Modular shutter

An adjustable, fastenerless modular shutter includes a pair of side rails, at least one shutter panel and a pair of end rails. A center rail can be provided. The side rails and end rails are mutually connected to form a frame for holding one or more shutter panels and center rails. Each end rails and the center rail has a front wall and a pair of runner portions having locking portions. The locking portions are slidably receivable in the pair of side rails and include interferingly, frictionally engaging projections for engaging the side rails to resist separation of the end rails from the side rails during assembly of the shutter. The side rails include front inwardly directed lips which assist in retaining the shutter panelis), the center rail and the end rails, particularly the runner portions. The end rails and the center rail include front surfaces raised from their respective runner portions to be planar with front surfaces of the side rails when the shutter is assembled. An overall aesthetically pleasing architectural appearance is achieved.

FIELD OF THE INVENTION 
This invention pertains to building shutters, and more particularly to 
modular shutters assembled from side rails and end rails which are rigidly 
mutually connected and which provide an aesthetically attractive frontal 
appearance. 
BACKGROUND OF THE INVENTION 
A variety of decorative building shutters are available for installation 
adjacent to openings in buildings, such as windows. One popular type of 
shutter which is available is assembled from modular components which are 
available in a range of sizes. Such modular shutters are easily tailored 
for particular installations. 
Examples of such modular shutters are disclosed in U.S. Pat. Nos. 4,251,966 
to Foltman, entitled "Adjustable Height Shutter", 5,152,166 to MacGowan, 
entitled "Modular Shutter Assembly", and 5,265,391 to Ricard et al., 
entitled "Stabilized Modular Shutter", all of which patents are assigned 
to the assignee of this application. Other examples of modular shutters 
are disclosed in U.S. Pat. Nos. 4,765,110 to MacLeod, entitled "Adjustable 
Plastic Shutter" and 5,060,442 to Chubb, entitled "Louvered Plastic 
Building Product." 
Typically, modular shutters have a pair of side rails, a central shutter 
panel which, for example, may be planar or louvered, and top and bottom 
end rails. Generally, the side rails are cut to meet the particular size 
requirements of the shutter installation. The shutter panels are cut or 
sized accordingly. The width of modular shutters can be adjusted by use of 
shutter panels, end rails and mullions of different dimensions. 
In many existing modular shutters, each shutter panel has a pair of runners 
extending along the opposite sides of the panel, transverse to the plane 
of the shutter panel. Typically, each of the side rails of such modular 
shutters has a channel formed on the inner wall thereof to slidably 
receive the runners of the shutter panel. The channel includes a front lip 
extending inwardly from a front edge of the inner wall and overlying an 
edge portion of the shutter panel. 
The end rails of many shutters also include runner portions which are 
slidably received in the side rails. The side rails can be C-shaped in 
cross section with inner and outer walls. Typically, such end rails also 
include depending tab-like portions which project into the side rails at 
the ends thereof, against the outer wall to retain the shape of the side 
rail and to properly position the end rail thereon. 
In assembling such shutters, the end rails are assembled to the side rails. 
One end rail can be assembled before the central panel and side rails are 
assembled. Typically, the side rails and end rails are fastened together, 
such as by stapling, to prevent separation thereof. The side and end rails 
are fastened along the portion where the end rail runner and side rail 
inner wall are adjacent to each other. While temporarily fastening the 
shutter in the assembled configuration with fasteners facilitates 
installation, it is nevertheless a time consuming and laborious task. When 
the shutter is installed, for example, adjacent to a window on a building 
surface, screws or other fasteners are driven through the side rails to 
secure the shutter to the building surface. 
In known modular shutters, the end rails and center rails are configured to 
be attached to the side rails by interfitting into the channel on the 
inner wall beneath the front lip. The end rails and center rail include a 
front wall surface which is slightly recessed from the front wall surface 
of the side rails to fit beneath the lip. 
When assembled, this also simplified the configuration of the end rails for 
insertion of the runner portions into the side rails. However, this 
presents an uneven and less than optimal appearance of the finished 
shutter. 
SUMMARY OF THE INVENTION 
A modular shutter incorporating the present invention includes a pair of 
side rails, one or more panel members disposed between and secured to the 
side rails, and end rails secured to the side rails. The end rails are 
disposed at either end of the panel member for enclosing the panel member. 
A center rail or mullion can also be provided. 
The end rails (and center rail if present) are configured to include raised 
front surfaces which are planar with front surfaces of the side rails. The 
raised front surfaces of the end rails and the center rail and the front 
surfaces of the side rails together provide a planar flush appearance 
which is a more aesthetically pleasing architectural design. The modular 
shutter in accordance with the present invention incorporates side rails 
and end rails which are configured to be mutually engageable in a rigid 
fashion to limit separation and disengagement of the end rails from the 
side rails prior to installation, without the use of extra fasteners, such 
as staples. The modular shutter provides an interfering engagement 
configuration which frictionally secures the end rails to the side rails 
during assembly. Such a configuration includes a locking portion, such as 
on the end rail, which interferingly, frictionally engages the respective 
other rail, such as the side rail, for resisting disengagement of the end 
rails from the side rails after assembly. 
Each of the side rails has a front wall, a generally planar inner wall, and 
an outer wall. The side rails are spaced apart one from the other with the 
inner walls facing each other and lying in generally parallel planes. The 
side rails include channeled outer edges, and the end rails include 
alignment tabs which engage the channeled outer edges. 
The side rails each include an inwardly directed front lip extending from a 
front edge of a respective inner wall which overhangs the panel member(s), 
the center rail, and the end rails when the shutter is asembled. The side 
rails can each include an L-shaped hook wall at a rear edge of the 
respective inner wall which forms a C-shaped channel with the respective 
front lip. An L-shaped recess can be provided in each of the inner walls. 
The panel member(s), center rail, and end rails each have a central 
portion and a pair of runner portions disposed along the sides thereof. 
The runner portions are oriented generally parallel to the inner walls of 
the side rails. The runner portions are fit within the C-shaped channels. 
Each of the runner portions includes at least one L-shaped hook which is 
engagable with an L-shaped recess formed into the inner wall of an 
associated side rail to secure the panel member(s), center rail and end 
rails to each of the side rails. 
The center rail and end rails include front walls having front surfaces 
which are raised from front edges of their associated runner portions. 
When installed to the side rails the runner portions underlie the front 
lips of the side rails, and the front surfaces of the center rail and end 
rails are flush or planar with front surfaces of the front walls of the 
side rails. 
The fastenerless shutter in accordance with the present invention aligns 
and secures the end rails and sides rails together, without extra 
fasteners, during assembly, and thus improves the resistance against 
disengagement (i.e., achieves a secure engagement) of the modular shutter 
assembly. By securing the components together during assembly without 
requiring additional procedures, such as the use of fasteners, the 
assembly of shutters is simpler and faster, and the cost of assembly is 
reduced due to the reduction in assembly time and the elimination of 
fasteners. 
Numerous other advantages and features of the present invention will become 
readily apparent from the following detailed description of the invention 
and embodiments thereof, from the claims, and from the accompanying 
drawings in which the details of the invention are fully and completely 
disclosed as a part of the specification.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
While this invention is susceptible of embodiment in many different forms, 
there is shown in the drawings and will be described herein in detail, 
specific embodiments thereof with the understanding that the present 
disclosure is to be considered an exemplification of the principles of the 
invention and is not intended to limit the invention to the specific 
embodiments illustrated. 
There is shown in FIG. 1 a fastenerless modular shutter 10 comprising a 
pair of side rails 12, one or more shutter panel members 14, a top end 
rail 16, and a bottom end rail 18. When, as shown in FIGS. 1 and 2, the 
shutter 10 includes more than one panel member 14, a mullion or center 
rail 20 may be disposed between adjacent panel members 14. 
Referring now to FIGS. 2 and 3, each side rail includes a front wall 22 
having a front surface 22a, an inner wall 24 and an outer wall 26, and is 
formed in a generally C-shaped cross section. In one embodiment, each rail 
12 includes a track 28 which may include a hook portion 30 at an end 
thereof. Each rail 12 may also include an offset retaining channel or slot 
34 which interrupts the plane of the inner wall 24. Such a configuration 
is described for example in U.S. Pat. No. 5,524,407, and co-pending U.S. 
Pat. Application Ser. No. 08/825,274 filed Mar. 27, 1997, which are 
commonly assigned herewith. 
The offset retaining channel 34 may have any number of shapes, such as the 
exemplary L-shaped cross-section best seen in FIG. 3. Each side rail 12 
also includes a front lip 36 extending from the front wall 22, inwardly 
relative to the shutter panel 14, at an edge 38 opposing the hook portion 
30, and adjacent the inner wall 24. 
Each shutter panel 14 has a central portion 42 and includes a pair of 
runners or mounting flanges 44, which extend along opposite sides of the 
panel 14 and run the length thereof. The runners 44 are oriented generally 
transverse to the plane of the central portion 42. 
The panel 14 may include a plurality of louvers 46 extending transverse to 
and between the runners 44, and score lines 48 in the runners 44 
corresponding to selected locations between the louvers 44. The score 
lines 48 facilitate separation of the panels 14 into shorter lengths 
according to the requirements of the particular installation. The runners 
44 slide into the track 28 of the side rails 12. The runners include 
L-shaped locking portions 49 which frictionally engage into the retaining 
channel 34. 
The center rail 20 includes a front wall 21 connected to runner portions 
59. The runner portions 59 extend rearwardly from the front wall 21 and 
transversely to the plane of the front wall 21. The runner portions 59 are 
slidably received into the channels 28. The runner portions 59 include 
hook portions 59c which are frictionally held within the retaining channel 
34. Recesses 59a, arranged between the front wall and the runner portions 
59, are sized and configured to receive the lips 36 of the side rails 12 
therein when the center rail or mullion 20 is installed. The front lips 36 
are received in the recesses 59a in a fashion similar to that shown in 
FIG. 6, wherein the front lip 36 is shown received into a similar recess 
51 of the end rail, as described below. The front wall 21 has a raised 
front surface 21a flush with the front surfaces 22a of the side rails when 
connected to the side rails 12. The raised front surface 21a is raised 
with respect to a front edge 59b of the runner portions 59. 
The top and bottom end rails or end caps, 16 and 18, respectively, are 
generally similarly formed. Each includes a front wall 50, and an end wall 
portion 52 formed adjacent and generally transverse thereto. The end wall 
portion 52 includes a pair of winglike extensions 54 which extend from the 
ends thereof, a distance sufficient to engage or cover the side rails 12. 
As shown in FIGS. 2 and 5, the end rails 16 and 18 each includes locking 
portions 56a, 56b which extends along each of two runner portions 58. The 
runner portions 58 extends rearwardly from and transverse to the front 
wall 50 at opposite ends of the front wall. 
As illustrated in FIGS. 2 through 6, between the front wall 50 and the two 
runner portions 58 are arranged longitudinal recesses 51 such that the 
front wall 50 includes a raised front surface 50a which is raised from a 
front edge 51a of the runner portions 58. The recesses 51 receive the lips 
36 of the side rails as shown in FIG. 6. In this manner the front surface 
50a of the front wall 50 is flush with, or planar with the front wall 
surfaces 22a of rail members 12 when installed. By providing the flush 
surfaces 50a and 22a a more attractive shutter is provided for 
architectural aesthetic appeal. 
The locking portions 56a, 56b include L-shaped hooks which have a shape 
complementary to the shape of the retaining channel 34 of the side rail 
12. The locking portions 56a, 56b are configured to interferingly, 
slidably engage the retaining channel 34 of the side rail 12 when the side 
rail 12 and end rails 16, 18 are assembled together. 
The end rails 16, 18 include a pair of aligning tabs 72 which depend from 
the wing-like extensions 54, and align the end rails 16, 18 with their 
associated side rails 12. Each tab 72 includes a reinforcing gusset 72a. 
The end rails 16, 18 also include L-shaped mounting flanges 74 which 
depend from the wing-like extensions 54, and have rear legs 74a which are 
oriented generally parallel to a shutter mounting surface. 
The mounting flanges 74 prevents or minimizes dimpling of the front wall 22 
due to over-driving of fasteners when mounting the shutter to the mounting 
surface. 
Extending from a back edge 26a of the outer wall 26 of each side rail is an 
L-shaped hook portion 27 which extends the length of the side rail 12. The 
L-shaped hook portion receives the aligning tab 72 of the end rail members 
as shown in FIG. 4. This engagement between the L-shaped hook portions 27 
and the aligning tab 72 provides a increases rigidity at the bottom of the 
shutter, particularly at the outer edges thereof. The side rails 12 are 
prohibited from separating from the end rails due to fastener 
overtightening into the mounting surface. Additionally, the L-shaped hook 
member 27 extends the entire length of each of the side rails 12 and adds 
bending rigidity to the rail members 12, as well as the entire shutter 
assembly 10 along its length. 
FIG. 7 illustrates a rear view of the end rail 18 engaged to two side rails 
12. On a rear side at the front wall 50 are reinforcing walls 86 which 
help rigidify the end rail 18 and the modular shutter 10. After assembly, 
the end rail 18 is permanently fixed to the side rails 12 by mechanical 
means such as by staples pushed through the inner wall 24 and the runner 
portion 58. 
Thus, there has been disclosed an aesthetically pleasing modular shutter 
having side rails, center rail and end rails with flush or planar front 
surfaces and which includes frictionally, interferingly engaging members 
which permit assembly of the shutter without extra fasteners, such as 
staples. The fastenerless modular shutter which incorporates side rails 
and end rails which are readily alignable and are configured to restrict 
and limit separation of the rails from each other prior to installation. 
From the foregoing, it will be observed that numerous variations and 
modifications may be effected without departing from the true spirit and 
scope of the novel concepts of the present invention. It is to be 
understood that no limitation with respect to the specific embodiments 
illustrated herein is intended or should be inferred. It is, of course, 
intended to cover by the appended claims all such modifications as fall 
within the scope of the appended claims.