and cooling the decorative security panel to an ambient temperature; b. disposing the decorative security panel between a first frame and a second frame, and engaging the first frame with the second frame; and c. disposing the first frame and the second frame within an opening in a door.