Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
The same reference numerals refer to the same parts throughout the various Figures.
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, or uses.
Referring to the Figures, a shutter assembly is generally disclosed at 10. By “assembly,” as that term is used herein, it is meant at least one shutter member.
The shutter assembly 10 can be mounted, either permanently or temporarily to a dwelling 12, such as a residential or commercial building, especially one that includes a stucco, stone, cement, and/or brick exterior.
Although raised/recessed panel shutter members are shown in connection with the shutter assemblies 10 in
It is to be understood that one shutter assembly 10 according to the subject invention is a single shutter 20. That is, one shutter assembly 10 is one left side shutter 20 or one right side shutter 20 such that two shutter assemblies 10 are preferred. For example, with specific reference to
The shutter assembly 10 includes a foam insert or core 100 that is completely or at least substantially completely enveloped or surrounded by a cementitious shell or coating 102. Additionally, various portions of the cementitious shell 102 can be permitted to infiltrate through various crevices, apertures, or spaces formed in the foam core 100, e.g., so as to form reinforcement or rib members 104 at various locations within the shutter assembly 10.
In accordance with one aspect of the present invention, the cementitious shell 102 is formed from a cementitious or cement slurry. The slurry can include hydraulic cement including, but not limited to, Portland, sorrel, slag, fly ash, or calcium alumina cement. Additionally, the cement can include a calcium sulfate alpha hemihydrate or calcium sulfate beta hemihydrate. The slurry can also utilize natural, synthetic, or chemically modified beta gypsum or alpha gypsum cement. The cementitious slurry preferably includes gypsum cement and a sufficient amount of water added thereto to produce a slurry having the desired consistency, i.e., not too dry nor not too watery.
Gypsum is a naturally occurring mineral, calcium sulfate dihydrate, CaSO4.2H2O (unless otherwise indicated, hereafter, “gypsum” will refer to the dihydrate form of calcium sulfate). After being mined, the raw gypsum is thermally processed to form a settable calcium sulfate, which can be anhydrous, but more typically is the hemihydrate, CaSO4.1/2H2O. For the familiar end uses, the settable calcium sulfate reacts with water to solidify by forming the dihydrate (gypsum). The hemihydrate has two recognized morphologies, alpha and beta hemihydrate. These are selected for various applications based on their physical properties. Upon hydration, alpha hemihydrate is characterized by giving rise to rectangular-sided crystals of gypsum, while beta hemihydrate is characterized by hydrating to produce needle-shaped crystals of gypsum, typically with large aspect ratio. In the present invention, either or both of the alpha or beta forms can be used, depending on the mechanical performance required. The beta form generates less dense microstructures and is preferred for low density products. Alpha hemihydrate could be substituted for beta hemihydrate to increase strength and density or they could be combined to adjust the properties.
The cementitious slurry can also include other additives. The additives can include, without limitation, accelerators and retarders to control setting times of slurry. Suitable accelerators include aluminum sulfate, potassium sulfate, and Terra Alba ground gypsum. Additional additives can be used to produce colored shutter assemblies 10, such dry powder metallic oxides such as iron and chrome oxide and pre-dispersed pigments used for coloring latex paints.
In accordance with one aspect of the present invention, a reinforcing material can also be disposed within the cementitious slurry, either prior to or after the introduction of the water thereto. The reinforcing material can include, without limitation, fibers, e.g., either chopped or continuous fibers, comprising at least one of polypropylene fibers, polyester fibers, glass fibers, and/or aromatic polyamide fibers. By way of a non-limiting example, the reinforcing material can include a combination of the fibers, such as the polypropylene fibers and the glass fibers or the polyester fibers and the glass fibers or a blend of the polypropylene fibers and the polyester fibers and the glass fibers. If included in the fiber composition, the aromatic polyamide fibers are formed from poly-paraphenylene terephthalamide, which is a nylon-like polymer commercially available as KEVLAR® from DuPont of Wilmington, Del. Of course, aromatic polyamide fibers other than KEVLAR® are also suitable for use in the fiber composition of the subject invention.
The cementitious slurry can then be mixed, either manually or automatically, so as to adequately combine the various ingredients thereof and optionally can also be agitated, e.g., by a vibrating table, to remove or lessen any air bubbles that formed in the cementitious slurry.
Referring to
A mold surface member 206 is preferably disposed within a cavity 208 formed in the lower or bottom mold surface portion 202. Although the lower or bottom mold surface portion 202 is shown as being an open shell having a substantially rectangular configuration, the lower or bottom mold surface portion 202 can have any number of various configurations. The mold surface member 206 can be formed of any type of material, such as rigid or flexible materials; however, preferably the mold surface member 206 is formed from a suitably flexible material that, e.g., can be removed from the cavity 208. The face 206a of the mold surface member 206 is essentially a negative image of the desired front exterior surface shape of the shutter assembly 10. Additionally, the mold surface member 206 preferably includes a peripheral lip member 210 to aid in grasping the mold surface member 206, e.g., when it is desired to remove the mold surface member 206 from the cavity 208. The foam core or insert 100 and an optional hanger member 300 are shown for illustrative orientation purposes.
Because of the weights involved of the various components, as well as the cementitious slurry, a transport device, such as a conveyor system 350 (e.g., see
After the cementitious slurry has been prepared, as described above, the cementitious slurry, preferably when still wet, is then poured into the bottom mold surface portion 202, either manually or mechanically, such that it contacts and fills the mold surface member 206 to a desired depth or volume (e.g., see
With specific reference to
The hanger member 300 can be used for mounting the shutter assembly 10 to the dwelling 12 instead of driving fasteners through the shutter assembly 10. The hanger member 300 includes an area defining a recess 302 that is operable to receive a bracket (not shown) or other mounting device mounted to the dwelling 12, thus obviating the need to drive fasteners through the shutter assembly 10, which could potentially damage the cementitious material, e.g., via cracking and/or the like. Additionally, the hanger member 300 can be designed to be disposed in a cutout portion 100a formed in the foam core or insert 100 itself, or alternatively, the foam core or insert 100 can be designed to only extend up to, but not past or above the level of the hanger member 300.
By way of a non-limiting example, the hanger member 300 can be temporarily attached to the upper or top mold surface portion 204, e.g., via a form fitting rubber plug (not shown) that prevents any cementitious slurry from seeping or leaking into the hanger member 300 (e.g., the recess 302) which is pushed into the cementitious slurry when the upper or top mold surface portion 204 is closed.
As noted, once a sufficient amount of the cementitious slurry is disposed onto the mold surface member 206, the foam core or insert 100 is then placed onto the cementitious slurry and is properly positioned in the mold in a desired orientation. The cementitious slurry initially penetrates through any crevices, apertures or spaces between adjacent portions of the foam core or insert 100, such as the crevices, apertures or spaces formed between the individual slat members 100a and in this manner forms the reinforcement or rib members 104 previously described. Optionally, a vibratory force can be applied to the mold system 200, e.g., to remove any residual air bubbles in the cementitious slurry, e.g., either before or after the foam core or insert 100 is placed therein.
Optionally, half of the cementitious slurry can be disposed onto the mold surface member 206, with the foam core or insert 100 being placed therein, with the remaining half of the cementitious slurry then being poured over the foam core or insert 100.
With specific reference to
In accordance with one aspect of the present invention, the upper or top mold surface portion 204 can be secured to the lower or bottom mold surface portion 202 with fastening devices 400 so as to prevent the upper or top mold surface portion 204 and the lower or bottom mold surface portion 202 from becoming inadvertently dislodged from one another. The cementitious slurry is then allowed to dry, harden or cure for a sufficient amount of time, which may depend, at least in part, on the specific composition of the cementitious slurry used. The mold system 200 can also be shuttled off of the conveyor system 350 and stored in a storage area (not shown) so that other shutter assemblies can be made in the interim.
With specific reference to
While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
The instant application claims priority to U.S. Provisional Patent Application Ser. No. 60/806,177, filed Jun. 29, 2006, the entire specification of which is expressly incorporated herein by reference.
Number | Date | Country | |
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60806177 | Jun 2006 | US |