Patent Application
20120144747
This description relates generally to window shutters and more specifically relates to window shutters having features to improve the performance, durability and operation of the shutters and also to substantially reduce light infiltration between the shutter frame and louvers, and other openings often inherent in shutter construction.
Various types of interior window treatments are utilized in both residential and commercial buildings. One such widely used and accepted window treatment is the shutter. Shutters are popular because of their pleasing aesthetic appearance, versatility, adjustability and other functional advantages.
One functional advantage of shutters is that the shutters can be provided with louvers which can be positioned or adjusted to change the desired light level and also to deflect light or reduce glare. Shutters are also insulative and assist in reducing the heat load transfer to the interior area through a window opening. Shutters are manufactured to fit window openings having a wide variety of sizes and shapes.
In the past, shutters have been made primarily of wood. Modern shutters are increasingly fabricated from more durable materials such as polymeric materials or a combination of composite materials such as wood and synthetic polymers. Common materials are polyvinyl chloride, polystyrene, polyurethane, polypropylene and composites of these materials. However wood shutters typically are quite rigid, and components such as louvers when made from polymeric materials alone may sag or bend, as they lack the rigidity of wood.
Fabrication of shutter components using various synthetic and engineered materials makes the manufacturing technique more efficient as many of the components can be extruded whereas in the past these components, when made of wood, required multiple operations such as milling, planing, shaping drilling and routing in the assembly process. Despite the materials used to construct shutters, the components used and their assembly have not changed a lot. In a shutter there are often many cracks, or openings where light may come through. Thus typical shutters may not completely block light and must often be used in conjunction with curtains or the like to completely block light from entering a room.
Accordingly, there exists a need for a shutter with improved light blocking features. Also a polymeric shutter louver with improved rigidity would be useful.
The following presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.
The present example provides a window shutter assembly having an exterior frame with vertical sides and horizontal top and bottom members which supports at least one louver panel with vertical stiles and top and bottom horizontal rails. The louver panel is hinged to the exterior frame so that the louver panel may open or close. A light blocking material may be included to prevent light from infiltrating space which may be present between the louver panel and frame. The louver panel comprises a plurality of louvers are arranged in parallel fashion and joined at opposite ends to the edges of the vertical stiles. The spaces between the louvers and stiles may also incorporate a light blocking material. The position of the louvers is established by a control rod or tilt rod connected to the individual louvers. The exterior frame which extends around the louver panels has a generally L-shaped, cross-sectional configuration to receive the louver panel and has a stop surface against which the louvers abut in a closed position.
With the present invention, a light-blocking seal is provided at various locations within the shutter assembly to substantially block light infiltration. In one embodiment, the light-blocking seal is in the form of a flexible member such as a flap integrally extruded as part of the shutter component, such as part of the exterior frame, or on the edge of the shutter panel stile to block light when the shutter panel is closed. The light-blocking seal is a flexible polymeric flap co-extruded with the stop surface of the exterior frame which seals areas between the shutter components which may otherwise allow light infiltration. The seal may also take other shapes such as round, oval or even semi-spherical.
The present invention can also eliminates the need for the structural divider rail that is common in larger louver panels such as those over 5 feet in height. Normally shutter panels of this size and larger have a fixed horizontal structural divider extending between the vertical stiles for structural integrity. A tight louver screw replaces dividers for taller shutter panels. The louver screw assembly includes a screw which extends from a recess in the vertical stile in which the head of the screw is located. The threaded portion of the screw extends through a bore into the adjacent louver panel. A thrust washer is interposed between the head of the screw and the bottom of the recess. Low friction washers of nylon or other material are preferably positioned on opposite sides of the thrust washer. The thrust washer supports rotation of the screws and the attached louver as a unit to provide structural integrity to the assembly maintaining the spacing between the vertical stiles, minimizing the tendency of the screw to “strip” from the louver ends.
In yet another embodiment of the present invention, a plurality of tension-control pins may be placed at selected locations between the stiles and the louvers, typically in about one-third of the locations. The tension-control pins secure the louvers and reduce wear by preventing the weight of the tilt rod from causing the louvers to pivot, particularly after wear has occurred.
Light-blocking around the various spaces described above may be accomplished is in the form of a strip of fibrous or pile, brush-like material having a generally round, T cross-sectional or other equivalent shape. The base of the T-shaped, flexible fibrous light-blocking strip is secured in suitable locations where light might infiltrate, such as in grooves routed in the edges of the vertical stiles and horizontal rails, as well as in the horizontal and vertical frame components.
Another light-blocking feature is the provision of interlocking or inter-engaging sections on the edges of the louvers. When the louvers are fully closed, these sections abut similar sections either on adjacent louvers or on an edge of a rail in interlocking or inter-engaging fashion to block light.
The present invention also provides an enhanced construction in which the individual louvers are a synthetic or composite material and are reinforced to further resist warpage and deformation due to wear, tear and environmental conditions.
Many of the attendant features will be more readily appreciated as the same becomes better understood by reference to the following detailed description considered in connection with the accompanying drawings.
The present description will be better understood from the following detailed description read in light of the accompanying drawings, wherein:
Like reference numerals are used to designate like parts in the accompanying drawings.
The detailed description provided below in connection with the appended drawings is intended as a description of the present examples and is not intended to represent the only forms in which the present example may be constructed or utilized. The description sets forth the functions of the example and the sequence of steps for constructing and operating the example. However, the same or equivalent functions and sequences may be accomplished by different examples.
The shutter assembly 10 has an exterior frame 12 which is shown as rectangular having an upper, lower and opposite sides 14, 16, 18 and 20 which extend around shutter panel 22. Shutter panel 22 is hinged to the frame 12 having multiple louvers 25 pivotally mounted at opposite ends to the stiles 28, 29. Rails 30, 32 extend between the stiles 28, 29 at the top and bottom of the shutter panel 22. A control rod or tilt bar 34 is provided to manually pivot the louvers 25 to establish a selected position to admit or block light. Although a single louver panel 22 is shown, the frame 12 may enclose two or more panels which are hinged either to the exterior frame 12 or to an adjacent louver panel. A divider rail 80 may be added for astetics, or to improve structural rigidity, especially in tall panels.
The shutter panel typically includes one or more louver apertures into which a plurality of louvers may be disposed. Where the ends of the louvers (not shown) abut a side wall of the shutter panel, light blocking material may be disposed there to fill gaps that would also allow unwanted light from entering the room.
The horizontal edges of the louvers may also form a pathway to admit unwanted light where the louvers at the end, and beginning of a set contact the shutter panel. In this case the top and/or bottom rail of the shutter panel and also the stile of the shutter panel may include a plurality of parallel groves that accept a plurality of mating groves disposed in the corresponding louver, where it would contact the shutter panel.
Each of the frame members are generally L-shaped having a facing 40, and a rearwardly depending leg 42 which is generally perpendicular to the facing 40 and may be relieved at 41 to reduce material requirements. The facing 40 abuts the wall W and the leg 42 is positioned in a recess R such as the space formed around a window. The recess R is often not dimensionally uniform and may be irregular. Shutter frames are often pre-manufactured based on the nominal dimensions of the recess and they may require extensive cutting and fitting at installation. Cutting and trimming requires time on the part of the installer, increasing costs to the consumer.
To provide for efficiency of installation and also to block light that may infiltrate around the frame, the outer frame or sections of the frame 18 are provided with a co-extruded seal 50 which is a flap of flexible material which will engage the recess wall, providing a clearance space to facilitate installation and squaring of the frame within the recess.
In alternative examples a light blocking seal 60 can be provided or attached to the surfaces “S” of the frame 12 along members 14, 16, 18 and 20. The seal 60, may be a flexible flap projecting from the edge of the frame. The seal is fabricated from a flexible polymeric material and co-extruded with a component of the assembly such as the louver panel frame section 18, making the seal an integral component which can be efficiently fabricated in the same process as the shutter components.
Blind bores 80 are provided in the outer edges of opposite stiles 28, 29 adjacent the ends of a louver 25 at a selected location. The blind bores 80 each receives a fastener 82 shown as an elongate, screw having a head 84, such as a flathead, and a threaded body section 85. The screws extend through bores 86 in the opposite stiles and the end of the screws engage the ends of the adjacent louver 25 end. Bearings 88, which are thrust bearings, are interposed between the bottom of the blind bores 81 and the heads 84 of the screws. Low friction flat washers 89 of nylon or other suitable material are interposed on opposite sides of the thrust bearing 88. The screws are then tightened into engagement with the louver 25 so that the screws and louver 25 turn together. The bearings 88 allow the screws to turn with the louver as an integral unit. Thus, the louver screw secured to the stiles and to the louver in this way provides additional structural integrity between the stiles, often eliminating the need for a divider rail and also reduce the tendency of the screws to “strip” out of the louver end.
The pivot pins 90 have an elongated cylindrical body 92 having a point 93 at one end and a head 94 at the opposite end. The body 92 has a section 95 of increased diameter immediately adjacent the had which is a bearing surface. A portion of the body 92 may be provided with axially extending ribs or splines 96 to increase frictional engagement with the louver 25.
A sleeve 98 extends about the bearing surface of section 95 and is retained by the head 94. The inner end of the sleeve carries a flange 99. The head and the sleeve of the tension pins are inserted in a blind bore in the stiles 28, 29 at selected locations. The flange 98 will abut the vertical, inner edge of the adjacent stile. The body of the pins 90 are inserted into an aligned bore 102 in the end of the louver in a tight fit and further secured by the splines 96. The louver 25 and pin body rotate supported by the fixed bearing sleeve 98, reducing the tendency of the pivot pin from “stripping” out of the louver.
A light seal 70b is disposed into to the edge of a shutter component such as adjacent to (such as being disposed into a grove 76b) the inner edges of stiles 18, 20, and rails 14, 16, or to the edges of the frame or other component in which light is to be blocked. The light-blocking seal 70b, rather than being co-extruded, is slidably disposed into a channel 76b, and in alternative examples may be or bonded or adhesively secured to hold it in place, to its associated shutter component. As shown, the light-blocking seal is generally made of a siliconized pile material 72d or its equivalent, and is generally curved, or round in shape, with a substantially tangent point on the outer circumference of the pile surface 72c bonded to a flexible strip 72b. Securing the pile 72d to the backing strip 72b in this way provides relief for the protruding ledges of the channel 76b so that the light blocking seal 70b may be easily slid into the channel 76b. The strip 70b is inserted into a typically T-shaped grove or channel 76b disposed into the stile 18 The backing strip 72b may be made of any suitable material that is rigid, flexible and also easily bonded glued or otherwise attached to the pile material 72d. The pile material may be a siliconized pile, a felt or pile material which may be natural fibers such as cotton or wool or synthetic fibers such as polyamide. The pile material 72d is provided in a suitable color such as black or white, depending on the light blocking preference of the user. The seal 70b, for example, will block much of the light infiltration between the stile and, louver edges.
The alternative light-blocking material 70, rather than being co-extruded, is adhesively secured or bonded to its associated shutter component. The light-blocking seal is generally T-shaped having a base 72 and an upwardly projecting leg 74. The base and leg are formed from a suitable material such as a felt or pile material which may be natural, fibers such as cotton or wool or synthetic fibers such as polyamide. The seal 70 is provided in a suitable color such as black or white, depending on the light blocking preference of the user. Preferably the edges of the stiles and, rails to which the seal 70 is attached are slightly undercut or routed at 75 to accommodate insertion and adhesive securement of the base portion 72 of the light-blocking seal. The seal 70, for example, will block much of the light infiltration between the stile and louver edges.
As mentioned above, the louvers 25 are preferably fabricated by extrusion from a suitable polymeric material. In order to provide additional strength and resistance to sagging and loss of structural integrity, the extruded louvers are provided with an embedded stiffening section 110. The embedded stiffening section 110 is shown as a generally inverted V-shaped metal section, preferably aluminum, which can be incorporated at the time of extrusion and to provide the desired additional strength. The section is perforated at multiple locations 112 along its length for weight reduction and for increased adhesion within the louver.
The upper louver rail and the lower louver rail are provided with compatible configurations to engage the upper edge of the upper most louver and the bottom edge of the lower most louver in the louver panel.
Although, for most efficient light-blocking, the louver edges with multiple grooves, may work well, since grooves in the shutter louver edges are an efficient light-blocking configuration, other inter-engaging configurations may also be utilized. A single groove along each louver edge may be sufficient for some installations.
It will be obvious to those skilled in the art to make various changes, alterations and modifications to the invention described herein. To the extent such changes, alterations and modifications do not depart from the spirit and scope of the appended claims, they are intended to be encompassed therein.
Those skilled in the art will realize that the process sequences described above may be equivalently performed in any order to achieve a desired result. Also, sub-processes may typically be omitted as desired without taking away from the overall functionality of the processes described above.
This application claims the benefit of U.S. Provisional Patent Application No. 61/403,837 filed Sep. 21, 2010 and U.S. Provisional Patent Application No. 61/572,424 filed Jul. 15, 2011 the contents of which are hereby incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 61403837 | Sep 2010 | US | |
| 61572424 | Jul 2011 | US |
