Patent Grant
11661792
The present invention relates to rolling shutters and, in particular, to a slat for a rolling shutter that minimizes the profile of the retracted rolling shutter and that may be formed from sheet metal.
Rolling shutters are commonly used in commercial, retail and residential applications as doors or to cover windows or other openings. The rolling shutter is made of a series of linked slats that hang from a spindle to cover a doorway, window or other opening of a building or fixture. When not in use, the rolling shutter is retracted by winding the slats about the spindle to form a roll.
The shutter slats typically have an upper edge with a hook-shaped engagement track, and a lower edge with a receiving track that forms a pocket for receiving the engagement track. The receiving track commonly comprises a branched structure with two elements—a complementary hook-shape for engaging the hook-shaped engagement track, and a guard that restricts the disengagement of the engagement track from the receiving track. The shutter slats are linked by the slidable engagement of the hook-shaped engagement track of a first slat in the pocket of the receiving track of a second slat, to form a loosely articulated hinge between the slats. An example of a shutter slat design is described in U.S. Pat. No. 8,944,137 to Miller, which is incorporated herein by reference.
The opening that is covered by the rolling shutter may be framed by guides or side tracks that keep the slats aligned and secure the rolling shutter within the opening. The rolling shutter incorporates an end retention system for engaging the side tracks. A cavity or a receptacle is typically formed within or adjacent to the receiving track for receiving an end retention device. An example of an end retention system is described in U.S. Pat. No. 8,616,261 to Miller, which is incorporated herein by reference.
Shutter slats are commonly manufactured by extrusion to produce the complex geometry and branched structure of the engaging and receiving tracks. Consequently, shutter slats are often made of plastic or relatively soft metals, such as aluminum. It would be preferable to produce the shutter slats from sheet metal, such as sheet steel which is significantly less expensive than aluminum as well as stronger and more resistant to damage. However, steel is difficult to work and the sheet metal cannot readily be formed into the complex profile of the shutter slat. Thus, it would be desirable to develop a shutter slat design and method for producing the slat using sheet metal, such as sheet steel.
A slat for a rolling shutter is disclosed, that comprises a single walled, continuous bent sheet that includes a curved body having first and second ends, and first and second sides. An engaging track is formed at the first end, having a first hook-shaped portion comprising a first bend curving toward the second side of the body. A receiving track is formed at the second end, that comprises a guard member and a lip member. The guard member includes a portion of the sheet that is bent over on itself. The lip member extends from the guard member and has a second hook-shaped portion comprising a second bend curving toward the first side of the body. The guard member and the lip member are spaced apart to define an aperture that is sized and shaped to receive the engaging track of another slat.
In another embodiment, a slat for a rolling shutter comprises a single walled, continuous bent sheet that includes a curved body having first and second ends, a first side with a convex curvature and a second side with a concave curvature. An engaging track is formed at the first end, having a first hook-shaped portion comprising a first bend curving toward the second side of the body. A receiving track is formed at the second end, comprising a guard member and a lip member. The guard member includes a portion of the sheet that is bent over on itself to form a base and an outer guard wall. The lip member extends from the base of the guard member and has a second hook-shaped portion comprising a bend curving toward the first side of the body. The guard member and the lip member are spaced apart to define an aperture that is sized and shaped to receive the engaging track of another slat.
In another embodiment, a slat for a rolling shutter comprises a single walled, continuous bent sheet that includes a curved body having first and second ends, a first side with a convex curvature and a second side with a concave curvature. An engaging track is formed at the first end, having a first hook-shaped portion comprising a first bend curving toward the second side of the body. A receiving track is formed at the second end, comprising a base extending from the second end, and a guard member extending from the base. The guard member includes a portion of the sheet that is bent over on itself. The lip member extends from the guard member and has a second hook-shaped portion comprising a bend curving toward the first side of the body. The base and guard member define an interior space. The guard member and the lip member are spaced apart to define an aperture that is sized and shaped to receive the engaging track of another slat.
In another embodiment, a slat for a rolling shutter comprises a single walled, continuous bent sheet that includes a curved body having first and second ends, a first side with a convex curvature and a second side with a concave curvature. An engaging track is formed at the first end, having a first hook-shaped portion comprising a first bend curving toward the second side of the body. A receiving track is formed at the second end, comprising a guard member extending from the second end, and a lip member extending from the guard member and having a second hook-shaped portion comprising a bend curving toward the first side of the body. The guard member and the lip member are spaced apart to define an aperture that is sized and shaped to receive the engaging track of another slat. A separately formed receptacle is coupled to the body adjacent to the receiving track, the receptacle having an interior space. In a further embodiment the first end of the body has a portion that is configured to be complementary to the shape of the receptacle.
In another embodiment, a slat for a rolling shutter comprises a bent, unbranched sheet that includes a body having a curvature with a convex side and a concave side, and opposite first and second ends. An engaging track is disposed at the first end of the body, and a receiving track is disposed at the second end of the body. The receiving track includes a guard member and a lip member that are spaced apart to define an aperture that is sized and shaped to receive an engaging track. The receiving track includes a portion of the sheet that is folded over on itself.
In another embodiment, a slat for a rolling shutter comprises a bent, unbranched sheet that includes a body having an outward facing side and an inward facing side, and opposite first and second ends. An engaging track is disposed at the first end of the body, and a receiving track is disposed at the second end of the body. The receiving track includes an aperture that is sized and shaped to receive an engaging track. A separately formed receptacle that is sized and shaped to receive an end retention device is coupled to the inward facing side of the body.
In another embodiment, a slat for a rolling shutter comprises a bent, unbranched sheet that includes a body having a curvature with opposite outward facing and inward facing sides, and opposite first and second ends, where the outward facing side has a convex curvature and the inward facing side has a concave curvature. An engaging track disposed at the first end of the body and a receiving track disposed at the second end of the body. The receiving track includes an articulation space that is sized and shaped to receive an engaging track through an articulation space aperture, a receptacle sized and shaped to receive an end retention device, and a receptacle aperture. The receptacle aperture and the articulation space aperture open towards opposite facing sides of the body.
Embodiments of the disclosure will now be explained in further detail by way of example only with reference to the accompanying figures, in which:
Referring to
As shown in
In examples where the engaging track 12 includes a base 12e that extends from the first edge 8, the shank 12a extends from the base 12e, the bend 12b extends from the shank 12a, the barb 12c extends from the bend 12b, and the point 12d is the end of the barb 12c and/or the terminus of the engaging track 12. The point 12d may also be a first end of the sheet forming shutter slat 1.
In further examples, the engaging track 12 includes a first face 13a disposed on the same side of the shutter slat 1 as the outward facing side 4 of the curved body 2. In some examples, the first face 13a extends from the point at which the outward facing side 4 of the curved body 2 ends, for example, at the first edge 8. The engaging track 12 may also include a second face 13b disposed on the same side of the shutter slat as the inward facing side 6 of the curved body 2. In some examples, the second face 13b extends from the point at which the inward facing side 6 of the curved body 2 ends, for example, at the first edge 8. The point 12d marks the place at which the first face 13a transitions to the second face 13b, and vice versa. As can be seen in
In examples where the base 12e extends from first edge 8 at an angle to body 2, a base angle 12f is formed between the outward facing side 4 (i.e., convex curved side) of the curved body 2 and the portion of the first face 13a extending along the base 12e. For example, there may be a bend in the metal sheet between the base 12e of the engaging track 12 and the first edge 8 of the body 2, which forms the base angle 12f. In some examples, the base angle 12f is less than 180°. In further examples, the base angle 12f is between about 90° and about 180°. In even further examples, the base angle 12f is about 110° to about 140°.
As shown in
Lip member 18 extends from guard member 16, and includes a hook-shaped portion comprising a shank 18a, a bend 18b, a barb 18c and a point 18d that are sized and shaped to engage the engaging track 12 of another slat. Bend 18b curves back toward outward facing side 4 of body 2. In the embodiment shown in
In some examples, point 18d may be the second end of the sheet forming shutter slat 1. In some examples, the shutter slat 1 is comprised of a single continuous, unbranched sheet extending from point 12d of the engaging track 12 to point 18d of the receiving track 14. This is accomplished, in part, by the portion of the guard member 16 that is bent over or folded on itself, which allows the shutter slat 1 to be made of a single continuous sheet of material—e.g., steel—and bent into the desired shape, rather than being manufactured by extrusion.
In further examples, the receiving track 14 includes a first face 15a disposed on the same side of the shutter slat 1 as the outward facing side 4 of the curved body 2. In some examples, the first face 15a extends from the point at which the outward facing side 4 of the curved body 2 ends, for example, at the second edge 10. The receiving track 14 may also include a second face 15b disposed on the same side of the shutter slat as the inward facing side 6 of the curved body 2. In some examples, the second face 15b extends from the point at which the inward facing side 6 of the curved body 2 ends, for example, at the second edge 10. The point 18d marks the place at which the first face 15a transitions to the second face 15b, and vice versa. As can be seen in
In some examples, where the guard member 16 is bent over on itself, portions of the second face 15b may face one another. In further examples, where the guard member 16 is bent over on itself, the second face 15b may be bent over in such a way that a portion of the second face 15b contacts another portion of the second face 15b at a contact point 17. In further examples, where the guard member 16 is bent over on itself, the bulge 22 is formed by leaving a portion of the second face 15b open at a gap 19 between the two points at which the second face 15b comes in contact with itself. For example, when the guard member 16 is bent over on itself the portion of the second face 15b traversing the guard articulation surface 24 is open such that the gap 19 is formed where the second face 15b does not contact itself.
Lip member 18 and guard member 16 are spaced apart to form an aperture 26 that is sized and shaped to receive the engaging track 12 of another slat. In one embodiment, point 18d of the hook-shaped portion of lip member 18 and guard articulation surface 24 of guard member 16 are spaced apart to form aperture 26.
Lip member 18 and guard member 16 define an interior space within receiving track 14, that comprises an articulation space 28 formed between the lip member and guard member, that is sized and shaped to receive the hook-shaped portion of the engaging track 12 of another slat. In one embodiment, the interior space within receiving track 14 also includes a receptacle 30 formed between the lip member and guard member, that is sized and shaped to receive an end retention device, such as the screw and washer of an end retention system as described in U.S. Pat. No. 8,616,261. In a preferred embodiment, shank 18a of lip member 18 has an interior surface 32. A shoulder 34 on interior surface 32 divides or separates the interior space within receiving track 14 into articulation space 28 and receptacle 30, as shown in
Referring to
In one embodiment, engaging track 12 and receiving track 14 are configured to reduce the profile of hinge 38 when the rolling shutter is in the retracted position. As shown in
In another embodiment, engaging track 12 and receiving track 14 are configured to reduce the profile of the hinge 38 when the rolling shutter is in the vertical or extended position. As shown in
The slats are preferably configured such that the hinges of a set of slats wound about a spindle 50 are nested with adjacent hinges 48 to reduce the profile of the rolling shutter in the retracted position. For example, when a set of slats are wound about a spindle 50, there are multiple windings of slats with each successive winding increasingly distal to the spindle. In the example depicted in
In some examples, the second hinges 48″ are nested adjacent to the first hinges 48′, that is, each second hinge 48″ is positioned circumferentially adjacent to the adjacent first hinge 48′ rather than sitting radially adjacent to the first hinge 48′. In such examples, the receiving track of a hinge on an outer winding (e.g., the second winding comprised of the second series of slats 5″) is adjacent to either the receiving track of a hinge on the immediately preceding winding (e.g., with respect to the second winding, the immediately preceding winding is the first winding comprised of the first series of slats 5′) or the engaging track of a hinge on the immediately preceding winding. For example, in the example depicted in
In some examples, the rolling shutter may comprises slats of different lengths to facilitate tight nesting of first and second hinges 48′, 48″. Those of skill in the art will appreciate that each successive winding of the rolling shutter will increase in circumference. In the example depicted in
The slats in the rolling shutter preferably have engaging and receiving tracks that are the same size—e.g., the engaging track 52′ for each slat in the first series of slats 5′ is the same size as the engaging track 52″ for each slat in the second series of slats 5″ and the receiving track 54′ for each slat in the first series of slats 5′ is the same size as the receiving track 54″ for each slat in the second series of slats 5″—such that the same tooling can be used to form all engaging and receiving tracks of all slats in the rolling shutter. The use of the same tooling for an entire set of slats allows for simpler and less-costly manufacturing procedures.
One factor that allows for the nesting configuration described above is the provision of a slat where a portion of the receiving track is formed to receive and/or enclose an end retention device. In conventional slat designs, a receptacle for receiving an end retention device must be coupled to the slat. In such examples, the space or volume taken by the end retention device is accounted for in the design of the receiving track, whereas in examples where the end retention device is otherwise coupled to a portion of the slat, the end retention device may interfere with a tightly nested configuration. For example, the receptacle 30 depicted in
In some cases, the configuration of the shutter slat may allow water to intrude into receiving track 14. In the embodiment shown in
Referring to
Receiving track 114 is configured to reduce the infiltration of water into the guard member. As shown in
Receiving track 114 has the same general configuration and relationship to body 102 as previously described. In the embodiment shown in
To reduce the accumulation of water, second edge 110 is positioned proximal to or at approximately the point 143 where lip member 118 extends from guard member 116, as shown in
In one embodiment, edge 110 is formed with a curve having a greater degree of curvature than the curve of body 102 (e.g., as shown in
The receiving track 114 also includes a first face 115a, a second face 115b, and a gap 119 which have the same general configuration and relationship to body 102 and guard member 116 as the previously described first face 15a, second face 15b, and gap 19. In examples where the second edge 110 has a curve with a greater degree of curvature than the curve of body 102 (e.g., as shown in
In some examples, the guard member 116 is bent over or folded on itself much like the guard member 16 described and disclosed with respect to
The rolling shutter may comprise individual slats having bodies with different lengths and curves. As shown in
The shutter slat may be formed of various materials as are known in the art, including plastic and aluminum as are used in conventional extruded shutter slats. However, the shutter slat is designed to be formed as a single walled, continuous bent, unbranched sheet, which allows the use of materials that are not readily extruded. In one embodiment, the shutter slat is produced from a sheet of material, and preferably sheet steel. Various manufacturing techniques or combinations of techniques for forming or bending sheet metal may be used, as are known in the art, including punch and die, wiping die edge bending, rotary die bending, air bending, offset bending, single or multiple die bending, hemming, and roll forming or roll bending. Different tooling may be used for different slats within a winding and/or between windings of a rolling shutter. Similarly, different gauges of sheet metal thickness may be used for different slats within a winding and/or between windings of a rolling shutter.
Referring to
As shown in
In some examples, the first edge 208 forms a first edge bend 209. In such examples, the first edge bend 209 forms an interior angle 211b between the engaging track 212 and the convex side (i.e., outward facing side 204) of the body 202. In some examples, the interior angle 211b formed by the first edge bend 209 is less than 180°. In other examples, the interior angle 211b formed by the first edge bend 209 is between about 45° and about 135°. In further examples, the interior angle 211b formed by the first edge bend 209 is about 90°. In further examples, the interior angle 211b formed by the first edge bend 209 is an acute angle. In some examples, a first face 213a of the engaging track 212 is disposed on the same side of the shutter slat 201 as the outward facing side 204 (i.e., the convex side) of the body 202. In examples where the convex curvature of the outward facing side 204 has a greater degree of curvature at the edge 208 (e.g., forming a first edge bend 209), a transition point 211a between the outward facing side 204 and the first face 213a of the engaging track 212 will not be along the same general curvature of the curved body 102. For example, the transition point 211a forms a transition angle (i.e., the interior angle 211b). In some examples, the transition angle is less than 180°. In further examples, the transition angle is less than 90°. In even further examples, the transition angle is between about 20° and about 70°. In some examples, such as the example depicted in
Receiving track 214 comprises a base 246, a guard member 216, and a lip member 218. Base 246 extends from edge 210 of body 202, and projects toward the inward facing side 206 of the body. Guard member 216 extends from base 246 and has a portion where sheet 201 is bent over on itself to form an outer guard wall 220a, an inner guard wall 220b, and a guard member end or point 222. In the embodiment shown in
Lip member 218 extends from guard member 216 and includes a hook-shaped portion comprising a shank 218a, a bend 218b, a barb 218c and a point 218d that are sized and shaped to engage the engaging track 212 of another slat. Bend 218b curves back toward outward facing side 204 of body 202. In the embodiment shown in
In one embodiment, receiving track 214 does not project beyond the convex curvature F of outward facing side 204 of body 202. Preferably, guard end 222 and/or at least a portion of a bend 218b are positioned approximately along the convex curvature F of outward facing side 204 of body 202. Articulation space aperture 226 and receptacle aperture 248 open toward the outward facing side 204 of body 202. Although the embodiment shown in
Referring to
Receiving track 314 comprises a guard member 316 and a lip member 318. Guard member 316 extends from edge 310 of body 302, and projects toward the inward facing side 306 of the body 302. Guard member 316 has an inward facing side 320a and an outward facing side 320b. Lip member 318 extends from guard member 316, and has a hook-shaped portion comprising a shank 318a extending from the guard member, a bend 318b, a barb 318c and a point 318d that are sized and shaped to engage the engaging track 312 of another slat. Bend 318b curves back toward outward facing side 304 of body 302. Lip member 318 and guard member 316 define an interior articulation space 328 within receiving track 214, that is sized and shaped to receive the hook-shaped portion of the engaging track 312 of another slat. Barb 318c and/or point 318d are spaced apart from guard member 316 and/or edge 310 of body 302 to form an opening or aperture 326 into articulation space 328, that is sized and shaped to receive the engaging track 312 of another slat.
In some examples, the second edge 310 forms a second edge bend 311 where the receiving track 314 extends from the second edge 310. In such examples, the second edge bend 311 forms an interior angle 317 between the receiving track 314 and the concave side (i.e., inward facing side 306) of the body 302. In some examples, the interior angle 317 formed by the second edge bend 311 is less than 180°. In other examples, the interior angle 317 formed by the second edge bend 311 is between about 45° and about 135°. In further examples, the interior angle 317 formed by the second edge bend 311 is about 90°. In some examples, the interior angle 317 conforms to the shape of a receptacle.
A receptacle 330 with an interior space 330a for receiving an end retention device, may be formed separately from body 302 and coupled to inward facing side 306 of the body, preferably adjacent to or near receiving track 314. Receptacle 330 may be coupled to body 302 by various means known in the art, including welding, adhesive, or using a fastener. In the embodiment shown in
In a preferred embodiment, receptacle 330 is coupled to body 302 at or near edge 310. Body 302 and/or receiving track 314 may be configured to receive receptacle 330. In one embodiment, the inward facing side 306 of body 302 and/or the inward facing side 320a of guard member 316 are configured to conform or be complementary to the size and shape of receptacle 330. For example,
In another embodiment, the shutter slat may include a well that is configured to receive a separately formed receptacle. Referring to
Slat 401 forms a well 452 for receiving a separately formed receptacle, that is preferably positioned at or near edge 410 of body 402. In the embodiment shown in
The receptacle may be secured in well 452 in the same manner described for coupling receptacle 330 to body 302. In another embodiment, well 452 may be configured to allow the receptacle to be friction fit within the well, in place of or in addition to other means of coupling the receptacle to the body 402. For example, rib 454 and guard member 416 may be spaced apart by a distance that is slightly smaller than the width of the receptacle. In other examples, rib 454 and guard member 416 may be spaced apart by a distance that is about the width of the receptacle.
Referring to
Similar to
Receiving track 514 comprises a base 546, a guard member 516, and a lip member 518. Base 546 extends from edge 510 of body 502, and projects toward the outward facing side 504 of the body. Guard member 516 extends from the base 546. Base 546 and guard member 516 define an interior space or receptacle 530 for receiving an end retention device. An opening or aperture 548 into receptacle 530 may be formed between edge 510 of body 502 and the guard member 516 at a guard member point 522. In some examples, base 546 forms a lip 546a at edge 510 and/or guard member point 522 may form a lip 522a, such that the width of aperture 548 is smaller than the interior width of receptacle 530 to assist in retaining an end retention device within receptacle 530.
Lip member 518 extends from guard member 516 and includes a hook-shaped portion comprising a shank 518a, a bend 518b, a barb 518c, and a point 518d that are sized and shaped to engage with engaging track 512 of another slat. Shank 518a extends from guard member 516 in a generally vertical direction (i.e., in a direction similar to the length of the body 502). Bend 518b extends from the shank 518a and curves toward outward facing side 504 of body 502. Lip member 518 and guard member 516 define an interior articulation space 528 within receiving track 514, that is sized and shaped to receive the hook-shaped portion of the engaging track 512 of another slat. Barb 518c and/or point 518d are spaced apart from guard member 516 to form an opening or aperture 526 into articulation space 528, that is sized and shaped to receive the engaging track 512 of another slat. In some examples, receiving track 514 does not project beyond (i.e., below or past the inward facing side of) the concave curvature H of the inward facing side 506 of body 502. In further examples, guard member point 522 and/or at least a portion of shank 518a and/or bend 518b are positioned approximately along the concave curvature H of outward facing side 504 of body 502. In further examples, engaging track 512 does not project beyond (i.e., above or past the outward facing side of) the convex curvature F′ of the outward facing side 504 of body 502. Articulation space aperture 526 and receptacle aperture 548 open toward opposing sides of body 502. For example, articulation space aperture 526 opens towards the outward facing side 504 of body 502 and receptacle aperture 548 opens toward the inward facing side 506 of body 502.
Although described herein as embodiments of a rolling shutter, the term “slat” may also refer to a curtain, screen, grille, or other covering for an opening that is retractable by stacking the components, such as by coiling or winding. For example, the term “slat” may include the stacking links of a coiling grille. Further, while particular embodiments of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the present disclosure. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this disclosure.
This application claims the benefit of U.S. Provisional Application No. 62/578,934, filed Oct. 30, 2017, which is hereby incorporated by reference herein in its entirety.
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