Patent Application
20090266012
The subject invention generally relates to a shutter assembly. More specifically, the subject invention relates to a shutter assembly for protecting an opening in a structure during inclement weather.
Shutters generally are either functional or decorative. The decorative shutters are fastened directly to an exterior wall adjacent a window and are merely for aesthetic purposes. Functional shutters are generally movable between an open position and a closed position. In the closed position, the shutters function to protect the windows during inclement weather, such as precipitation storms, wind storms, and hurricanes.
During such inclement weather, it is desirable to lock the shutters in the closed position such that the shutters can continue to provide adequate protection to the windows throughout the inclement weather. If the weather causes the shutters to open then the functional purpose of the shutters is defeated.
The conventional locking systems disclosed in the prior art do not adequately retain the shutters in the closed position throughout the inclement weather. If the wind or storm cause the locking systems to bend or break, the shutters will open, exposing the window to the inclement weather.
Conventional locking systems are secured, typically screwed, directly into the structure on each side of the closed shutters to prevent the shutters from opening during the inclement weather. Installation of many of these conventional locking systems onto the structure is cumbersome and usually requires more than one person or the use of a specialized tool.
Due to the deficiencies in the locking systems of the prior art, including those described above, it is desirable to provide a locking system for shutters that is easy to install, and adequately retains the shutters in a closed position such that protection to the window is maximized throughout any inclement weather.
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:
Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a shutter assembly is generally shown at 20. As best shown in
The shutter assembly 20 comprises a first shutter 30 having a first attachment end 32 and a first free end 34. The first shutter 30 defines a first width W1 between the first attachment end 32 and the first free end 34. The first shutter 30 presents a first inner surface 48 which faces the interior of the structure when the first shutter 30 is in a closed position. Similarly, the first shutter presents a first outer surface 50 which faces the exterior of the structure when the first shutter 30 is in an open position. A first plurality of hinges 36 are disposed on the first attachment end 32 and are adapted to pivotally couple the first shutter 30 to the structure 24. The first plurality of hinges 36 allow the first shutter 30 to pivot between the open position and the closed position. The open position is defined as when the first shutter 30 is not covering the opening 22. The closed position is defined as when the first shutter 30 partially covers the opening 22 in the structure 24.
The shutter assembly 20 further comprises a second shutter 38 having a second attachment end 40 and a second free end 42. The second shutter 38 defines a second width W2 between the second attachment end 40 and the second free end 42. The second shutter 38 presents a second inner surface 52 which faces the interior of the structure when the second shutter 38 is in the closed position. Similarly, the second shutter presents a second outer surface 54 which faces the exterior of the structure when the second shutter 38 is in the open position. A second plurality of hinges 44 are disposed on the second attachment end 40 and are adapted to pivotally couple the second shutter 38 to the structure 24. The second plurality of hinges 44 allow the second shutter 38 to pivot between the open position and the closed position. Similar to the first shutter 30, the open position is defined as when the second shutter 38 is not covering the opening 22. The closed position is defined as when the second shutter 38 partially covers the opening 22 in the structure 24.
Each of the shutters 30, 38 comprise a rigid material such as wood, fiberglass, composite material or any other suitable material known in the art. The present invention may be practiced on a variety of shutter designs, including but not limited to raised panel, louver, or board and batten styles.
The shutter assembly 20 further comprises a plurality of sheets 56 disposed on the outer surfaces 50, 54 of each of the shutters 30, 38. The sheets 56 define shapes that are complementary in configuration to the outer surfaces 50, 54 of the shutters 30, 38 that the sheets 56 will be disposed upon. In other words, the sheets 56 are sized such that the sheets 56 substantially cover the entire outer surface 50, 54 of the shutter 30, 38 but do not extend beyond the perimeter of the shutter 30, 38. The sheets 56 improve the impact resistance of the shutters 30,38 such that the shutter assembly 20 meets the requirements of the Large Missile Impact Test as defined by ASTM E 1886-05 and ASTM E 1996-05 as specified in the International Residential Code (IRC) and the International Building Code (IBC) 2006. The Large Missile Impact Test consists of mounting a test specimen, the shutter assembly 20, in a test fixture. A piece of 2×4 dimensional lumber (the missile) is launched at specified locations on the test specimen at a specified velocity and the results of the impact are recorded. This is a pass/fail type of test to determine if the test specimen is able to withstand conditions specified in the testing specification. A rating is determined for the specimen's impact resistance based on the amount of damage sustained through the testing. Sample Impact Test Results are provided below (references in the Test Results to panels corresponds to the first and second shutters 30, 38 each with the sheets 56 disposed thereon). Although the Test Notes on the Impact Test Results state that the “Shutter cracked at impact locations, top corner impacts bent hinge” the shutter assembly still satisfied the ASTM specification by preventing penetration.
The sheets 56 are secured to each of the shutters 30, 38 with fasteners 58, such as screws, rivets, or any other appropriate fastener, including appropriate adhesives. The sheets 56 preferably comprise an impact-resistant material such as polycarbonate or any other suitable material known in the art. Additionally, the sheets 56 are preferably transparent so as to not diminish the aesthetic quality of the shutters 30, 38 when viewed in the closed position. The sheets 56 preferably have a thickness of about 0.125 inches or greater, most preferably 0.125 inches. In some embodiments, the sheets 56 may be thicker or thinner and may be from about 0.03 to about 0.5 inches.
A crossbar 46 spans the first and second shutters 30, 38 on the outside of each of the sheets 56 when each of the shutters 30, 38 are in the closed position. The crossbar 46 has a length that is equal to or less than the sum of the first width W1 and the second width W2. In other words, the crossbar 46 terminates at or before each of the first attachment end 32 and second attachment end 40 when the shutters 30, 38 are in the closed position. Thus, the length of the crossbar 46 may also account for any gaps between the shutters 30, 38 when in the closed position. The crossbar 46 will be discussed in greater detail below.
A first plurality of studs 64 are disposed through the first shutter 30 and through the sheets 56. A second plurality of studs 66 are disposed through the second shutter 38 and through the sheets 56 and are linearly aligned with the first plurality of studs 64. The crossbar 46 is adapted to engage the first and second plurality of studs 64, 66 for securing the shutter assembly 20 in the closed position.
The crossbar 46 includes a first end 68 and a second end 70 spaced from the first end 68. The crossbar 46 includes a central portion 72 disposed between the first end 68 and the second end 70. The crossbar 46 defines a plurality of apertures 74. Two of the apertures 74 are elongated slots defined slightly inboard of the ends 68, 70. Two of the apertures 74 are elongated slots defined in central portion 72. The location of the apertures 74 generally corresponds to the first and second plurality of studs 64, 66. The crossbar 46 has a fastening portion 76 in which the plurality of apertures 74 are defined and which accepts the studs 64, 66 there through. Additionally, the crossbar 46 includes a stiffening member 78 disposed substantially perpendicular to the fastening portion 76 for providing rigidity and strength to the crossbar 46. The crossbar 46 has a generally L-shaped configuration and is preferably formed of metal such as aluminum or steel or the like with the fastening portion 76 being one leg of the L-shape and the stiffening member 78 forming the other leg of the L-shape. However, it should be appreciated that any other appropriate configuration may be utilized without deviating from the subject invention.
The studs 64, 66 each include a shaft portion 80 for engaging each of the shutters 30, 38 and the sheets 56, wherein each shaft portion 80 defines a primary diameter. A head portion 82 is disposed on the shaft for abutting the shutters 30, 38 and not allowing the studs 64, 66 to pass through, thereby creating a positive stop feature. Each of the studs 64, 66 further includes a tip portion 84 disposed on the shaft portion 80 opposite the head portion 82. The tip portion 84 presents a plurality of threads 86 adapted to protrude from each of the first shutter 30 and the second shutter 38 and the sheets 56 disposed on each of the shutters 30,38. The studs 64, 66 are preferably carriage bolts. It is to be appreciated that any other suitable stud may be utilized without deviating from the subject invention.
A plurality of retaining rings 88 are disposed over each of the studs 64, 66 for holding the studs 64, 66 substantially perpendicular to each of the shutters 30, 38 and the sheets 56. Each of the retaining rings 88 defines a hole 90 having a secondary diameter slightly smaller than the primary diameter of the shaft portion 80 of the studs 64, 66. A plurality of slots extend radially from the hole 90 defined by each of the retaining rings 88 for allowing the retaining rings 88 to be pressed over the tip portion 84 of the studs 64, 66 and against the sheets 56 to restrict removal of the studs 64, 66.
A plurality of threaded fasteners 94 are adapted to mate with the tip portion 84 of each of the studs 64, 66. When the shutters 30, 38 are in the closed position and the crossbar 46 engages the studs 64, 66, each of the threaded fasteners 94 mate with the studs 64, 66 for securing the crossbar 46 over the shutters 30, 38 and the sheets 56 for locking the shutter assembly 20 into the closed position. A wing nut style fastener is preferably used. However, other types of fasteners, such as hex nuts, clips, or any other appropriate fastener known in the art may be used without deviating from the subject invention.
Additional crossbars 46 may be utilized if required to secure larger shutters in the closed position. Typically, two crossbars 46 will be required for many applications, but it should be appreciated that any number of crossbars 46 may be employed without deviating from the subject invention. If more than one crossbar 46 is utilized, the crossbars 46 will typically be spaced and substantially parallel to each other.
As described above, the studs 64, 66 are held in place within each of the shutters 30, 38 and the sheets 56. The shutters 30, 38 are pivoted to the closed position and the crossbar 46 is placed over the tip portion 84 of the studs 64, 66 extending through the shutters 30, 38 and the sheets 56. The threaded fasteners 94 are tightened to secure the crossbar 46 in place, thereby locking the shutter assembly 20 in the closed position. The shutter assembly 20 can be quickly and easily secured in the closed position by an individual without any type of specialized tools.
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described.
This application claims the benefit of U.S. Provisional Patent Application No. 61/048,790, filed on Apr. 29, 2008, which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 61048790 | Apr 2008 | US |
