Patent Application
20050210749
1. Technical Field
The present invention relates to a mechanical device for actuating linear movement of an object and, more particularly, a mechanical device for opening and closing hurricane shutters or the like.
2. Background Information
In coastal areas that are frequently subjected to the threat of an approaching hurricane, homeowners and business owners often install hurricane shutters to protect glass windows or doors. It is known that glass windows or doors may shatter upon impact with an object propelled by the winds of a hurricane, subjecting the building's interior space to wind and water damage. Many homeowners and business owners employ hurricane shutters because they are more convenient than securing plywood over window openings, particularly since time is often tight when a hurricane is approaching the coast. Hurricane shutters are permanently affixed to a building and need only be opened and closed, while plywood must be attached as the hurricane approaches, and then detached after the hurricane or hurricane threat is over. Also, plywood supplies at local stores are often depleted as the hurricane approaches and homeowners rush to the stores to purchase plywood. There are several different types of commercially available hurricane shutters, including roll-down shutters, Bahamas shutters, colonial shutters, accordion shutters, and storm panels, each of which is discussed below.
Roll-down shutters have many connected slats. When it is not in use, the roll-down shutter can be rolled up for storage into a box mounted above a window. The slats, guided by tracks, roll vertically down to cover the window. The position of roll-down shutters is ordinarily changed from inside the building. Roll-down shutters may be manually operated with a hand crank, or automatically operated by an electric motor. Unfortunately, roll-down shutters are often expensive to purchase.
Bahamas shutters form attractive awnings when they are open. A hinge attaches a top edge of the Bahamas shutter to an exterior face of a building immediately above a window opening, so the shutter pivots towards and away from the window. Telescoping side arms hold Bahamas shutters in position over the window. Bahamas shutters must be manually opened and closed from outside the building.
Colonial shutters are mounted at the sides of a window and fold over the window. They must also be manually opened and closed from outside the building.
Accordion shutters have many connected panels that move horizontally along a lower track and an upper track. An accordion shutter made be any width, but its height is restricted according to the elevation at which it is hung. Accordion shutters are manually operated, can be fairly expensive, require frequent maintenance, and are not particularly aesthetically appealing.
Like plywood, storm panels are fastened over windows when a hurricane is imminent and stored during the rest of the year. Storm panels fit into tracks in window frames. Unfortunately, they require time-consuming outdoor installation (and later detachment), are usually heavy, and they require a substantial amount of storage space.
Roll-down shutters are expensive and, as previously mentioned, the other shutters have various shortcomings. With the exception of roll-down shutters, all of these shutters must be manually operated from outside the building. Even if ground floor windows are manageable, outdoor manipulation of shutter mechanisms for second floor windows and above requires use of a ladder. The elderly and infirm in particular can have difficulty installing hurricane protective panels and the like, especially when they are anxious about the approaching storm. When a hurricane is approaching, it is next to impossible to find an available professional service to perform the task either. Thus, there is a need for an inexpensive and effective hurricane shutter system that is easy for lay people of any age to use.
The present invention may be employed as part of a hurricane shutter system with shutters that can easily be opened or closed manually or automatically from the interior of the building. In fact, the present gear shaft assembly can be utilized in a variety of systems for moving an object in a linear direction.
The present invention is a gear shaft assembly for actuating linear movement of an object attached thereto. The present gear shaft assembly includes a lower channel assembly, which includes:
(a) a threaded rod;
(b) a first gear adjacent an end of the threaded rod;
(c) a second gear engageable with the first gear and attached to the end of the threaded rod;
(d) a mechanism for driving the first gear against the second gear;
(e) at least one threaded journal bearing threaded on the correspondingly threaded rod;
(f) at least one bearing housing supporting the at least one journal bearing;
(g) a movable carrier arm mounted on the threaded rod and attachable to the object;
wherein, when the mechanism for driving the first gear against the second gear is activated, the first gear drives the second gear, rotating the threaded rod, and moving the carrier arm on the threaded rod. Also included herein is a method of installing a gear shaft assembly and shutter on a window.
Also included herein is a tandem gear shaft assembly for actuating simultaneous linear movement of two objects attached thereto. The tandem gear shaft assembly includes a second lower channel assembly, which includes:
(a) two same-sized threaded rods oriented in the same direction as one another;
(b) a first gear between two ends of the two threaded rods;
(c) two same-sized second gears, each engageable with the first gear and attached to the end of each of the threaded rods;
(d) a mechanism attached to the first gear for driving the first gear against the second gears;
(e) at least two same-sized threaded journal bearings, each threaded on one of the correspondingly threaded rods;
(f) at least two same sized bearing housings, each holding one of the at least two journal bearings; and
(g) two same sized movable carrier arms, each mounted on one of the threaded rods, each being attached to one of the objects.
A more complete understanding of the invention and its advantages will be apparent from the following detailed description taken in conjunction with the accompanying drawings, wherein examples of the invention are shown, and wherein:
In the following description, like reference characters designate like or corresponding parts throughout the several views. Also, in the following description, it is to be understood that such terms as “front,” “back,” “within,” and the like are words of convenience and are not to be construed as limiting terms. Referring in more detail to the drawings, the invention will now be described.
The present invention is a gear shaft assembly, generally referred to by reference number 10, for actuating linear movement of an object, preferably a hurricane shutter. Referring to
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Continuing with
Any other suitable mechanism for driving the first gear against the second gear may be employed in place of a drive shaft 15. The driving mechanism may be manual, mechanical, or automatic. When the mechanism for driving the first gear against the second gear, preferably the drive shaft 15, is activated, the first gear 23a drives the second gear 23b, rotating the threaded rod 30, and moving the carrier arm 41 on the threaded rod. Spur, bevel, or worm gears may be used instead of or with mitered gears. The first and second gears 23a, 23b, which are preferably made of a plastic material, may be any size or ratio. The threaded rod may be made of steel or any suitable rigid material.
An external bearing housing 24 is attached to the end of the lower housing 63 opposite the drive shaft 15 (see
Continuing with
Although other means of holding the threaded rod within the journal bearing may be employed, the lock nut is preferred for its simplicity. The journal bearing and lock nut permit alteration of the threaded rod, if desired, to fit different size windows. The rod may be shortened and the journal bearing and lock nut reapplied, and the gear shaft assembly 10 will work just as well.
On the opposite end of the round threaded rod 30 adjacent to the drive shaft 15, an internal bearing housing 35 transversely spans the lower channel 14, as shown in
The second 45 degree mitered gear 23b is attached to the end of the threaded rod 30 such that rotation of the second gear 23b clockwise rotates the threaded rod 30 clockwise. Conversely, rotation of the second gear 23b counterclockwise rotates the threaded rod 30 counterclockwise. As the threaded rod 30 rotates, a conventional, threaded T-nut 40 threaded on the rod 30 between the internal bearing housing 35 and the external bearing housing 24 travels along the rod 30. If the threaded rod 30 rotates clockwise, the T-nut 40 travels in one direction along the threaded rod 30. If the threaded rod 30 rotates counterclockwise, the T-nut 40 travels in the opposite direction along the threaded rod 30 (see
A planar, substantially rectangular-shaped carrier arm 41 inserted into a slot 42 of the T-nut 40 extends in a substantially vertical direction from the T-nut 40. As depicted in
Within the lower housing channel 14, a plurality of spaced apart, narrow support disks 46 are rotatably attached to the lower housing front wall 17 and rear wall 18. The support disks 46 are same sized and generally cylindrical in shape. Each support disk 46 has a generally circular disk hole 49 through its center. To attach the disks to the lower housing walls 17, 18, set screws 47 are preferably inserted through generally circular, spaced apart lower housing wall holes 48 bored through the lower housing walls 17, 18 and the disk holes 49. Nuts 50 threaded on the set screws 47 abutting the lower housing walls 17, 18 hold the support disks 46 in place adjacent to the lower housing walls 17, 18. The set screws 47 and the nuts 50 permit the support disks 46 to rotate freely. A bottom edge of the shutter panel 11 rests on the support disks 46. The support disks are beneficial in that they guide the shutter panel 11 and keep it elevated above the threaded rod 30 and the first and second gears 23a, 23b, so the shutter panel does not rest on the threaded rod. Also, the bottom edge of the shutter panel 11 rests on a top edge of the internal bearing housing 35, which helps maintain the shutter panel in position and avoids interference with the threaded rod.
Preferably, the end of the drive shaft 15 behind the shutter panel (see
In use, a user first removes the drive shaft cover from the drive shaft 15. Then the user engages a screw driver having a square head, or a ratchet, with the square-shaped orifice 51 of the drive shaft 15. The screw driver may be hand-operated or electric. Operating an electric screw driver in forward mode (or turning a hand-operated screw driver clockwise) rotates the drive shaft 15 clockwise. This rotates the first 45 degree mitered gear 23a clockwise. As the teeth of the first 45 degree mitered gear 23asuccessively engage the teeth of the second 45 degree mitered gear 23b, clockwise rotation of the first mitered gear 23a induces clockwise rotation of the second mitered gear 23b. In turn, clockwise rotation of the second gear 23b causes clockwise rotation of the threaded rod 30. The lock nuts 34 allow the threaded rod 30 to rotate in place without shifting along the lower housing channel 14. As the threaded rod 30 rotates clockwise, the T-nut 40 and the carrier arm 41 advance along the threaded rod in a direction away from the external bearing housing 24 and toward the internal bearing housing 35, carrying with them the attached shutter panel 11. As a result, the shutter panel 11 gradually slides out of the lower housing channel 14 and obstructs the window.
is designed so that the support disks 46 bear the weight of the shutter panel 11 and reduce friction between the lower housing walls 17, 18 and the shutter panel 11. The internal bearing housing 35 also bears the weight of the shutter panel 11 and prevents the T-nut 40 from impacting the second gear 23b. The shutter panels 11 may be made from one piece of material or several pieces of material. Preferably, the shutter panels 11 are made of aluminum.
To retract the hurricane shutter panel 11 within the lower housing channel 14, the user removes the drive shaft cover (not shown) from the drive shaft 15. Then the user inside the house or other building engages a screw driver having a square head, or a ratchet, with the square shaped orifice 51 of the drive shaft 15. Operating an electrically-operated screw driver in reverse mode (or turning a hand-operated screw driver counterclockwise) turns the drive shaft 15 counterclockwise. This causes the first 45 degree mitered gear 23a outside the house behind the shutter panel to rotate counterclockwise. As the teeth of the first 45 degree mitered gear 23a engage the teeth of the second 45 degree mitered gear 23b, counterclockwise rotation of the first gear 23ainduces counterclockwise rotation of the second gear 23b. In turn, counterclockwise rotation of the second gear 23b causes counterclockwise rotation of the threaded rod 30. The counterclockwise rotation of the threaded rod 30 causes the T-nut 40 and the carrier arm 41 to advance along the threaded rod away from the internal bearing housing 35 toward the external bearing housing 24, carrying with them the attached hurricane shutter panel 11. As a result, the hurricane shutter panel 11 slides into the lower housing channel 14 so that it no longer obstructs the window.
Again, the support disks 46 bear the weight of the shutter panel 11 and reduce friction between the lower housing walls 17, 18 and the shutter panel 11. The internal bearing housing 35 also bears the weight of the shutter panel 11. The external bearing housing 24 prevents the shutter panel from sliding out of the end of the lower housing channel 14.
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The upper channel assembly 13 and lower housing 63 are preferably made of aluminum or steel. They are preferably channel-shaped, but may be round pipe or rectangular/square hollow steel. The upper channel 52 may telescope to accommodate a wider or narrower window and therefore a larger or smaller number of rollers 58. The lower housing 63 may telescope so as to accommodate the variable length threaded rod. One gear shaft assembly kit comprising two matching upper channel assemblies 13 and two matching lower channel assemblies 12 can therefore be altered to accommodate a variety of window sizes.
In use, the upper channel assembly 13 is oriented directly above the lower channel assembly 12, as seen in
As seen in
Continuing with
Unlike commercially available shutters, the present gear shaft assembly 10 is conformable to virtually any size window. The unique lockable journal bearings 29 allow the length of the threaded rod 30 to be custom cut for each window. The length of the channels 14, 52, the number of support disks 46, and the number of upper channel rollers 58 will also vary depending upon the size of the window. During installation, an installer selects lower and upper channels 14, 52 of appropriate length depending upon the width of the shutter panel 11 required for the particular window. The installer also cuts an appropriate length of threaded rod 30 (e.g. the installer cuts a 36 inch rod down to 24 inches) for the lower channel 14. Of course, as the width of the window increases, the width of the shutter panel 11 increases, and the lower and upper channel assemblies 12, 13 must comprise a greater number of support disks 46 and upper channel rollers 58 to guide and support the weight of the shutter panels 11.
The upper channel assembly 13 and the rest of the lower channel assembly 12 may be assembled on-site or at the factory for quicker installation. The gear shaft assembly 10 is easily manufactured because all of its components may be manufactured in one size, except the lower channel 14 and the upper channel 52.
As previously described, movement of each shutter panel 11 is controlled by a separate gear shaft assembly 10. However, movement of both shutter panels 11 may be simultaneously controlled by an alternate embodiment, called here a tandem gear shaft assembly 70 shown in
As seen in
In the tandem gear shaft assembly embodiment 70 of
The tandem gear assembly 70 includes a tandem lower housing 64 that resembles the single lower housing 63, except that the tandem lower housing 64 is almost twice as long and the drive shaft apertures 21, 22 occur at the center of the tandem lower housing rather than near one end. The channel-shaped tandem lower housing 64 is formed from a lower housing bottom wall 16, front wall 17, and rear wall 18, each of which is generally rectangular in shape. The tandem lower housing may alternatively be round or rectangular/square. There are two mirror image external bearing housings 24 at the opposite ends of the tandem lower housing 64, each with an end of a threaded rod 30 extending into it. There is a lock nut 34 outside each external bearing housing 24.
In addition to manually/mechanically opening or closing shutter panels using the gear shaft assembly 10, 70, a conventional electrical mechanism may be employed for rotating the drive shaft 15 of either gear shaft assembly 10, 70. Using this electrical mechanism, the user need only push a button to open or close the shutter panels 11 over a window or door. An electric motorized mechanism may be backed up by a hand crank in case the motor or power fails. The electric opening/closing mechanism may be operated with a remote device, so the shutter panels can be opened or closed from within a home, for example. Mechanisms for operating the gear shaft assembly 10, 70 by telephone or instructions from a personal computer or cellular device may be employed. With such a mechanism in place, a user visiting another state who hears of hurricane warnings for his coastal home state could telephone home and instruct the gear shaft assembly 10, 70 to close all of the shutter panels on the house.
The tandem gear shaft assembly 70 is also conformable to virtually any size window. Again, only the length of the threaded rod 30, the length of the lower and upper channels 14, 52, the number of support disks 46, and the number of upper channel rollers 58 vary depending on the size of the window. The tandem gear shaft assembly 70 is installed in the same manner as the gear shaft assembly 10.
As extra insurance against jamming of the assembly over time, the tandem gear shaft assembly preferably includes an in-line slip clutch 66, preferably on the input drive. The slip clutch 66 signals that the shutter panels, or other objects attached to the assembly, are closed, and provides protection from overload during closing or opening of the shutter panels.
In addition to shutter panels, the carrier arm 41 may be attached to any object to move the object in a linear direction. The gear shaft assembly 10, 70 may move the object in a horizontal plane, a vertical plane, or a plane oriented between a horizontal plane and a vertical plane.
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In
The gear assembly shaft 10 can be fitted inside a side arm of a Bahamas shutter, which pivots towards and away from a window. The Bahamas shutters can then be manually or electrically opened and closed from inside or outside the building on which they are installed.
A solar panel can be attached to the gear shaft assembly 10, or two solar panels can be attached to a tandem gear shaft assembly 70, so that the solar panel(s) can be opened or closed from inside the building housing them, either manually or via a motorized mechanism. Alternatively, an impact resistant sliding glass door coated with a thermal insulative coating may be attached to a gear shaft assembly 10 for movement of the door in a forward or backward direction (open or closed).
The present invention further includes a method for installing a gear shaft assembly 10 on a window, including the steps of:
The method preferably further includes the steps between steps (e) and (f) of:
From the foregoing it can be realized that the described device of the present invention may be easily and conveniently utilized as a gear shaft assembly for opening and closing hurricane shutter panels or actuating linear movement of another object. It is to be understood that any dimensions given herein are illustrative, and are not meant to be limiting.
While preferred embodiments of the invention have been described using specific terms, this description is for illustrative purposes only. It will be apparent to those of ordinary skill in the art that various modifications, substitutions, omissions, and changes may be made without departing from the spirit or scope of the invention, and that such are intended to be within the scope of the present invention as defined by the following claims. It is intended that the doctrine of equivalents be relied upon to determine the fair scope of these claims in connection with any other person's product which fall outside the literal wording of these claims, but which in reality do not materially depart from this invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
