The present invention relates to plastic sheets, and more particularly to plastic sheets and systems that can be used to protect windows and doors in walled structures during a storm such as a hurricane.
Violent storms often generate strong winds that can damage or destroy property. The strong winds may carry debris that can impact against glass windows and doors and cause them to break. Storm shutter assemblies are known in the art. However, the prior art storm shutter assemblies are often costly and difficult to manufacture. Additionally, the prior art storm shutter assemblies may be difficult to install and may not offer adequate protection during violent storms. Thus, the present invention provides a storm shutter assembly that can be manufactured in a cost effective manner, can protect glass windows and doors from being destroyed by windborne debris, and can be easily installed and removed as needed.
In accordance with one embodiment of the present invention, a plastic sheet is provided. The sheet comprises top, bottom and lateral edges, a corrugated region oriented substantially parallel to the lateral edges, and a pair of lateral corrugated regions. The corrugated region comprises at least one substantially planar mounting region and at least one intermediate inclined region projecting away from the at least one planar mounting region in the direction of an adjacent corrugation. The pair of lateral corrugated regions comprise lateral corrugations along the lateral edges of the sheet. Each of the lateral corrugations have a substantially planar mounting region, an intermediate inclined region projecting away from the planar mounting region in the direction of an adjacent corrugation, and a lateral inclined region projecting away from the planar mounting region in the direction of one of the lateral edges. The corrugated region and the lateral corrugated regions are configured such that the sheet can resist a missile weighing about 9.4 lbs (4.3 kgs), having a cross-sectional impact area of about 5.25 in2 (34 cm2), and impacting the sheet at a velocity of about 50 ft/s (15.24 m/s).
In accordance with another embodiment of the present invention, a plastic sheet is provided. The sheet comprises top, bottom and lateral edges, a corrugated region oriented substantially parallel to the lateral edges, and a pair of lateral corrugated regions. The corrugated region comprises at least one substantially planar mounting region and at least one intermediate inclined region projecting away from the at least one planar mounting region in the direction of an adjacent corrugation. The pair of lateral corrugated regions comprise lateral corrugations along the lateral edges of the sheet, each of the lateral corrugations having a substantially planar mounting region, an intermediate inclined region projecting away from the planar mounting region in the direction of an adjacent corrugation, and a lateral inclined region projecting away from the planar mounting region in the direction of one of the lateral edges. The lateral inclined region projects a distance that is less than a distance projected by the intermediate inclined regions, and the plastic is selected from polypropylene, polyethylene, and combinations thereof.
In accordance with yet another embodiment of the present invention, a storm shutter kit for protecting an opening in a walled structure is provided. The kit comprises a pair of mounting tracks to be mounted to opposite sides of the opening, wherein each of the mounting tracks has a plurality of fasteners and each of the fasteners has a shank and a head, and a plurality of plastic sheets. Each of the sheets comprises top, bottom and lateral edges, a corrugated region oriented substantially parallel to the lateral edges, and a pair of lateral corrugated regions. The corrugated region comprises at least one substantially planar mounting region and at least one intermediate inclined region projecting away from the at least one planar mounting region in the direction of an adjacent corrugation. The pair of lateral corrugated regions comprise lateral corrugations along the lateral edges of the sheet. Each of the lateral corrugations have a substantially planar mounting region, an intermediate inclined region projecting away from the planar mounting region in the direction of an adjacent corrugation, and a lateral inclined region projecting away from the planar mounting region in the direction of one of the lateral edges. The corrugated region and the lateral corrugated regions are configured such that the sheet can resist a missile weighing about 9.4 lbs (4.3 kgs), having a cross-sectional impact area of about 5.25 in2 (34 cm2), and impacting the sheet at a velocity of about 50 ft/s (15.24 m/s). The lateral inclined region projects a distance that is less than a distance projected by the intermediate inclined regions such that a portion of one of the lateral corrugations of one of the sheets may be overlapped with a portion of one of the lateral corrugations of another one of the sheets to form a panel that substantially covers the opening. At least one mounting slot is provided adjacent to the top edge on the planar mounting region, and at least one mounting slot is provided adjacent to the bottom edge on the planar mounting region. The mounting slots are positioned and configured such that each of the sheets may be mounted to the mounting tracks by placing the fasteners through the mounting slots.
In accordance with yet another embodiment of the present invention, an assembly for protecting an opening in a walled structure is provided. The assembly comprises a pair of mounting tracks mounted to opposite sides of the opening wherein each of the mounting tracks has a plurality of fasteners, each of the fastener having a shank and a head. The assembly further comprises a plurality of plastic sheets. Each of the sheets comprises top, bottom and lateral edges, a corrugated region oriented substantially parallel to the lateral edges, and a pair of lateral corrugated regions. The corrugated region comprises at least one substantially planar mounting region and at least one intermediate inclined region projecting away from the at least one planar mounting region in the direction of an adjacent corrugation. The pair of lateral corrugated regions comprise lateral corrugations along the lateral edges of the sheet, each of the lateral corrugations having a substantially planar mounting region, an intermediate inclined region projecting away from the planar mounting region in the direction of an adjacent corrugation, and a lateral inclined region projecting away from the planar mounting region in the direction of one of the lateral edges. The corrugated region and the lateral corrugated regions are configured such that the sheet can resist a missile weighing about 9.4 lbs (4.3 kgs), having a cross-sectional impact area of about 5.25 in2 (34 cm2), and impacting the sheet at a velocity of about 50 ft/s (15.24 m/s). At least one mounting slot is provided adjacent to the top edge on the planar mounting region, and at least one mounting slot is provided adjacent to the bottom edge on the planar mounting region. The mounting slots are positioned and configured such that each of the sheets may be mounted to the mounting tracks by placing the fasteners through the mounting slots. A portion of one of the lateral corrugations of one of the sheets may be overlapped with a portion of one of the lateral corrugations of another one of sheets. The plurality of sheets are mounted to the mounting tracks to substantially cover the opening. The corrugated region, the lateral corrugated regions, and the mounting tracks are configured to withstand a pressure differential that reciprocates from about 0 to at least about 40 psf across first and second sides of the plurality of sheets.
In accordance with another embodiment of the present invention, a storm shutter kit for protecting an opening in a walled structure is provided. The kit comprises a pair of mounting tracks to be mounted to opposite sides of the opening, wherein each of the mounting tracks has a plurality of fasteners and each of the fasteners has a shank and a head, and a plurality of high density polyethylene sheets. Each of the sheets comprises top, bottom and lateral edges, a corrugated region oriented substantially parallel to the lateral edges, and a pair of lateral corrugated regions. The corrugated region comprises at least one substantially planar mounting region and at least one intermediate inclined region projecting away from the at least one planar mounting region in the direction of an adjacent corrugation. The pair of lateral corrugated regions comprise lateral corrugations along the lateral edges the sheet. Each of the lateral corrugations has a substantially planar mounting region, an intermediate inclined region projecting away from the planar mounting region in the direction of an adjacent corrugation, and a lateral inclined region projecting away from the planar mounting region in the direction of one of the lateral edges. The lateral inclined region projects a distance that is less than a distance projected by the intermediate inclined regions such that a portion of one of the lateral corrugations of on of the sheets may be overlapped with a portion of one of the lateral corrugations of another one of the sheets to form a panel that substantially covers the opening. At least one double key-way type slot is provided adjacent to the top edge on the planar mounting region, and at least one double key-way type slot is provided adjacent to the bottom edge on the planar mounting region. The double key-way type slots have an enlarged portion larger than the head of the fastener, an upper portion smaller than the head of the fastener, and a lower portion smaller than the head of the fastener. The double key-way type slots are reinforced by an insert arranged along a periphery of the double key-way type slots. The double key-way type slots are positioned and configured such that each of the sheets may be mounted to the mounting tracks by placing the fasteners through the double key-way type slots.
The following detailed description of the preferred embodiments of the present invention can be best understood when read in conjunction with the following drawings, in which:
Referring to
The pair of lateral corrugated regions 14 are lateral corrugations along the lateral edges 8 of the sheet 2. Each of the lateral corrugations 14 have a substantially planar mounting region 12 and an intermediate inclined region 13 projecting away from the planar mounting region 12 in the direction of an adjacent corrugation. The lateral corrugations 14 also have a lateral inclined region 20 projecting away from the planar mounting region 12 in the direction of one of the lateral edges. The corrugated region 10 and the lateral corrugated regions 14 are generally configured such that the sheet 2 can resist a missile weighing about 9.4 lbs (4.3 kgs) having a cross-sectional impact area of about 5.25 in2 (34 cm2) and impacting the sheet 2 at a velocity of about 50 ft/s (15.24 m/s).
The lateral inclined region 20 may project a distance that is less than a distance projected by the intermediate inclined regions 13. The lateral inclined region 20 may be any suitable length. For example, the lateral inclined region 20 may be about 1¼ inches long. Generally, the lateral inclined region 20 is configured to provide adequate overlap when the sheets 2 are mounted as described hereinafter.
Referring to
Referring to
In accordance with one embodiment of the present invention, at least one of the first mounting slots 22 may be a key-way type mounting slot. For purposes of defining and describing the present invention, a “key-way type mounting slot” is a mounting slot having at least one portion that is smaller than a head of a fastener and at least one portion that is larger than head of the fastener. Additionally, at least one of the second mounting slots 24 may be a key-way type mounting slot. The key-way type mounting slot may be a single key-way mounting slot having one portion that is larger than head of a fastener and one portion that is smaller than the head of a fastener. The key-way type mounting slots may be double key-way type slots having an enlarged portion 27 larger than the head of a fastener and upper 25 and lower 23 portions smaller than the head of a fastener.
In accordance with another embodiment of the present invention, at least one of the first mounting slots 22 may be a mounting slot suitable for receiving the shank of a fastener. Additionally, at least one of the second mounting slots may be a mounting slot suitable for receiving the shank of a fastener.
Referring again to
Generally, suitable plastics include those having a tensile strength at yield as measured by ASTM test method D638 of less than about 5500 psi. More generally, suitable plastics include those having a tensile strength at yield of about 3,000 psi to about 4,600 psi. Additionally, suitable plastics include those having a flexural modulus as measured by ASTM test method D790 of less than about 250,000 psi, and, more generally, suitable plastics include those having a flexural modulus of about 150,000 psi to about 235,000 psi. The sheet 2 may be formed using extrudable plastics, and the sheet 2 may be formed using a translucent plastic. The plastic sheet 2 generally has a wall thickness of about 0.060 to about 0.250 inches, and, more generally, the plastic sheet 2 has a wall thickness of about 0.125 inches to about 0.250 inches.
Referring to
The sheet 2 may be formed using any suitable plastic forming method. For example, the sheet may be formed using a thermo-forming or injection molding process. The sheet 2 may alternatively be formed by any suitable extrusion processes and apparatuses. For example, a variety of suitable extrusion apparatus are described in U.S. patents classified in class 425 subclasses 369 (apparatus wherein reshaping means creates accordion-like pleats or wrinkles or the like in a perform by distorting a section thereof transverse to its axis into a plurality of reversing curves) and 336 (apparatus comprising means for shaping an advancing length of work into ridges and grooves). It is generally not preferred to form the sheet 2 utilizing a profile extrusion because the sheet 2 may deform during the rapid cooling steps typically associated with profile extrusion.
In accordance with one embodiment of the present invention, a storm shutter kit and an assembly for protecting an opening in a walled structure is provided. Referring to
One suitable mounting track system is illustrated in
Additionally, the corrugated region 10, the lateral corrugated regions 14, and the mounting tracks 28 may be configured to withstand a pressure differential that reciprocates from about 0 to at least about 40 psf across first and second sides of the sheet 2 when the sheets are mounted. The pressure differential may reciprocate from about 0 up to at least about 150 psf across the first and second sides of the sheet 2. It shall be understood by those having skill in the art that “withstand” refers to the sheet, sheets, and/or mounting tracks not being subject to failure under the pressure differential. For example, failure may mean a sheet or sheets breaking away from the mounting tracks, a sheet or sheet tearing, a mounting track or tracks loosening, and the like.
Referring to
Referring to
Similarly, the mounting slot 24 may be a double key-way type slot, and the user may mount the sheet 2 in a similar manner to that employed for a single key-way type slot. When the mounting slots 22, 24 are double key-way type slots, the user does not need to distinguish between the top 4 and bottom 6 edges of the sheet 2 because the mounting slots 22, 24 may be utilized in either position. Thus, the sheets 2 may generally be easily mounted without requiring special tools or requiring that the sheets 2 be used in a particular order. Additionally, when the key-way type slots are utilized over the head 33 of the fastener 32, installation of the sheets 2 is eased because no additional parts such as wing nuts are needed.
Generally, the sheets 2 and sheet kits of the present invention do not require any reinforcement bars running parallel to or perpendicular to the width W through the center of the sheet 2 because the sheet 2 is formed from a suitable plastic and is stiff enough to provide adequate storm protection without reinforcement. Thus, a user may easily install the sheets 2 to protect an opening in a walled structure in a short period of time.
It will be obvious to those skilled in the art that various changes may be made without departing from the scope of the invention, which is not to be considered limited to what is described in the specification.
This application claims priority to U.S. Provisional Application No. 60/349,106, filed Jan. 16, 2002.
Number | Name | Date | Kind |
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3167840 | Hoffman | Feb 1965 | A |
4048131 | Keske et al. | Sep 1977 | A |
4229504 | Brachman | Oct 1980 | A |
5457921 | Kostrzecha | Oct 1995 | A |
5996292 | Hill et al. | Dec 1999 | A |
6079168 | Shaver | Jun 2000 | A |
6324810 | Thompson | Dec 2001 | B1 |
Number | Date | Country | |
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20030134091 A1 | Jul 2003 | US |
Number | Date | Country | |
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60349106 | Jan 2002 | US |