Patent Application
20090193730
Not applicable.
Not applicable.
The invention relates to flexible panels that can be used to protect structures from hurricane and wind damage.
During hurricanes and other high wind storms, windows are often damaged, and the breach can cause great damage to the structure. Hurricane shutters are often used to protect building openings from the hazards of wind-blown debris and pressure changes. These are usually made from a rigid material, such as aluminum, wood and sometimes plastic. However, shutters are expensive, cumbersome and heavy. Plywood is inexpensive and is often used as a window covering during storms. But, although inexpensive, plywood is not durable, is awkward to store, difficult to put up, and does not provide optimal protection.
From our experience in the environmental and petrochemical industry, we believed that there were a variety of flexible liner products available from landfill preparation or the petrochemical industry that could provide hurricane protection for homes and businesses in a more cost effective manner.
Hurricane panels made of fabric are available. These panels are manufactured and installed to provide the protection required by the building codes of particular geographic areas. The building codes are based on standardized testing to meet certain standards of strength and integrity.
For example, flexible hurricane window panels are described in U.S. Pat. No. 6,865,852, U.S. Pat. No. 6,325,085 U.S. Pat. No. 6,176,050, U.S. Pat. No. 6,886,299, and US2004159345 by TARGUS INTERNATIONAL™. These patents describe a protective barrier device formed of a flexible mesh material having a burst strength greater than 61.3 psi and an interstice size constructed and arranged to prevent passage of wind-borne objects greater than about 3/16 inch diameter, whereby the protective barrier is placed in front of a window, and secured thereto. Preferably, the protective barrier device is a textile formed from synthetic threads, for example, polypropylene.
U.S. Pat. No. 6,341,455 by Gunn describes flexible material used to cover a window whereby cylinder or roller bar is used to deploy the covering in a manner analogous to a shade. However, the roller bar is difficult to fabricate and subject to jamming.
U.S. Pat. No. 6,296,039, U.S. Pat. No. 6,341,639, and U.S. Pat. No. 6,431,250 by WAYNE DALTON™ describe a curtain system covering an opening in a building, but again the window attachment mechanism is cumbersome. Another cumbersome attachment means is described in U.S. Pat. No. 6,851,464, also by WAYNE DALTON™. U.S. Pat. No. 6,886,300, also by WAYNE DALTON™, requires that the panel edges be inserted into channels, and the fabric material stretched between the channels.
What is needed in the art is a panel with sufficient strength that can be applied to a building in a simple manner with readily available hardware.
The invention generally relates to methods, kits and panels for protecting a window in a building using a geocomposite membrane having reinforced edges and a core of impermeable plastic surrounded on both sides by batting and having a puncture resistance of 250 lbs when measured by ASTM D-4833. The geocomposite membrane can be anchored over the window with any anchoring and attachment means, including grommets and fasteners. In preferred embodiments, the method also employs a deflection inhibitor comprising at least one elongated member so placed as to span said building opening and placed underneath said geocomposite membrane, and the deflection inhibitor can be telescoping. In other embodiments, a rectangular strip is used on the edges further contribute to the attachment of the panel over the window. The rectangular strip also contributes to edge reinforcement since it spreads the attachment load over more of the edge of the panel.
We designed a much stronger flexible panel than has been used in the past. The panel has an impermeable core (e.g., it lacks interstices), and is surrounded by batting layers on each side, giving the panel greatly increased strength, yet keeping it flexible for easy storage. We called the panel a Weathervest™ and a cross-section in
The panel can be mounted directly to the building using readily available hardware, such as nails, bolts, hooks, screws, tapons, washers, clamps and the like, and as appropriate for the building construction. Alternatively, the panel can be attached with an attachment strip that allows fewer direct attachments to the building and spreads the load. A deflection limiter can be attached under the panel to limit the deflection caused by a hurricane-blown missile. The attachment strip and deflection limiter are preferably aluminum for lightweight strength and resistance to corrosion, however, other materials can be used, including sufficiently strong plastic or resin, iron, wood, metals, and the like. In one embodiment, the attachment strip can be affixed to the geocomposite membrane, and if so it is preferred that the strips be of shorter length with some space between strips so as to allow for easy folding of the panel during storage.
The attachment strip and deflection limiter can be the same, or a special deflection limiter can be designed to be telescoping, for example. Where the attachment strip and deflection limiter are the same, they can be made available in a few standard sizes, allowing the home owner to select the sizes appropriate for the building windows.
The edges of the panel can be reinforced for maximum strength at the point of attachment to the building. The reinforcement can be a flexible strip sewn or glued to the edges (e.g., a selvage), but for ease of manufacture and cost the panel may be folded back on itself and attached with grommets, glue, stitching and the like. In one embodiment the grommets are attached approximately 2 inches from the edge of the material.
Grommets Size range from 3/16″ (00), ¼″ (0), 9/32″ (1), ⅜″ (2), 7/16″ (3), ½″ (4), ⅝″ (5), 13/16″ (6), 15/16″ (7), 1 1/16″ (8), 1½″ (10), 1 9/16″ (12). Grommet size can be adjusted to fit a variety of bolt, screw or fastener configurations.
The panel is light, can be rolled up or folded, stored easily, and used multiple times. If desired, permanent yet discreet fasteners can be added to the house, allowing quick set up after the first use. For example, a hook or eye bolt is added to the house, and short stretchy cords (such as a bungy cord) can be used to hold the panel. Alternatively, a bolt can be added to the house, and the panel fitted over the bolt and a nut used to fasten the panel. In yet another alternative, a releasable clamp can be added to the house, that in the open position allows easy mounting of the panel, but when closed tightens the panel across the opening.
Our testing shows that the panel can take multiple hits from hurricane-blown missiles with no damage. Another benefit is that the panel is impermeable to wind and water.
The preferred geocomposite panel is constructed with something similar to the C
The invention provides a novel use of a geocomposite that has traditionally been used as a chemical pond liner. The material is extremely tough, yet flexible and affordable. Further, it can be attached with readily available hardware, or can be attached with attachment strips. In a preferred embodiment, it is combined with a deflection limiter.
In one embodiment, the invention is a hurricane panel made of a geocomposite membrane shaped to cover a building opening. The geocomposite membrane has a core of impermeable plastic surrounded on both sides by batting and a puncture resistance of 250 lbs when measured by ASTM D-4833. At least two edges of the membrane have anchoring means for attaching said panel to said building so as to cover said building opening, and preferably all edges have anchoring means.
In another embodiment, the protective building panel comprises a geocomposite membrane having a core of impermeable plastic surrounded on both sides by batting and having a puncture resistance of 250 lbs when measured by ASTM D-4833. The geocomposite membrane is configured to cover a building opening. Further, a plurality of grommets are placed 2 inches from the edge of the panel on opposing sides of the panel. In use the panel further comprises at least one elongated attachment strip having openings at the same spacing. The attachment strip is placed over the reinforced edge, so that the openings and grommets are aligned. The panel is attached to the building by at fastener, passing through said openings and grommets and connecting to said building. Either embodiment can be combined with deflection limiters that span the opening, minimizing the deflection of the panel when struck by debris.
The batting of the geocomposite membrane can be nonwoven or woven, or combinations thereof. The batting materials can include polyester, polyolefin, cotton, air-fluffed wood fiber, and the like. The batting can also comprise mixtures of resins, one of which is a low melt fiber that can be used to impart further strength to the batting when heat set. The core can be any sufficiently strong plastic, including HDPE, LDPE, MDPE, LLDPE, EVA, composites, reinforced plastics and the like. Various combinations are possible, provided that the three layers together maintain the requisite puncture resistance. Suitable geomembrane composites include C
In our first attempt to devise a flexible window covering we tried a reinforced polypropylene membrane from CARLISLE™. The membrane was prepared by doubling the edges and heat welding. Grommets were spaced at approximately 1 ft apart. The initial material was taken to an independent laboratory and tested by firing a 2″×4″ board at 50 ft/sec at the panel. The material failed the test by tearing at the grommets. It was decided that the grommet spacing was too wide, and that the tensile strength and puncture resistance of the fabric were not strong enough. A stronger material was needed.
In our second attempt, we searched for a much stronger commercially available material. We chose a geocomposite with nonwoven batting on both sides for added strength, but having a core of EVA geomembrane in the center. We believed that batting would add considerable strength where it was needed, on the outside of the panel, and the interior core rendered the entire panel completely water- and wind-proof.
Suitable materials were available in three different weights (C
The three geocomposites were purchased, fabricated into panels and tested by an independent laboratory, as above. Two of the three geocomposite panels failed the test tearing the material either at impact or at the grommets from the force of the 2″×4″ hitting them. The other geocomposite panel made from C
C
An independent laboratory performed testing on four (4) Weathervest panels. The following tests were performed:
1) ASTM E 1886-02: Standard Test Method for Performance of Exterior Windows, Curtain Walls, Doors and Storm Shutters Impacted by Missile(s) and Exposed to Cyclic Pressure Differentials.
2) ASTM E 1996-02: Standard Specification for Performance of Exterior Windows, Glazed Curtain Walls, Doors and Storm Shutters Impacted by Wind Borne Debris in Hurricanes.
3) TAS 202-94: Criteria for Testing Impact and Non Impact Resistant Building Envelope Components Using Uniform Static Air Pressure Loading.
The test specimens were 6′3″ wide by 9′0″ Weathervest™ fabricated from C
The following results were recorded in the TAS 202-94, Static Air Pressure Tests, at a design pressure of +31.6/−34.6 psf:
Specimens tested for TAS 202-94 met the requirements of Section 1620 of the Florida Building Code, Building (2004). Tape and film were used to seal against air leakage during structural testing. The tape and film did not influence the results of the test.
The following results (Table 5) were recorded in the ASTM E 1896-2: Large Missile Impact Test with a missile weight of 8.8 lbs, length of 8′1″, muzzle distance from test specimen of 17.0 ft. and average ambient air temperature of 91° F.
The following results (Table 6a) were recorded in ASTM E 1886-02: Air Pressure Cycling test at a Design Pressure of +31.6/−34.6 psf:
In a second test the following results (Table 6b) were recorded.
In another test at the following results (Table 6c) were recorded:
One of the disadvantages of the impermeable core is that no wind passes through the panel, thus the full force of the wind or debris impacts the panel and can cause significant deflection (as much as 20″ over a 6′3″×9′ panel). There are buildings where such deflection would allow the impact to reach and break the window. In such cases, we have added a deflection inhibitor to further protect the windows, which is merely an elongated strip that crosses over the window and is placed behind the panel. Alternatively, or in combination, the anchoring means can be raised or thickened to place the panel further away from the window.
In a preferred embodiment, the elongated member is telescoping to fit a range of window sizes, and multiple elongated members are arranged appropriately over the window in either parallel or crossed manner, or combinations thereof.
End views of three embodiments are shown in
This application claims priority to 60/954,567 (incorporated by reference in its entirety) filed Aug. 7, 2007.
| Number | Date | Country | |
|---|---|---|---|
| 60954567 | Aug 2007 | US |
