Abstract:
A shutter assembly having a foam insert or core enveloped by a cementitious shell is provided with integrated spaced and opposed top and bottom hanger members that allow the shutter assembly to be mounted to an exterior wall of a dwelling or other structures via spaced and opposed brackets affixed to the exterior wall. The shutter assembly can be mounted to an exterior wall of a dwelling or other structure by selectively engaging the top and bottom hanger members with corresponding top and bottom bracket members mounted to the exterior wall of the dwelling or other structure.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The instant application claims priority to U.S. Provisional Patent Application Ser. No. 60/821,597, filed Aug. 7, 2006, the entire specification of which is expressly incorporated herein by reference. 
     
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The subject invention relates to shutter assemblies and more specifically to hanging systems for shutter assemblies, especially those formed from cementitious slurries. 
         [0004]    2. Description of the Related Art 
         [0005]    Many different modern building designs take advantage of modular shutters for purely aesthetic purposes to decorate exterior windows. The modular shutter assemblies are generally an assembly of plastic parts that are individually formed and then secured together in a cost effective manner. The different plastic parts can be formed by different plastic fabrication techniques such as injection molding and extrusion. The plastic parts are secured together by appropriate fastening mechanisms, such as screws, adhesives, and/or the like, in a manner that is well understood in the art. 
         [0006]    Because the shutters are employed for purely aesthetic purposes, it is important to choose an appropriate shutter style that complements, rather than detracts from, the exterior wall surface of the building onto which it is to be mounted. In this respect, certain buildings, especially upscale residential and commercial buildings having stucco, stone, and/or brick exterior walls, are generally not enhanced by the use of plastic, or even metallic, shutters, regardless of the quality and/or cost thereof. That is, the use of a plastic or metallic shutter does not, from an aesthetic viewpoint, coordinate very well with a building having stucco, stone, and/or brick exterior walls. 
         [0007]    Additionally, it has been problematic to install shutter assemblies to the building&#39;s exterior walls without having to drill large and deep holes therein to accommodate screws that hold the shutter assemblies securely in place. These holes provide ingress for water, dirt, insects, and/or the like that could damage the wall or other surrounding structures. Toward this end, certain municipalities have enacted regulations on if, and how, holes can or cannot be provided in exterior walls for any purpose, including the hanging of shutter assemblies. 
         [0008]    Recently, the use of shutter assemblies formed from cementitious slurries, including those with a foam core, has been suggested for use with buildings having stucco, stone, and/or brick exterior walls. However, securely hanging these types of shutter assemblies onto exterior walls, especially those formed from stucco, stone, and/or brick, has been problematic. 
         [0009]    Therefore, it would be advantageous to provide new and improved hanging systems for shutter assemblies, such as but not limited to those formed from cementitious slurries, including those with a foam core, that overcome at least one of the aforementioned problems. 
       SUMMARY OF THE INVENTION AND ADVANTAGES 
       [0010]    The subject invention provides a hanging system for a shutter assembly, including those having a foam core enveloped by a cement or cementitious exterior shell. The cementitious shell can also be provided with a first hanger member that allows the top portion of the shutter assembly to be mounted to a dwelling, e.g., via a bracket affixed to an exterior wall surface thereof. The cementitious shell can also be provided with a second hanger member that allows the bottom portion of the shutter assembly to be mounted to a dwelling, e.g., via a bracket affixed to an exterior wall surface thereof, wherein a free end of a tie member secured by the bracket extends around a bar member fixed in a cavity formed in the cementitious shell. The free end of the tie member is then threaded through a securing member and drawn taut around the bar member, thus drawing the shutter assembly tightly against the dwelling. Any excess portion of the free end of the tie member can be trimmed so as to not be seen extending from the bottom of the shutter assembly. In this manner, the shutter assembly is securedly fastened to the dwelling and will not be easily dislodged therefrom, e.g., in case of high winds, storms, hurricanes, tornados, and/or the like. To remove the shutter assembly, a portion, e.g., the securing member, of the tie member is cut, e.g., by snips, scissors, and/or any other cutting tool, thus releasing the tie member from the bar member whereupon the shutter assembly can be lifted up and/or off of the first hanger member and removed from the exterior wall of the dwelling. 
         [0011]    The shutter assembly is formed in a closed mold from a cementitious slurry comprising gypsum cement (e.g., white or grey Portland cement) and water. The slurry can also contain other materials such as but not limited to reinforcement materials (e.g., fibers), as well as other materials that are known in the art (e.g., plasticizers and/or the like). An appropriate amount of the cementitious slurry is added onto a bottom mold surface portion to a desired depth. The respective hanger members are placed onto the bottom mold surface portion, e.g., prior to the introduction of the cementitious slurry. The foam core is then placed atop the cementitious slurry in a desired orientation, the mold is vibrated and pressure is applied to close the mold to a predetermined thickness, such that the top mold surface portion is brought into contact with the bottom mold surface portion. After an appropriate curing or drying time, the shutter assembly is removed from the mold and is ready for immediate use and/or further processing, such as but not limited to painting and/or the like. 
         [0012]    In accordance with one embodiment of the present invention, a method for forming a molded component, such as a shutter, is provided, comprising providing a mold surface member, charging an amount of a cementitious material onto the mold surface member, and providing a hanger member that is at least partially enveloped by the cementitious material. 
         [0013]    The hanger member can include a body portion having an inner surface and an outer surface, wherein the body portion includes at least one angled portion formed therein. The outer surface is substantially submerged within the cementitious material, whereas the inner surface is substantially free of cementitious material. The outer surface includes at least one fin member formed thereon. The inner surface includes an area defining a recess. The recess is selectively operable to receive a mounting member therein. 
         [0014]    A second hanger member can also be provided, wherein the second hanger member includes a body portion having an inner surface and an outer surface. The body portion includes at least one angled portion formed therein, wherein the second hanger member is spaced and opposed from the hanger member. The outer surface of the second hanger member is substantially submerged within the cementitious material, whereas the inner surface of the second hanger member is substantially free of cementitious material. The outer surface of the second hanger member includes at least one fin member formed thereon. The inner surface of the second hanger member includes an area defining a recess. A bar member traverses across the recess of the second hanger member. The recess of the second hanger member is selectively operable to receive a mounting member therein, wherein the mounting member is selectively operable to extend around at least a portion of the bar member. 
         [0015]    A foam member can be disposed into the cementitious material such that the foam member is at least partially enveloped by the cementitious material. 
         [0016]    In accordance with another embodiment of the present invention, a molded component, such as a shutter, is provided, comprising a hanger member, and a cementitious shell at least partially enveloping the hanger member. The hanger member includes a body portion having an inner surface and an outer surface, wherein the body portion includes at least one angled portion formed therein. The outer surface is substantially submerged within the cementitious material, whereas the inner surface is substantially free of cementitious material. The outer surface includes at least one fin member formed thereon. The inner surface includes an area defining a recess, wherein the recess is selectively operable to receive a mounting member therein. 
         [0017]    A second hanger member can also be provided, wherein the second hanger member includes a body portion having an inner surface and an outer surface, wherein the body portion includes at least one angled portion formed therein. The second hanger member is spaced and opposed from the hanger member. The outer surface of the second hanger member is substantially submerged within the cementitious material. The inner surface of the second hanger member is substantially free of cementitious material. The outer surface of the second hanger member includes at least one fin member formed thereon. The inner surface of the second hanger member includes an area defining a recess. A bar member traverses across the recess of the second hanger member, wherein the recess of the second hanger member is selectively operable to receive a mounting member therein, wherein the mounting member is selectively operable to extend around at least a portion of the bar member. 
         [0018]    A foam member can be disposed into the cementitious material such that the foam member is at least partially enveloped by the cementitious material. 
         [0019]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposed of illustration only and are not intended to limit the scope of the invention. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0020]    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: 
           [0021]      FIG. 1  is a front elevational view of a dwelling having a plurality of shutter assemblies mounted thereto, in accordance with a first embodiment of the present invention; 
           [0022]      FIG. 2  is a front elevational view of a louvered shutter, in accordance with a second embodiment of the present invention; 
           [0023]      FIG. 3  is a front elevational view of a plain panel shutter, in accordance with a third embodiment of the present invention; 
           [0024]      FIG. 4  is a front elevational view of a batten shutter, in accordance with a fourth embodiment of the present invention; 
           [0025]      FIG. 5  is a perspective view of a batten shutter, in accordance with a fifth embodiment of the present invention; 
           [0026]      FIG. 6  is a partial sectional view taken along line  6 - 6  of  FIG. 5 , in accordance with a sixth embodiment of the present invention; 
           [0027]      FIG. 7  is a sectional view taken along line  7 - 7  of  FIG. 5 , in accordance with a seventh embodiment of the present invention; 
           [0028]      FIG. 8  is an exploded view of a molding system for forming a shutter assembly, in accordance with an eighth embodiment of the present invention; 
           [0029]      FIG. 9  is a perspective view of a bottom molding member on a conveyor system, in accordance with a ninth embodiment of the present invention; 
           [0030]      FIG. 10  is an exploded view of a mold surface member and the bottom molding member on the conveyor system depicted in  FIG. 9 , in accordance with a tenth embodiment of the present invention; 
           [0031]      FIG. 11  is a perspective view of the mold surface member and the bottom molding member on the conveyor system depicted in  FIG. 10 , in accordance with an eleventh embodiment of the present invention; 
           [0032]      FIG. 12  is a perspective view of a cementitious slurry being added onto the mold surface member depicted in  FIG. 11 , in accordance with a twelfth embodiment of the present invention; 
           [0033]      FIG. 13  is a perspective view of the cementitious slurry having been added to a desired depth onto the mold surface member depicted in  FIG. 12 , in accordance with a thirteenth embodiment of the present invention; 
           [0034]      FIG. 14  is a perspective view of a foam insert and a top hanger member and a bottom hanger member being placed onto the cementitious slurry depicted in  FIG. 13 , in accordance with a fourteenth embodiment of the present invention; 
           [0035]      FIG. 14   a  is a perspective view of the top hanger member, in accordance with a fifteenth embodiment of the present invention; 
           [0036]      FIG. 14   b  is a perspective view of the bottom hanger member, in accordance with a sixteenth embodiment of the present invention; 
           [0037]      FIG. 15  is a perspective view of the foam insert and top and bottom hanger members depicted in  FIG. 14  being substantially enveloped by the cementitious slurry, in accordance with a seventeenth embodiment of the present invention; 
           [0038]      FIG. 16  is a perspective view of the upper mold member being brought into contact with the lower mold member depicted in  FIG. 15 , in accordance with an eighteenth embodiment of the present invention; 
           [0039]      FIG. 17  is an exploded view of the mold surface member being removed from the lower mold member depicted in  FIG. 16 , in accordance with a nineteenth embodiment of the present invention; 
           [0040]      FIG. 18  is an exploded view of the shutter assembly being removed from the mold surface member depicted in  FIG. 17 , in accordance with a twentieth embodiment of the present invention; 
           [0041]      FIG. 19  is a partial perspective view of a top bracket system and a bottom bracket system attached to an exterior wall of a dwelling, in accordance with a twenty-first embodiment of the present invention; 
           [0042]      FIG. 20  is a partial sectional view of a shutter assembly being mounted to the top bracket system depicted in  FIG. 19 , in accordance with a twenty-second embodiment of the present invention; 
           [0043]      FIG. 21  is a partial sectional view of a shutter assembly being mounted to the bottom bracket system depicted in  FIG. 19 , in accordance with a twenty-third embodiment of the present invention; and 
           [0044]      FIG. 22  is a bottom view of a mounted shutter assembly, in accordance with a twenty-fourth embodiment of the present invention. 
       
    
    
       [0045]    The same reference numerals refer to the same parts throughout the various Figures. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0046]    The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, or uses. 
         [0047]    Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a shutter assembly is generally disclosed at  10 . By “assembly,” as that term is used herein, it is meant at least one shutter member. 
         [0048]    The shutter assembly  10  can be mounted, either permanently or temporarily to a dwelling  12 , such as a residential or commercial building, especially one that includes a stucco, stone and/or brick exterior.  FIG. 1  shows an exterior front view of a house  12  that includes two lower story front windows  14   a ,  14   b , respectively, positioned on opposite sides of a door  16  and an upper story front window  18 . Positioned on both sides of each of the windows  14   a ,  14   b ,  18 , respectively, is a shutter assembly  10 . The shutter assemblies  10  are rigidly secured to a front wall of the house  12  by appropriate securing devices, to be described herein, at a location that aesthetically accents the windows  14   a ,  14   b ,  18 , respectively. 
         [0049]    Although raised/recessed panel shutter members are shown in connection with the shutter assemblies  10  in  FIG. 1 , it should be appreciated that various other configurations of the shutter assembly  10  can be employed with the practice of the present invention. With specific reference to  FIGS. 2-4 , the shutter assemblies  10  of the present invention can include, without limitation, a louvered shutter member  11 , a flat panel shutter member  13 , a batten shutter member  15 , and/or the like. 
         [0050]    It is to be understood that one shutter assembly  10  according to the subject invention is a single shutter  20 . That is, one shutter assembly  10  is one left side shutter  20  or one right side shutter  20  such that two shutter assemblies  10  are preferred. For example, with specific reference to  FIGS. 5-7 , each shutter assembly  10  has a top  22 , a bottom  24  and two sides  26   a ,  26   b , respectively, extending between the top  22  and bottom  24 . 
         [0051]    The shutter assembly  10  includes a foam insert or core  100  that is completely or at least substantially completely enveloped or surrounded by a cementitious shell or coating  102 . Various portions of the cementitious shell  102  can be permitted to infiltrate through various crevices, apertures, or spaces formed in the foam core  100 , e.g., so as to form reinforcement or rib members  104  at various locations within the shutter assembly  10 . 
         [0052]    In accordance with one aspect of the present invention, the cementitious shell  102  is formed from a cementitious or cement slurry. The slurry can include hydraulic cement including, but not limited to, Portland, sorrel, slag, fly ash, or calcium alumina cement. Additionally, the cement can include a calcium sulfate alpha hemihydrate or calcium sulfate beta hemihydrate. The slurry can also utilize natural, synthetic, or chemically modified beta gypsum or alpha gypsum cement. The cementitious slurry preferably includes gypsum cement and a sufficient amount of water added thereto to produce a slurry having the desired consistency, i.e., not too dry nor not too watery. 
         [0053]    Gypsum is a naturally occurring mineral, calcium sulfate dihydrate, CaSO 4 .2H 2 O (unless otherwise indicated, hereafter, “gypsum” will refer to the dihydrate form of calcium sulfate). After being mined, the raw gypsum is thermally processed to form a settable calcium sulfate, which can be anhydrous, but more typically is the hemihydrate, CaSO 4 .½H 2 O. For the familiar end uses, the settable calcium sulfate reacts with water to solidify by forming the dihydrate (gypsum). The hemihydrate has two recognized morphologies, alpha and beta hemihydrate. These are selected for various applications based on their physical properties. Upon hydration, alpha hemihydrate is characterized by giving rise to rectangular-sided crystals of gypsum, while beta hemihydrate is characterized by hydrating to produce needle-shaped crystals of gypsum, typically with large aspect ratio. In the present invention, either or both of the alpha or beta forms can be used, depending on the mechanical performance required. The beta form generates less dense microstructures and is preferred for low density products. Alpha hemihydrate could be substituted for beta hemihydrate to increase strength and density or they could be combined to adjust the properties. 
         [0054]    The cementitious slurry can also include other additives. The additives can include, without limitation, accelerators and retarders to control setting times of slurry. Suitable accelerators include aluminum sulfate, potassium sulfate, and Terra Alba ground gypsum. Additional additives can be used to produce colored shutter assemblies  10 , such dry powder metallic oxides such as iron and chrome oxide and pre-dispersed pigments used for coloring latex paints. 
         [0055]    In accordance with one aspect of the present invention, a reinforcing material can also be disposed within the cementitious slurry, either prior to or after the introduction of the water thereto. The reinforcing material can include, without limitation, fibers, e.g., either chopped or continuous fibers, comprising at least one of polypropylene fibers, polyester fibers, glass fibers, and/or aromatic polyamide fibers. By way of a non-limiting example, the reinforcing material can include a combination of the fibers, such as the polypropylene fibers and the glass fibers or the polyester fibers and the glass fibers or a blend of the polypropylene fibers and the polyester fibers and the glass fibers. If included in the fiber composition, the aromatic polyamide fibers are formed from poly-paraphenylene terephthalamide, which is a nylon-like polymer commercially available as KEVLAR® from DuPont of Wilmington, Del. Of course, aromatic polyamide fibers other than KEVLAR® are suitable for use in the fiber composition of the subject invention. 
         [0056]    The cementitious slurry can then be mixed, either manually or automatically, so as to adequately combine the various ingredients thereof and optionally can also be agitated, e.g., by a vibrating table, to remove or lessen any air bubbles that formed in the cementitious slurry. 
         [0057]    Referring to  FIGS. 8-18 , one illustrative system and method of forming the shutter assembly  10  of the present invention is shown as being formed in a selectively closable mold system  200 . With specific reference to  FIG. 8 , the mold system  200  includes a lower or bottom mold surface portion  202  and an upper or top mold surface portion  204  that are selectively operable to come into and out of contact with one another. By way of a non-limiting example, the upper or top mold surface portion  204  can be hingedly attached to the lower or bottom mold surface portion  202 , such that the upper or top mold surface portion  204  can rotate downwardly towards or upwardly away from the lower or bottom mold surface portion  202 . Additionally, the mold system  200 , and components thereof, can be operated either manually and/or automatically. 
         [0058]    A mold surface member  206  is preferably disposed within a cavity  208  formed in the lower or bottom mold surface portion  202 . Although the lower or bottom mold surface portion  202  is shown as being an open shell having a substantially rectangular configuration, the lower or bottom mold surface portion  202  can have any number of various configurations. The mold surface member  206  can be formed of any type of material, such as rigid or flexible materials; however, preferably the mold surface member  206  is formed from a suitably flexible material that, e.g., can be removed from the cavity  208 . The face  206   a  of the mold surface member  206  is essentially a negative image of the desired front exterior surface shape of the shutter assembly  10 . Additionally, the mold surface member  206  preferably includes a peripheral lip member  210  to aid in grasping the mold surface member  206 , e.g., when it is desired to remove the mold surface member  206  from the cavity  208 . The foam core or insert  100  and an optional hanger member  300  are shown for illustrative orientation purposes. 
         [0059]    Because of the weights involved of the various components, as well as the cementitious slurry, a transport device, such as a conveyor system  350  (e.g., see  FIG. 9 ), either manually or automatically operated, can be employed to guide the mold system  200  along during the manufacturing process, e.g., from an initial processing station, to a curing station, and finally to a product removal station. In this manner, many shutter assemblies can be produced sequentially and rapidly (e.g., in an assembly line process) without having to wait for each individual shutter assembly to be finally and completely manufactured. 
         [0060]    After the cementitious slurry has been prepared, as described above, the cementitious slurry, preferably when still wet, is then poured into the bottom mold surface portion  202 , either manually or mechanically, such that it contacts and fills the mold surface member  206  to a desired depth (e.g., see  FIGS. 10-13 ). By way of a non-limiting example, the cementitious slurry is poured onto the mold surface member  206  until it reaches a depth of about one-half way up the exterior wall of the mold surface member  206 . However, it should be appreciated that either less than or more than this amount of the cementitious slurry can be used, e.g., depending on the specific application. 
         [0061]    With specific reference to  FIGS. 14 ,  14   a ,  14   b , and  15 , it should be noted that a top hanger member  300  and a bottom hanger member  350  can be placed, in a proper orientation, on the mold surface member  206  prior to the introduction of any cementitious slurry therein. However, it should be appreciated that the top hanger member  300  and bottom hanger member  350  can also be placed on the mold surface member  206  after the introduction of any cementitious slurry therein. 
         [0062]    The top hanger member  300  can be used for mounting a top portion of the shutter assembly  10  to the dwelling  12  instead of driving fasteners through the shutter assembly  10 . The top hanger member  300  includes an area defining a recess  302  that is operable to receive a bracket (to be described herein) or other mounting device mounted to the dwelling  12 , thus obviating the need to drive fasteners through the shutter assembly  10 , which could potentially damage the cementitious material, e.g., via cracking and/or the like. The recess  302 , or a portion thereof, can be angled with respect to the other portions of the top hanger member  300 . The angled configuration can provide better anchoring of the top hanger member  300  in the cementitious slurry, especially after curing. Additionally, the top hanger member  300  can be designed to be disposed in a cutout portion  100   b  formed in the foam core or insert  100  itself, or alternatively, the foam core or insert  100  can be designed to only extend up to, but not past or above the level of the top hanger member  300 . An optional face plate  303  can be provided around the periphery to prevent any cementitious slurry from flowing into the recess  302 . Furthermore, optional fin or blade members  304  can be provided on an exterior surface of the top hanger member  300  to better mate with the surrounding cementitious slurry, especially after curing. 
         [0063]    The bottom hanger member  350  can be used for mounting a bottom portion of the shutter assembly  10  to the dwelling  12  instead of driving fasteners through the shutter assembly  10 . In this manner, both the top hanger member  300  and the bottom hanger member  350  can securely fasten the shutter assembly  10  to the dwelling  12 , instead of relying on a single hanger member. The bottom hanger member  350  includes an area defining a recess  352  that includes a bar member  354  extending there across. The recess  352 , or a portion thereof, can be angled with respect to the other portions of the bottom hanger member  350 . The angled configuration can provide better anchoring of the bottom hanger member  350  in the cementitious slurry, especially after curing. The recess  352  is operable to receive a fastening member (to be described herein) or other mounting device mounted to the dwelling  12 , thus obviating the need to drive fasteners through the shutter assembly  10 , which could potentially damage the cementitious material, e.g., via cracking and/or the like. Additionally, the bottom hanger member  350  can be designed to be disposed in a second cutout portion  100   c  formed in the foam core or insert  100  itself, or alternatively, the foam core or insert  100  can be designed to only extend up to, but not past or above the level of the bottom hanger member  350 . An optional face plate  355  can be provided around the periphery to prevent any cementitious slurry from flowing into the recess  302 . Furthermore, optional fin or blade members  356  can be provided on an exterior surface of the bottom hanger member  350  to better mate with the surrounding cementitious slurry, especially after curing. 
         [0064]    As noted, once a sufficient amount of the cementitious slurry is disposed onto the mold surface member  206 , the foam core or insert  100  is then placed onto the cementitious slurry and is properly positioned in the mold in a desired orientation. The cementitious slurry initially penetrates through any crevices, apertures or spaces between adjacent portions of the foam core or insert  100 , such as the crevices, apertures or spaces formed between the individual slat members  100   a  and in this manner forms the reinforcement or rib members  104  previously described. Optionally, a vibratory force can be applied to the mold system  200 , e.g., to remove any residual air bubbles in the cementitious slurry, e.g., either before or after the foam core or insert  100  is placed therein. 
         [0065]    It should be noted that the exact sequencing of the positioning onto the mold surface  206  of either of the top hanger member, bottom hanger member  350  and/or the foam core or insert  100  is not thought to be critical to the success of the present invention. That is, for example, the foam core or insert  100  can be positioned first, the bottom hanger member  350  positioned second, and the top hanger member  300  positioned last, or any combination of these individual steps. Additionally, any of these positioning steps can take place prior to and/or after the pouring of the cementitious slurry onto the mold surface  206 . 
         [0066]    With specific reference to  FIG. 16 , because the foam core or insert  100  can have a tendency to float, the upper or top mold surface portion  204  is brought into contact with the lower or bottom mold surface portion  202  so as to keep the foam core or insert  100  at least partially and preferably completely submerged within the cementitious slurry. The upper or top mold surface portion  204  can be provided with a series of members  204   a , e.g., bumps, which project outwardly from the face of the upper or top mold surface portion  204  such that they contact, either constantly or intermittently, the foam core or insert  100  and keep the same from excessively floating upwardly out of the cementitious slurry. 
         [0067]    In accordance with one aspect of the present invention, the upper or top mold surface portion  204  can be secured to the lower or bottom mold surface portion  202  with fastening devices  400  so as to prevent the upper or top mold surface portion  204  and the lower or bottom mold surface portion  202  from becoming inadvertently dislodged from one another. The cementitious slurry is then allowed to dry, harden or cure for a sufficient amount of time, which may depend, at least in part, on the specific composition of the cementitious slurry used. The mold system  200  can also be shuttled off of the conveyor system  350  and stored in a storage area (not shown) so that other shutter assemblies can be made in the interim. 
         [0068]    With specific reference to  FIGS. 17 and 18 , once the cementitious slurry has dried, hardened or cured, the shutter assembly  10  can then be removed from the mold system  200 . By way of a non-limiting example, the fastening devices  400 , if used, are disengaged so as to enable the upper or top mold surface portion  204  to be removed from the lower or bottom mold surface portion  202 , thus exposing the rear face  10   a  of the shutter assembly  10 . The mold surface member  206  can then be removed from the cavity  208  by grapping the peripheral lip member  210  and lifting the mold surface member  206  upwardly and out of the cavity  208 . The mold surface member  206  is then removed from the shutter assembly  10 , thus exposing the finished product, which is preferably allowed to dry to a suitable extent, after which time it can then be used immediately or further processed, e.g., painted or otherwise treated. 
         [0069]    An illustrative example of mounting the shutter assembly  10  to a surface (e.g., an exterior wall, an interior wall, and/or the like) of a dwelling  12 , or other structures, will now be described. 
         [0070]    With reference to  FIG. 19 , there is shown a perspective view of a top bracket system  500  and a bottom bracket system  600  attached to an exterior wall  601  of a dwelling, in accordance with a twenty-first embodiment of the present invention. The top bracket system  500  includes a bracket member  502  that includes a bracket surface  504  (e.g., a substantially L-shaped member) and a mounting surface  506 . Fastening members  508  (e.g., screws, bolts and/or the like) are used to mount the mounting surface  506  (e.g., through appropriately spaced apertures formed in the mounting surface  506 ) to the exterior wall  601  of the dwelling. The bottom bracket system  600  includes a bracket member  602 . Fastening members  604  (e.g., screws, bolts and/or the like) are used to mount the bracket member  602  (e.g., through appropriately spaced apertures formed in the bracket member  602 ) to the exterior wall  601  of the dwelling. However, a tie member  606  is placed between the exterior wall  601  and the bracket member  602  such that the tie member  606  is held tightly against the exterior wall  601  by the bracket member  602 . The tie member  606  is positioned such that a securing portion  608  is adjacent to or abuts an edge surface (e.g., a bottom edge) of the bracket member  602  and a free end  610  of the tie member  606  extends upwardly past an edge surface (e.g., a top edge) of the bracket member  602 . 
         [0071]    Referring to  FIG. 20 , there is shown a partial sectional view of a shutter assembly  700  being mounted to the top bracket system  500  depicted in  FIG. 19 , in accordance with a twenty-second embodiment of the present invention. In this view, the shutter assembly  700  is positioned such that the bracket surface  504  is received within the recess  302  formed in the top hanger member  300 , as previously described. The bracket surface  504  then merely rests upon the upper portion of the recess  302  of the top hanger member  300 . 
         [0072]    Referring to  FIG. 21  is a partial sectional view of the shutter assembly  700  being mounted to the bottom bracket system  600  depicted in  FIG. 19 , in accordance with a twenty-third embodiment of the present invention. In this view, the shutter assembly  700  is positioned such that the free end  610  of the tie member  606  is able to be looped around the bar member bracket  354  disposed in the recess  352  of the bottom hanger member  350 . Once this is done, the free end  610  of the tie member  606  is then threaded through the securing portion  608  and drawn therethrough such that the shutter assembly  700  is drawn tight against the bottom bracket system  600  and thus against the exterior wall  601 . The securing portion  608  can be configured so as to prevent the free end  610  of the tie member  606  from slipping back out of the securing portion  608  once is it is inserted therethrough (e.g., through a modified “pawl and ratchet” system used in conventional plastic zip ties, cable ties and/or the like). 
         [0073]    Referring to  FIG. 22 , there is shown a bottom view of the mounted shutter assembly  700 , in accordance with a twenty-fourth embodiment of the present invention. In this view, the excess portion of the free end  610  of the tie member  606  has been removed (e.g., with snips, scissors, clippers, and/or the like) such that it is hard to detect the presence of the bottom bracket member  350  and/or the bottom bracket system  600 . The free end  610  is preferably removed such that only a very small portion of the free end  610  can be seen extending from the securing portion  608 . Alternatively, the free end  610  is preferably removed such that none of the free end  610  can be seen extending from the securing portion  608 , i.e., only the securing portion  608  is visible. Additionally, because of the configuration of the mounted shutter assembly  700 , even the securing portion  608  itself would be very difficult to be seen, thus not detracting from the aesthetic value of the shutter assembly  700 . Accordingly, a person viewing the mounted shutter assembly  700  would be unable to instantly discern how the shutter assembly  700  has been mounted to the exterior wall  601  of a dwelling due, in part, to the concealed nature of the mounting system of the present invention. 
         [0074]    Additionally, once the hanger members are suitably secured to the building, e.g., as described above, the peripheral areas of the hanger members can be caulked or otherwise sealed in order to prevent the intrusion of water, and/or other undesirable elements, into the building. 
         [0075]    While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.