A shutter panel and an installation including a shutter panel in an architectural opening. The shutter panel has mitered corners without exposed end grain. The shutter panel is connected directly to structures defining the architectural opening.

FIELD OF THE INVENTION

The present invention relates generally to shutters for architectural openings and the manner in which such shutters are installed in the openings; and, more particularly, the invention pertains to the shutter structure, hinge, installation and fit.

BACKGROUND OF THE INVENTION

Interior shutters on windows, doors and other architectural openings are used for purposes that are both functional and aesthetic. A shutter can provide effective, adjustable light control and a pleasing appearance that enhances room decor.

A known shutter panel construction includes a pair of opposed stiles connected to a pair of opposed rails, the stiles and rails together defining an interior region in which adjustable louvers are mounted. The stiles are vertical components along opposite sides of the shutter panel, and the rails are horizontal components along the top and bottom of the shutter panel. It is known to butt-end join the horizontal rails to the interior edges of the vertical stiles. For a strong connection, mortise and tenon joints can be used. A disadvantage of known stile and rail constructions for window shutters is that a raw end surface of each vertical stile is exposed along the top edge surface and the bottom edge surface of the shutter panel. Frequently, the open end grain of the stiles exposed along the top and bottom edges of the shutter panel will not stain or otherwise surface finish in the same way as other areas of the stiles or rails. The exposed end grain can be unappealing aesthetically. Further, because cut ends or other machined surfaces are exposed in the completed shutter panel, it is necessary to stain and finish wood shutters or paint MDF shutters after the shutter panel is assembled. This often requires manually intensive processes rather than automated processes for finish application.

It is known to use a given number of louvers overlapping one another by fixed dimensions for a range of shutter sizes, and to adjust the height of a shutter panel by reducing the width of the rail pieces at the top and bottom of the shutter. With known panel frame construction, an unbalanced appearance can be a problem. Vertical frame members are not as wide as horizontal members, and the top and bottom members can vary in width from panel to panel.

To install a shutter, it is known further to mount one or more shutter panel in a mounting structure, such as a frame completely surrounding the shutter, or at least an edge mounting board. The panel or panels are connected to the mounting structure by hinges. The mounting structure is connected in a fixed position to the window jamb or other structure of the architectural opening in which the shutter is installed. The mounting structure is relatively immovably positioned, and the shutter panels secured thereto by hinges can be pivoted on the hinges toward and away from the architectural opening over which the shutter is positioned.

Procedures for mounting a shutter as described above have been used extensively and provide acceptable results in many situations; however, the design is not optimal for several reasons. For inexperienced individuals, measuring for the proper size of shutter can be difficult, allowing for tolerances of the separate independent structures, including the mounting frame and shutter panels. Assembling the complete shutter structure can be difficult, to maintain squareness of the frame, the panel and the panel within the frame. The completed assembly can be difficult to install correctly. Even when properly sized and installed, the mounting structure of a frame or board along at least the hinged side of the shutter effectively reduces the size of the window or other opening due to the fixed components secured to the opening. The fixed components block a portion of the opening, whether the shutter is opened or closed. Accordingly, the operation of a tilt in window may be compromised due to the mounting board or mounting frame obstructing window operation. Further, the known mounting arrangement can result in an installation incapable of opening through an angle greater than 90 degrees. For these reasons and more, the usefulness of known shutters is less than optimal.

Accordingly, there is a need for an improved shutter construction, to improve appearance and/or functionality while facilitating efficient manufacture, assembly and/or installation.

SUMMARY OF THE INVENTION

The present invention provides a shutter for windows, doors and other architectural openings having with mitered corners and variably overlapped louvers. The shutter is mounted directly by hinges, without the need for a separate mounting structure such as a mounting board or mounting frame. Extendable hinges can be used to move the shutter panel outwardly as the shutter is opened, to clear window trim surrounding the window opening.

In one aspect of one form thereof, the present invention provides a shutter panel with a top piece, a bottom piece and two side pieces connected to one another to define a space; a plurality of louvers disposed in the space, the louvers being rotatable between a closed position in which adjacent louvers overlap, and an open positioning in which spaces are provided between adjacent louvers. The top, bottom and side pieces are connected at mitered joints without exposed end grain.

In another aspect of another form thereof, the present invention provides a shutter installation for an architectural opening defined by a head structure above the architectural opening, a bottom structure below the architectural opening and jamb structures at the sides of the architectural opening. The shutter installation has a shutter panel having a top piece, a bottom piece and side pieces defining a panel opening there between and angularly adjustable louvers disposed in the panel opening between the top piece, the bottom piece and the side pieces. The top piece, the bottom piece and the side pieces having mitered surfaces connected one to another without exposed end grain. A hinge having releasable first and second components has one of the components connected to one of the side pieces and the other of the components connected to one of the jamb structures.

In still another aspect of still another form thereof, the present invention provides a shutter installation with an architectural opening having a head structure, a bottom structure and jamb structures defining the architectural opening, and a shutter panel covering at least a portion of the architectural opening, the shutter panel having a top piece, a bottom piece and side pieces defining a panel opening there between, and angularly adjustable louvers disposed in the panel opening between the top piece, the bottom piece and the side pieces. The top piece, the bottom piece and the side pieces have mitered end surfaces connected one to another without exposed end grain. A hinge has releasable first and second components, one of the components being connected to one of the side pieces and the other of the components being connected to one of the jamb structures.

An advantage of the present invention, in at least one form thereof, is providing a shutter for windows, doors and other architectural openings that is unique in appearance and aesthetically pleasing.

Another advantage of the present invention, in at least one form thereof, is providing a shutter that is uniform in appearance with top, bottom and side margin pieces of equal width, size and shape.

A further advantage of the present invention, in at least one form thereof, is providing a shutter having top, bottom and side pieces that are without exposed end grain or machined surfaces, to improve consistency of finishing characteristics and allow pre-finishing of component pieces.

Still another advantage of the present invention, in at least one form thereof, is providing a shutter for windows, doors and other architectural openings that includes appropriate light blocks so that cracks or openings are not visible from light infiltration above and below rotatable louvers of the shutter when the louvers are in a closed position.

Yet another advantage of the present invention, in at least one form thereof, is providing a shutter that does not permanently block a significant portion of a window, but instead can be opened to expose substantially the entire window.

Still another advantage of the present invention, in at least one form thereof, is providing a shutter for windows, doors and other architectural openings that is easy to install, and that can be mounted directly as an inset in the window or as an overlay of the window without a separate mounting frame.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now more specifically to the drawings and toFIGS. 1 and 2in particular, a shutter panel100in accordance with the present invention is shown installed on an architectural opening102. Shutter100includes opposed top and bottom pieces104,106and opposed side pieces108and110. Top piece104, bottom pieces106and side pieces108and110are connected to each other at mitered corner joints112,114,116and118. Thus, an outer frame defined by top and bottom pieces104,106and side pieces108,110defines a central open area120. Closely adjacent, adjustable slats or louvers122are rotatably mounted in open area120, rotatably secured in side pieces108,110. Top and bottom pieces104,106include light block extensions124,126respectively, which will be described in greater detail hereinafter. A tilt control rod128is connected to each louver122for adjusting the angular orientation of all louvers122simultaneously.

Architectural opening102includes a head130at the top of opening102, a sill132at the bottom of window102, and jambs134,136on opposite sides of opening102. Architectural opening102can be the opening of a window, door, access portal or other structure. Shutter panel100is mounted to jamb134by two hinges138,140. Hinges138,140are separable, two-part hinges that are adjustable, each having a first component142,144secured to shutter panel100and second component146,148secured to jamb134, respectively.

The two part hinges useful in the present invention make installation easy in that the assembled hinge on the shutter can be positioned where needed and the jamb marked so that screws can be used to secure the hinge in its proper place. For custom installations, hinge placement with respect to any desired shutter panel overlap of the opening or no overlap can be fixed relative to the opening dimension so that a jig or guide can be used for marking hinge locations on the architectural opening. In this way, it is not necessary to use the hinge itself for marking, and the shutter panel need not be held in position for determining hinge mount location. The hinge components can be separated, facilitating connection of the jamb component without the inconvenience of holding the shutter in place. After the jamb component of the hinge is connected to the jamb, the two hinge components are reconnected, and the hinge is adjusted to align the shutter as desired. Hinges such as that shown and others that can be used advantageously in preferred embodiments of the present invention provide multiple adjustments along three axes such that the shutter can be properly positioned and vertically aligned, particularly when two adjacent moveable panels are used. Different hardware packs, including different style hinges can be used to achieve desired shutter operation as an insert, a partial overlay or a full overlay and the desired arc through which the shutter can be opened. Articulating hinges that move the hinge pivot point outwardly can be used to provide full opening of shutter panels even when decorative trim is provided around the architectural opening and the shutter panel is positioned inwardly of the trim when closed. The method of installation is the same regardless of the installation option selected, be it as an overlay to or as an insert in the architectural opening. With standardization of hinge location and the use of separable two-part hinges, shutter panels of different patterns and appearance can be interchanged on an architectural opening. Accordingly, seasonal panels or other changes in color or appearance can be provided for a single opening and changed when desired simply by disconnecting one panel and connecting the second panel using the two-part hinges. Suitable two-part, multi-axis adjustable hinges are available from various furniture hardware suppliers, including but not limited to Arturo Salice S.p.A., Italy; Grass GmbH Furniture Hardware, Austria; and Julius Blum GmbH, also of Austria.

FIG. 3is an exploded view of a shutter in accordance with the present invention. Shutter panel200includes top and bottom pieces202,204and side pieces206,208connected by mitered joint surfaces210,212,214,216,218,220,222and224at the ends thereof, which can be shaped so as to include mortise and tenon connections for added strength. As illustrated, the angular end surfaces218,220and222,224of vertical side pieces206,208, respectively, form tenons230,232,234,236that are received in pockets formed in the angular end surfaces210,212,214,216of top and bottom pieces202,204. Only one such pocket244formed in mitered joint surface214is visible inFIG. 4; however, the locations of pockets240,242and246, which are not visible in the angular perspective ofFIG. 3, are shown in dashed lines.

Louvers250are connected by pins252at each end of the louver to vertical side pieces206,208; the pins252being received in holes254whereby louvers250can rotate. Some, but not all pins252and holes254have been shown and designated with reference numerals inFIG. 3. As those skilled in the art will readily understand further that one or more set of pins252for one or more louver250may be replaced by a tension rod, torque louver or other structure extending through the louver and anchored in side pieces206,208to draw side pieces206,208toward one another and inhibit bowing or other deformation of the shutter assembly.

A divider rail260having tenons262,264at the ends thereof is positioned between upper and lower groups of louvers250. Tenons262,264are received in pockets266,268formed in the inside surfaces of vertical pieces206,208. Pocket266is shown for side piece206, and the location of pocket268in side piece208is shown in dashed lines.

Light blocks270,272,274and276are provided on the inner edges of top piece202and bottom piece204, and on the top and bottom edges of divider rail260, respectively. Light blocks270,272,274and276are elongated, continuous, inwardly projecting protrusions that extend from one side piece206,208to the other side piece206,208. Each light blocks270,272,274and276is overlapped by an edge of the louver250immediately adjacent thereto, when the louver is in a closed position. Accordingly, in closed positions for the louvers of the shutter panel, with each light block270,272,274and276overlapped by an immediately adjacent louver250, light infiltration is effectively blocked, minimizing light leakage around the edges of the louvers.

It should be understood that the present invention is capable of many variations and changes. A shutter of the present invention can be provided in various sizes and shapes, and with different appearances. For example, and not for limitation, a shutter of the present invention can be provided with or without a divider rail as shown inFIG. 3, or can be provided with multiple divider rails if desired. More or fewer louvers can be provided, with different overlap dimensions for adjacent louvers. The louvers can be provided in a different dimensions and contours, to achieve the desired function and appearance. The top, bottom and a side pieces can be provided in simple shapes as shown, or can be provided in various ornate contours commonly used for moldings and trim. Shutter panels can be provided individually over an opening, or multiple shutter panels can be used separately hinged to the architectural opening. Further, two or more shutter panels can be connected by hinges one to another to provide a bi-fold or overlapping opening arrangement. Still further variations can be incorporated into shutters of the present invention. The simple, basic structures shown and described herein should not be interpreted as limitations of the invention in any way.

FIGS. 4-16illustrate some variations for installations of shutters in accordance with the present invention. The variations shown and described are exemplary and should not be considered exhaustive of the installation variations that can be used.

FIGS. 4-6illustrate a shutter installation300having first and second shutter panels302,304installed in a window or opening306. Window/opening306is surrounded by trim or molding pieces308on all four sides. A window sill is not provided. Panel302includes a top piece310a bottom piece312and side pieces314,316connected at miter joints320,322,324,326. Light blocks330,332are provided on top piece310and bottom piece312, respectively. A plurality of louvers334connected by a tilt control rod336are provided within an opening338defined by top piece310, bottom piece312and side pieces314,316. Panel304includes a top piece340, a bottom piece342and side pieces344,346connected at miter joints350,352,354,356. Light blocks360,362are provided on top piece340and bottom piece342. A plurality of louvers364connected by a tilt rod366are provided within an opening368defined by top piece340, bottom piece342and side pieces344,346.

Window opening306is defined by a head structure370, a bottom structure372and side jamb structures374,376. A trim or molding piece308is connected to each of head structure370, bottom structure372and jamb structures374,376. In the exemplary installation shown, shutter panels302,304are installed within the space defined between head structure370, bottom structure372and jamb structures374,376. Accordingly, head the structure370extends over shutter panels302,304; bottom structure372extends beneath shutter panels302,304and jamb structures374,376extend alongside shutter panels302,304. Light blocks378,380,382,384are provided on head structure370, bottom structure372and jamb structures374,376, respectively. Light blocks378,380,382,384block light infiltration along the spaces defined between shutter panels302,304and window opening306. A plurality of hinges connect each shutter panel302,304to window opening306, one such hinge386being shown for shutter panel302and another such hinge388being shown for shutter panel304. Side piece344is provided with an astragal390to overlap with side piece316to block light infiltration between panels302,304.

In the exemplary installation illustrated inFIGS. 4-6, shutter panels302,304are mounted within the architectural opening306, a window opening as shown. As can be seen from the cross-sectional views, shutter panels302,304do not project outwardly beyond trim pieces308. Articulating hinges can be used to move shutter panels302,304outwardly of the window opening306, to clear trim pieces308provided around the opening and to provide substantially complete exposure of window opening306.

FIGS. 7-9illustrate a shutter installation400similar to installation300shown inFIGS. 4-6. Shutter panels402,404are installed in a window opening406; however, a sill407extends inwardly at the bottom of window opening406, and trim or molding pieces408are provided only on three sides of opening406. An apron trim piece409is provided beneath sill407.

Panel402includes a top piece410a bottom piece412and side pieces414,416connected at miter joints420,422,424,426. Light blocks430,432are provided on top piece410and bottom piece412, respectively. A plurality of louvers434are provided within an opening438defined by top piece410, bottom piece412and side pieces414,416.

Panel404includes a top piece440, a bottom piece442and side pieces444,446connected at miter joints450,452,454,456. Light blocks460,462are provided on top piece450and bottom piece452. A plurality of louvers464are provided within an opening468defined by top piece440, bottom piece442and side pieces444,446.

Window opening406is defined by a head structure470, a bottom or sill structure472and side jamb structures474,476. A trim or molding piece408is connected to each of head structure470and jamb structures474,476. A plurality of hinges connect each shutter panel402,404to window opening406, one such hinge486being shown for shutter panel402and another such hinge488being shown for shutter panel404. In this embodiment, a center post490is connected to head structure470and sill structure472. Side piece416of shutter panel402and side piece444of shutter panel404overlap center post490. Center post490blocks light infiltration between shutter panels402,404. One or the other of shutter panels402,404can be, but need not necessarily be, connected by hinges to center post490. Alternatively, each of shutter panels402,404can be connected by hinges to a jamb structure474,476.

As shown most clearly in the cross-sectional views ofFIGS. 8 & 9, shutter panels402,404slightly overlap head structure470and jamb structures474,476. A well used finish carpentry technique is to install trim pieces408recessed slightly from the inner edges of underlying structures such as head structure470and jamb structures474,476. Accordingly, a so-called “reveal” or exposed surface of the underlying structure is provided. A reveal492is shown for a head structure470and reveals494and496are shown for jamb structures474,476respectively. Top pieces410,440of shutter panels402,404overlap reveal492, and side pieces414and446of shutter panels402,404overlap jamb structure reveals494,496respectively. Light infiltration is restricted by the overlapping installation of shutter panels402,404. To minimize light infiltration beneath shutter panels400,402a light block similar to light block380can be used on top of sill407, overlapped by bottom pieces412,442.

It should be understood that the overlapping installation within the reveals of the trim finish, as shown and described for shutter installation400, can be used in other types of window structures as well. For example, while shown in an installation having a sill407, a similar overlapping installation could be used in an installation for a window not having a sill, such as window opening306described for installation300.

FIGS. 10-12illustrate another embodiment for an installation500in accordance with the present invention in which shutter panels502,504are installed on an architectural opening506having no trim or molding pieces there around. In exemplary installation500, shutter panels502,504are mounted on the surface of architectural opening506, and not within architectural opening506. Shutter panel502includes a top piece510a bottom piece512and side pieces514,516connected at miter joints520,522,524,526. Light blocks530,532are provided on top piece510and bottom piece512. A plurality of louvers534are provided in an opening538defined by top piece510, bottom piece512and side pieces514,516. Panel504includes a top piece540, a bottom piece542and side pieces544,546connected at miter joints550,552,554,556. Light blocks560,562are provided on top piece550and bottom piece552. A plurality of louvers564are provided within an opening568defined by top piece540, bottom piece542and side pieces544,546.

Window opening506is defined by a head structure570, a bottom structure572and side jamb structures574,576. In the exemplary installation shown, shutter panels502,504are installed on the surface of window opening506, not within the space defined between head structure570, bottom structure572and jamb structures574,576. Shutter panels502,504overlap head structure570, bottom structure572and jamb structures574,576. Accordingly, like blocks within the window opening are not required. Hinges connect shutter panel502to window opening506, one such hinge586being shown for shutter panel502. Another hinge or hinges588connect shutter panel504to shutter panel502in a bi-fold arrangement. Accordingly, as illustrated in the exemplary illustration, both shutter panels502,504are opened to the left of the window opening506.

FIGS. 13 and 14illustrate yet another shutter panel installation600in accordance with the present invention. One feature of the invention is that the pieces defining the top, bottom and sides of the shutter panel and the opening thereof in which louvers are installed are similarly configured. Accordingly, unlike known structures in which butt joints are formed leaving raw edges of the stiles at the top and bottom edges of the shutter panel, the present mitered corners can be installed in any orientation. A shutter having horizontal louvers can be installed sideways, with louvers vertically positioned. Installation600includes a panel602installed in a trim-less window opening606having a sill607. Panel602has a top-now-side piece610, a bottom-now-side piece612, a side-now-top piece614and a side-now-bottom piece616connected at miter joints620,622,624,626. Light blocks630,632are provided. A plurality of louvers634are provided in an opening638. Unlike previous installations described here in, louvers634are vertically arranged rather than horizontally arranged. Window606includes jamb structures674,676at the sides thereof. Shutter panel602is connected to jamb structure674by an articulating hinge686. Only a single panel is shown for installation600; however it should be understood that two panels separately hinged or hinged in a bi-fold arrangement as described in previous embodiments also can be used.

FIGS. 15 and 16illustrate yet another shutter installation700in accordance with the present invention. Installation700includes a panel702installed in a trim-less window opening706having a sill707. Panel702has a top piece710, a bottom piece712and side pieces714and716connected at miter joints720,722,724,726. A vertical divider stile728is connected between top piece710and bottom piece712. Light blocks730,732are provided on top piece710and bottom piece712, respectively, between side piece714and divider stile728. A first plurality of louvers734are provided in an opening defined by top piece710, bottom piece712, side piece714and divider stile728. Light blocks760,762are provided on top piece710and bottom piece712, respectively, between side piece7164and divider stile728. A second plurality of louvers764are provided in an opening defined by top piece710, bottom piece712, side piece716and divider stile728. Window706includes jamb structures774,776at the sides thereof. Shutter panel702is connected to jamb structure774or jamb structure776by a hinge (not shown).

The shutters described herein and still other variations of the invention can be manufactured by automated equipment in custom sizes, including infinite louver spacing and arrangement while maintaining advantages of mass-production. Through algorithmic control of the manufacturing and assembly processes, the positions and spatial relationships of parts within the assembly can be adjusted and customized for customized overall assemblies. For example, divider rail or divider stile positioning can be customized to a customer's specifications, and need not be centrally positioned as described herein. The numbers of louvers used and the overlap dimension of adjacent louvers can be changed to accommodate different sizes required for shutter panels. While an embodiment has been shown with an integral astragal formation, for further standardization of parts, and the minimization of different parts of the shutters and add-on astragal can be used, either as a structural insert or as a bonded attachment with adhesive. All of outer pieces of the shutter panels, including the top piece, the bottom piece and both side pieces can then be of the same design.

Cut ends of the shutter panel outer components are incorporated in the joint formations, and not exposed. Accordingly, long pieces can be pre-finished in automated processes and subsequently cut to required lengths. This reduces manually intensive hand operated processes often used for prior art constructions. Shutters of the present invention can be shipped ready for installation, without further assembly required.

It should be understood also that the concepts disclosed herein are not limited in scope to rectangular window shutters, but can have other applications as well. For example and not limitation, the invention can be applied to arched shutters and shutters for other irregularly shaped applications, French-style doors and the like.