Patent Application
20060101717
The present invention relates to window shutters. In particular, the present invention relates to a venetian blind style of window shutter which m ay be used in a window opening comprising an arch. In another embodiment the invention relates to a palladian blind style of window shutter.
It is known to provide a window covering for an arched window. Examples of such window coverings include those described in U.S. Pat. No. 5,794,680 entitled “Retractable Arced Window Covering” to Xue (“Xue”) and U.S. Pat. No. 5,584,329 entitled “Movable shade for Palladian Windows” to Thomas (“Thomas”).
Xue teaches a pleated fan covering for an arched window which can be drawn across the window by pulling a cord attached to one side of the pleated fan. Thomas describes two sets of linked blades which can be separately drawn across either the left side or the right side of an arched window.
It is also known to provide a shutter for an arched window in which louvers are arrayed radially about an arched window. Examples of such radially arranged shutters include those described in U.S. Pat. No. 5,537,780 entitled “Louver Mechanism for Palladian Windows” to Cleaver et al (“Cleaver”) and U.S. Pat. No. 6,341,447 entitled “Half Circle Window Shutter/Blind” to Jean (“Jean”).
Jean teaches a radially arrayed louver system in which each louver may be manually rotated individually into a desired position. The invention in Cleaver comprises a radially arrayed louver system in which the louvers are turned in unison by a motor-driven gear mechanism.
It is further known to provide a louvered shutter for an arched window in which the louvers are arranged horizontally. U.S. Pat. No. 6,062,291 entitled “Venetian Blind for Palladian-Style Window to Morgan et al (“Morgan”) teaches a window shutter in which horizontal louvers are suspended by a plurality of ladder cords which are connected to a gear mechanism to permit rotation of the suspended louvers.
There are a number of desirable objectives in relation to shutters for arched windows. Such shutters should preferably comprise horizontal louvers to optimize control of light entry through the window. The shutter assembly should be mechanically simple for ease of manufacture and operation. The shutter opening means should preferably be integrated into the shutter design for aesthetic and safety reasons.
Existing arched window coverings achieve some of these objectives, but with varying degrees of success. For example, Xue and Thomas describe window coverings which do not permit incremental control of light for each area of the window. Rather, the fan-style covering may only be open or closed over a particular portion of the window.
Jean and Cleaver permit greater control over light entry through use of radially arrayed louvers. However, such radially arrayed louvers would not permit an even entry of light through the window. Rather, for a particular sun position, distinct portions of the shutter will block the light to varying degrees across the arched window. In addition, as the sun passes generally horizontally across the sky, the shutters of Jean and Cleaver would need to be frequently adjusted to maintain consistent light levels.
Morgan teaches a shutter for an arched window having horizontally arranged louvers. However, the system for rotating the louvers to permit or exclude light is relatively complex, involving rollers, ladder cords and gears. Such complexity increases the cost and difficulty of manufacturing of the shutters, and increases the likelihood of mechanical failure.
It is an object of the present invention to provide, for an arched window, a shutter which provides rotatable horizontal louvers which allow consistent, controllable light entry across the entire window area. It is a further object of the present invention to provide such a shutter which is mechanically simple for ease of manufacture and repair.
One aspect of the invention relates to a shutter for an arch window having at least one rotatable louver.
According to another aspect of the present invention, there is provided a shutter for an arched window, comprising a base member, a curved member secured to the base member, at least one louver having an axis of rotation, at least one pair of louver receiving means disposed about the curved member for releasably attaching the louver to the curved member, and means for rotating the louver about the axis of rotation between an open position and a closed position.
The shutter may comprise a plurality of louvers each having an axis of rotation, disposed generally parallel to one another. The louvers and the louver receiving means may have substantially the same cross-section.
In one embodiment, there is provided a shutter for an arched window comprising a curved member having horizontally opposed ends, a horizontal member extending between the opposed ends of the curved member, one or more pairs of louver receiving means for releasably attaching louvers to the curved member, each element of each pair fixedly attached at horizontally opposed positions to the curved member, one or more louvers having opposed ends and opposed first and second lateral edges, each end of each louver releasably attached by rotating means only to a corresponding element of a corresponding pair of louver receiving means, and light control means for rotating the one or more louvers, fixedly attached at vertically adjacent positions to the first lateral edge of each louver, wherein the light control means are vertically displaceable to a selected position between an open position and a closed position.
The shutter may comprise at least one stile extending vertically between the base member and the curved member, the stile fixedly attached to an adjacent edge of each louver.
The curved member may have a generally U-shaped cross section, flat section, hollow tubular or rectangular section, or other suitable sections.
The shutter may further comprise a valance releasably attachable to the curved member and base member, which may be formed by a roll-forming machine, which may be computerized. The shutter may be formed of aluminum, wood or PVC.
The rotating means may comprise a spring-loaded pin.
A further aspect of this invention relates to a shutter for an arched window comprising a base member, a curved member secured to said base member, said curved member having a hollow cross-section, a plurality of radially overlapping louvers having one end connected to said curved member and said other end connected to said base member, said louver each rotated about a radial axis of rotation.
Still yet another aspect of this invention relates to a method of manufacturing a shutter for an arched window comprising the steps of forming a curved member, attaching a base member to opposite ends of said curved member, placing a plurality of overlapping louvers on said member, cutting each said louver to the shape of said arched window, and to form a louver and louver receiving means attached to said curved member, attaching each said pair of louver receiving means to said curved member.
In another of its aspects, the present invention provides a method of manufacturing a shutter for an arched window comprising the steps of preparing a template of the shape of the blind, forming a curved member which geometrically corresponds to the template, attaching a base member to opposed ends of the curved member, cutting one or more source members to a length which corresponds to the horizontal width of the curved member at the installation position corresponding for each louver, cutting each end of each source member to geometrically correspond to the curved member at the installation position for each louver, cutting a straight edge through each source member at a position proximal to each end to form a louver and a pair of corresponding louver receiving means, preparing and painting each straight edge of each louver and each pair of louver receiving means, drilling a hole in each louver and for attachment of a light control means pin, drilling a hole in the straight edge of each louver and each louver receiving means for attachment of louver pins, fastening each pair of louver receiving means to horizontally opposite corresponding positions on the curved member, fastening each louver to a corresponding pair of louver receiving means and to the light control means, cutting a flexible valance to a length corresponding to the combined length of the curved member and base member, and attaching the valance to the exposed face of curved member and base member.
The method of manufacturing the shutter may further comprise the steps of, after attaching the base member to the curved member, attaching one or more vertical stiles between adjacent vertical positions of the base member and the curved member, drilling a hole in adjacent positions on one lateral edge of each louver for attaching the one or more vertical stiles to each louver and a series of corresponding holes on the one or more stiles, and fastening each louver to the one or more stiles.
The step of preparing a template of the shape of the blind may comprise the steps of measuring and recording on recording media with measuring means the linear distance from the horizontal mid-point of the base of the arched window to one end of the base of the arched window, measuring and recording on recording media the linear distance from the horizontal mid-point of the base of the arched window to a point incrementally along the arc of the arched window and the angle of the radius at that point relative to the base of the window, and repeating the previous step until the entire arched window has been measured and recorded on recording media.
The recording media may comprise a markable grid, or an electronic recording medium.
The measuring means may comprise a measuring device having telescoping arms which selectively transmits the linear distance between the distal ends of the telescoping arms to an electronic recording medium.
The step of forming a curved member which corresponds to the template may comprise the steps of cutting a length of linear rail corresponding in length to the perimeter of the arc of the arched window, and passing the linear rail through roller forming means, the roller forming means comprising three rollers, each adjustable by adjustment means for shaping the rail into a curved member corresponding to the template.
The adjustment means may comprise manual adjustment means, or a computerized system interfaced with the template.
According to a further aspect of the invention, there is provided a measuring device for measuring the arc of an arched window, comprising a leveling mechanism, a pivot arm having first and second opposed ends, a measuring arm swingable at a first end to the first end of the pivot arm, measuring means for determining the linear distance between the second ends of the arms, and recording means for selectively recording the distance between the distal ends of the arms.
A further aspect of this invention relates to a finished surface for an aluminum extrusion formed in a curve for receiving retractable shutters, said finished surface removably securable to said aluminum extrusion.
Other aspects of the invention will be appreciated by reference to the description of the preferred embodiment which follows, and to the claims.
The invention will be described by reference to the preferred embodiment and the drawings thereof in which:
As shown in
In another embodiment shown in
In
Referring now to
The window shutter in one embodiment is designed to be custom fit to an arched window. Alternatively the shutter may be formed to standard sized arches. Once the window shutter is assembled, it is easily inserted into and attached to the frame surrounding the arched window. The louvers may then be adjusted by raising or lowering the light control means to control the amount of light entering the window.
The horizontal arrangement of the louvers allows for consistent light control. As horizontal Venetian-style blinds are in common use, the horizontal arrangement of the louvers of the present invention will provide a uniform appearance with standard rectangular shutters covering the non-arched lower portion of an arched window.
The louvers of the present invention in one embodiment can be rotated as much as 160 degrees, and their rotation can be motorized.
In contrast with many light control means for shutters which comprise long cords potentially harmful to young children, the light control means of the present invention remains safely out of reach of young children for improved safety.
The shutter may be manufactured of wood, aluminum, polyvinylchloride or plastic material or other suitable materials. Louvers may be spring-loaded in engagement with the louver receiving means, permitting easy removal for cleaning and repair.
In order to ensure an optimal fit of the window shutter in the arched window frame, the shape of the window opening should be accurately determined. Such determination may be made with the arched window measuring device 18 of the present invention. According to one embodiment of an arched window measuring device, there is provided a leveling mechanism 20 as shown in
In one embodiment of the invention a series of holes 19 spaced at for example 10 degree increments can be adapted to receive a projection 21 on the underside of arm 22. In one embodiment the projection can comprise a spring loaded ball to engage the holes 19. Once the ball engages one hole 19 it can easily be displaced to the next available hole at a selected angular displacement.
Another measuring means can comprise the grid depicted in
In an alternative embodiment of an arched window measuring device as shown in
The shutter of the present invention is adaptable to a wide variety of arched window openings, including windows with low arch heights, sometimes referred to as “eye-lid” windows, as shown in
The curved member of the present invention may be formed by a computerized roll-forming machine having a CNC machine or the like. As shown in
Referring again to
Window measurement data are entered into the processor of the roll-forming machine to vertically displace the second roller and horizontally displace the third roller to effect the desired curvature to the curved member. The resulting curvature will correspond to the measured geometry of the arched window opening.
In the preferred embodiment, the process of manufacturing the shutter begins with preparation of a template of the geometry of the window opening by obtaining a series of measurements of the horizontal and vertical coordinates along the perimeter of the window opening. Next, an aluminum member is curved according to the template to correspond to the curve of the perimeter of the window opening. The member may be curved using a computerized three-roller roll-forming machine. As shown in
As shown in
A hole 70 is drilled at adjacent positions in the straight edge of each louver and corresponding louver receiving means for insertion of a louver pin. If one or more stiles are incorporated in the shutter, a series of holes is drilled in the stiles to correspond to the holes in the adjoining louvers. A pull bar hole 72 is drilled in each louver for insertion of a pull-bar pin 74. Other light control means, however, can be used such as staples or other structures to move the louvers.
As shown in
As shown in
The one piece aluminum construction of the curved member provides a high degree of structural strength, and the roll-forming machine process allows a precise match between the shape of the shutter and the shape of the arched window opening, as well as increased productivity time.
The relatively simple manufacturing process described above is cost effective and efficient. It eliminates the need for expensive machinery, highly skilled craftspersons, and extensive labour. The shutters can be manufactured in a space as small as 1000 square feet. By way of example each worker should be able to produce 3.5 shutters per day. There is less than 10% scrap produced.
The entire shutter can be manufactured and assembled remote from the installation site.
Another embodiment of the invention is shown in
A plurality of overlapping source members 62 can be disposed as shown in
Furthermore valance 90 having a cross-section shown in
Moreover the valance 90 can also be curved to the curvature of the arched window as previously described.
The plurality of louver receiving means 10 may be secured by a plurality of fastening means 9 as shown. In the embodiment shown in
Furthermore the flat curved member 6 can be used as a template or jig so as to cut the ends of the source members 62 at the same time once connected as shown in
Another embodiment of the invention is shown in
In particular the palladian style shutter comprises of a curved member 6 and a base member 2. The base member 2 has a central region 3 which is adapted to contact one end 100 of the louvers 8. The other end 102 of the louvers 8 are adapted to be adjacent the curved member 6.
The curved member 6 may comprise of a channel, hollow tubular, rectangular, or other suitable cross-section which can be adapted to receive securing means 104 for securing the end 102 of the rotatable louvers 8. More particularly the securing means 104 comprise of for example screws, pins, rivets 104 or the like which permit the louvers 8 to rotate about an axis of rotation defined by the securing means 104 and 105 for each louver 8.
The other end 100 of the louver 8 is secured for rotation about securing means 105 which are similar to those of securing means 104. The ends 100 and 102 of the louvers 8 are configured so as to permit rotational movement about the axis defined by pins 104 and 105. The louvers 8 as shown in
The embodiment shown in
The curve and base members 2 and 6 are manufactured as previously described. The palladian style louvers 8 are cut to size and the ends 100 and 102 drilled to receive the receiving means 104. The curved section is also drilled to produce the holes 107 which are adapted to receive the securing means 104.
Another embodiment of the invention is illustrated in
The shutters shown in
The curved section 6a, 6b and linear section 7 can comprise of an aluminum extrusion having the profile shown in
Coping or finishing surface 210 includes compression fingers 219 which are adapted to embrace the front extrusion surface 206 and 209 as shown.
It will be appreciated by those skilled in the art that other variations of the preferred embodioment may also be practiced without departing from the scope of the invention. For example the base member case either be horizontally or vertically disposed depending on the direction of the window. Furthermore the base member may also be disposed at an angle to the horizontal.
