Abstract:
Sheets and sheet kits for use in protecting openings in a walled structure are provided. The sheets are generally plastic sheets having at least one corrugated region and a pair of lateral corrugated regions. 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 in 2  (34 cm 2 ), and impacting the sheet at a velocity of about 50 ft/s (15.24 m/s). The sheet kits include mounting tracks. It is emphasized that this abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that is will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b).

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]    This application claims priority to U.S. Provisional Application No. 60/349,106, filed Jan. 16, 2002. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    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.  
           [0003]    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.  
         SUMMARY OF THE INVENTION  
         [0004]    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 in 2  (34 cm 2 ), and impacting the sheet at a velocity of about 50 ft/s (15.24 m/s).  
           [0005]    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.  
           [0006]    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 in 2  (34 cm 2 ), 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.  
           [0007]    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 in 2  (34 cm 2 ), 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.  
           [0008]    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.  
       
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0009]    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:  
         [0010]    [0010]FIG. 1 is an plan illustration of a sheet in accordance with the present invention.  
         [0011]    [0011]FIG. 2 is a cross-sectional illustration of a sheet in accordance with the present invention.  
         [0012]    [0012]FIG. 3 is an illustration of a mounting slot in accordance with the present invention.  
         [0013]    [0013]FIG. 4 is side view of one embodiment of a sheet kit in accordance with the present invention.  
         [0014]    [0014]FIG. 5 is a cross-sectional view of one embodiment of a sheet kit in accordance with the present invention.  
         [0015]    [0015]FIG. 6 is a partial cross-sectional view of another embodiment of a sheet kit in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0016]    Referring to FIGS. 1 and 2, a sheet  2  in accordance with one embodiment of the present invention is illustrated. The sheet  2  has top  4 , bottom  6 , and lateral edges  8 . The sheet  2  has a corrugated region  10  that is oriented substantially parallel to the lateral edges  8 . Additionally, the sheet has a pair of lateral corrugated regions  14 . The corrugated region  10  generally has at least one planar mounting region  12  and at least one intermediate inclined region  13 . The intermediate inclined region  13  projects away from the planar mounting region  12  in the direction of an adjacent corrugation. It will be understood by those having skill in the art that the corrugated region  10  may have any suitable number of planar mounting regions  12  and intermediate inclined regions  13 . Increasing the number of planar mounting regions  12  and the number of intermediate inclined regions  13  will generally increase the number of corrugations or the width W of the panel.  
         [0017]    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 in (34 cm 2 ) and impacting the sheet  2  at a velocity of about 50 ft/s (15.24 m/s).  
         [0018]    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.  
         [0019]    Referring to FIG. 1, the sheet  2  may be formed in any suitable width. For example, the sheet may have a width W of about 13.5 inches. However, this width W may vary depending on the size of the opening that is to be covered with the sheets  2  of the present invention. Similarly, the length L of the sheet may vary depending on the length of the opening that is to be covered.  
         [0020]    Referring to FIGS. 1 and 3, at least one of the corrugated region  10  and the lateral corrugated regions  14  may also have at least one first and second mounting slots  22 ,  24 . The first mounting slot  22  may be adjacent to the top edge  4  of the sheet  2 , and the first mounting slot  22  may be disposed on a planar mounting region  12 . The second mounting slot  24  may be adjacent to the bottom edge  6  of the sheet  2 , and the second mounting slot  24  may be disposed on a planar mounting region  12 . The first mounting slot  22  and the second mounting slot  24  may have inserts  26  that are arranged about the periphery of the mounting slots  22 ,  24  and provide reinforcement. The inserts  26  may be formed of any suitable material. For example, the inserts  26  may be metal, such as aluminum, or the inserts may be formed from plastic. The inserts  26  may help to prevent tearing of the mounting slots  22 ,  24  when the sheet  2  is mounted as described hereinafter.  
         [0021]    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.  
         [0022]    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.  
         [0023]    Referring again to FIGS. 1 and 2, the sheet  2  is generally a plastic sheet. The sheet  2  may be made of any suitable plastic that will provide suitable impact resistance to protect a door or window from windborne debris. For example, the sheet  2  may be made of any suitable polypropylene plastic. For example, the sheet  2  may be made from Pro-fax® SG702 available from Montell Polyolefins (Wilmington, Del.). Alternatively, the sheet  2  may be made from any suitable polyethylene. Additionally, the sheet  2  may be made from any suitable high density polyethylene (HDPE). For purposes of defining and describing the present invention, HDPE is to be understood as referring to polyethylenes having a density above about 0.940 g/cm 3 . For example, the sheet  2  may be made from Paxon AF50-003 Blow Molding Resin, Paxon AA60-003 Blow Molding Resin, and Paxon BA50-100 Sheet Extrusion and Blow Molding Resin all available from ExxonMobil Chemical (Houston, Tex.).  
         [0024]    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.  
         [0025]    Referring to FIG. 2, the inclined regions  13  and the lateral inclined regions  20  may be formed such that they project from the substantially planar mounting regions  12  at an angle θ. The angle θ may be between about 10° to about 90°. More generally, the angle θ is between about 45° to about 55°. It will be understood by those having skill in the art that each individual inclined region  13  and lateral inclined region  20  may project at a different angle θ.  
         [0026]    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.  
         [0027]    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 FIGS. 4 and 5, the kit and assembly may utilize mounting tracks  28 . The mounting tracks  28  may be mounted to opposite sides of an opening  36 , and the mounting tracks  28  may be mounted utilizing any suitable fastener  34 . For example, the mounting tracks  28  may be mounted on the top and bottom of an opening such as a window. Alternatively, the mounting tracks  28  may be mounted on lateral sides of an opening such as a window. The mounting tracks  28  may be of any suitable configuration and be made of any suitable material. The mounting tracks  28  may be made from metal, plastic, or the like.  
         [0028]    One suitable mounting track system is illustrated in FIGS. 4 and 5. The mounting track  28  is configured to hold a fastener  32  such that the shank of the fastener  32  is disposed to receive the sheet  2 . As shown in FIG. 5, the sheets  2  may be mounted such that a portion of one lateral corrugated region  14  overlaps with a portion of another lateral corrugated region. In this manner, the sheets  2  may be used to substantially cover the opening  36 . Additionally, this. overlap of the sheets  2  may assist in preventing objects from passing between the sheets  2  into the opening  36  during a storm.  
         [0029]    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.  
         [0030]    Referring to FIGS. 1, 4, and  5 , when mounting the sheet  2 , the user generally places the shank of the track fasteners  32  into the mounting slots  22 ,  24  of the sheet. Cross-sectional lines in FIG. 4 have been omitted for clarity. The user may then secure the sheet  2  to the track  28  by utilizing a wing nut  37  or other suitable securing means. The mounting slots  22 ,  24  may be single or double key-way type slots or may be any opening configured to allow the shank of the track fasteners  32  to pass therethrough.  
         [0031]    Referring to FIGS. 1 and 6, another suitable mounting track  28  configuration is illustrated, and cross-sectional lines in FIG. 6 have been omitted for clarity. The mounting track  28  is configured to hold a fastener  32  such that the head  33  is disposed to receive the sheet  2 . The fastener  32  may be secured to the track  28  in any suitable fashion. For example, the fastener  32  may be threaded into the track  28  or the track  28  may be formed integrally around the fastener  32 . The mounting slots  22 ,  24  may be single key-way type slots, and the user may mount the sheet  2  by ensuring that the head  33  of the fastener  32  is placed in the region of the mounting slot  22 ,  24  that is larger than the head  33  and then clicking the sheet  2  into place by ensuring that the fastener  32  is in the region of the mounting slot that is smaller than the head  33 .  
         [0032]    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.  
         [0033]    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.  
         [0034]    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.