Accordion-type transparent segmented shutter and shutter assembly

A shutter blade and blade assembly in an accordion shutter assembly used to protect a building opening from flying object damage caused by storm or hurricane. The blade assembly includes one or a plurality of preferably transparent or translucent plastic, preferably polycarbonate blades each having one molded edge defining a male hinge half and a slide-on metal female hinge half slidably engaged into the other edge of the shutter blade which is formed as a rail. The molded plastic male and slide-on metal female hinge halves have pivotally interacting features which matably engage with the corresponding edge of the next adjacent blade assembly to form the shutter assembly. Each blade assembly is preferably formed of a plurality of blades connectable together in an end-to-end arrangement and strengthened into a blade assembly by the preferably one-piece metal female hinge half.

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BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to accordion-type hurricane shutters and assemblies thereof which, when deployed, protect windows and doors from flying object impact during storms and hurricanes, and more particularly to such a shutter, which is segmented for manufacturing ease, having transparency which allows light to enter into the building while still being fully protectively deployed over such building openings.

2. Description of Related Art

Accordion-type shutter assemblies and roll-up shutter assemblies have become extremely popular for protecting the windows and doors, and thus the interiors, of buildings during severe storms and hurricanes. Flying objects, which, when airborne, can exceed well over one hundred miles an hour during a hurricane, are easily able to penetrate through unprotected doors and windows leading to more severe building damage as a result thereof.

One drawback has developed with respect to the added protection afforded accordion shutters and roll-up shutters in that more occupants are choosing to remain in the building during a storm or hurricane rather than evacuating the building. However, when the accordion shutter assemblies are deployed over windows and doors, very little light is allowed to enter into the building and, as a result, should electric power be interrupted, the occupants may find themselves in virtual total darkness.

The following prior patents are intended to alleviate this shortcoming of accordion-type shutter assemblies by providing transparency for at least a portion of each of the shutters of the assembly.

U.S. Pat. No. 4,345,635 to Solomon discloses a rolling protective gate or door for store fronts, building entrances or the like in which vertical rods or links are completely eliminated and in which the gate is not made in open grille form, but which provides a high degree of visibility therethrough when the gate is in the lowered position.

Snarli teaches a rollable or foldable shutter for protecting window areas where all or parts of the shutter are transparent in U.S. Pat. No. 5,456,305.

A combination blade of extruded aluminum and transparent impact plastic such as polycarbonate to protect glass windows and doors is disclosed in U.S. Pat. No. 6,546,681 to Trundle.

The present invention also provides an improved transparent shutter for accordion-type shutter assemblies for protecting windows and doors during storms and hurricanes. However, the present disclosure further teaches such an improved transparency feature without the need for the use of overmolding, adhesives, or additional mechanical fasteners to effect strong positive engagement between the metallic hinge half edge and the transparent blade provided by this invention. Moreover, this invention will more than adequately meet current impact test requirements for such accordion shutter assemblies as set forth in municipal building codes.

The foregoing examples of the related art and limitations related therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those skilled in the art upon a reading of the specification and a study of the drawings.

BRIEF SUMMARY OF THE INVENTION

This invention is directed to a shutter blade and blade assembly in an accordion shutter assembly used to protect a building opening from flying object damage caused by storm or hurricane. The blade assembly includes a preferably transparent or translucent plastic, preferably polycarbonate shutter blade having one molded edge defining a male hinge half and a slide-on metal female hinge half slidably engaged into the other edge of the shutter blade which is formed as a rail. The molded plastic male and slide-on metal female hinge halves have pivotally interacting features which matably engage with the corresponding edge of the next adjacent blade assembly to form the shutter assembly. Each blade assembly is preferably formed of a plurality of blades connectable together in an end-to-end arrangement and strengthened into a blade assembly by the preferably one-piece metal female hinge half.

It is therefore an object of this invention to provide an improved accordion-type shutter assembly and blade assembly therefor which facilitates light entering into a building opening protected by this invention.

Yet another object of this invention is to provide an improved shutter blade for accordion-type shutter assemblies for windows and doors which is easily assemblable and affords the necessary strength and security by these assemblies without the need for adhesives or mechanical fasteners to effect adequate assembly strength.

It is still another object of this invention to provide an improved accordion-type shutter assembly wherein each shutter blade is made up of a plurality of shutter blades which are connectable together in end-to-end fashion by transversely oriented interlocking end structure on opposite ends thereof.

The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative and not limiting in scope. In various embodiments one or more of the above-described problems have been reduced or eliminated while other embodiments are directed to other improvements. In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following descriptions.

Exemplary embodiments are illustrated in reference figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered to be illustrative rather than limiting.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, the invention is there shown generally at numeral10in a partially open, deployed orientation inFIG. 1and in a folded closed position inFIG. 2. The shutter assembly10includes a plurality of blade assemblies12, each of which includes a solid shutter blade panel14which is a mold formed of transparent, preferably polycarbonate plastic, and a metal, preferably aluminum extruded, metal female hinge half18. Each of the shutter blades14is mold formed as a unit to define a central transparent or translucent flat viewing panel22, a plastic male hinge half16molded along one side thereof, and an elongated T-shaped rail20molded along the other side of the blade14. The elongated rail20includes a first portion19and a second portion21. The first portion19extends outwardly from the blade14so as to be coplanar with the blade14and includes a proximate end connected to the other side of the blade14. The second portion21extends generally normal from said distal end so as to provide the elongated rail20with the T-shape. The male hinge half16and the elongated rail20are formed as one piece with the blade14and composed of the same material as the blade14. The male half hinges16include lightening holes38for economy and first hinge portion36.

The female hinge half18is formed as an aluminum extrusion and includes a hinge portion having a semi-circular cavity48as best seen inFIG. 10sized to lengthwise slidably receive each mating molded male hinge half16formed as a unit with each of the end-to-end-connected molded blades14. The female hinge half18also includes an inwardly extending channel or entrapping cavity46which lengthwise tightly slidably engages over the elongated rail20which has been mold formed as a single piece made of the same material as the blades14. The female hinge half18includes a pair of fingers54which defines the entrapping cavity46. The pair of fingers54are configured so as to provide the entrapping cavity46with a first section56and a second section58having a width in the W direction greater than the width of the first section56. The first section56receives the first portion19of the elongated rail20and the second section58receives the second portion21of the elongated rail. The engagement of the elongated rail20with the cavity46is such that the female hinge half18does not pivot relative to the blade14. The hinge halves16and18, when engaged as shown inFIGS. 4A and 4Ballow each of the blade assemblies12to freely pivotally move one to another between the closed position of the shutter assembly10inFIG. 4Aand the opened position inFIG. 4B. Tabs40,42and44formed onto the male hinge half16interengage with stops50and52of the female hinge half18to control the pivotal opening movement of the shutter assembly10.

Referring now toFIGS. 3 and 5to9, each of the blades14is preferably mold formed in shorter sections so as to facilitate overall quality and straightness of each of the molded blades14. Although typically a shutter blade as part of a shutter assembly has a length generally equal to the average height of the building opening, mold forming a plastic polycarbonate shutter blade of that length as a single molded unit while maintaining overall quality and transparent clarity is virtually impossible. Therefore, each of the blades14is mold formed in shorter lengths, typically in the range of about 18 inches long.

To interconnect each of these shorter shutter blades14together in end to end fashion, the blade14includes a first end tab24and a second end tab26which include a cavity28/30and a locking button32/34such that, which, when positioned end to end one to another, interlocking engagement of blades14together is accomplished by the locking button32/34being received within the cavities38/30. As best seen inFIG. 8, the first end tab24and the second end tab26are offset from said blade14in opposite directions. The first end tab24extending beyond the male half hinge16and the elongated rail20. The offset of the first end tab24and the second end tab26allows the adjacent blades14to connect such that the blades14extend coextensively as seen inFIGS. 1 and 2.

To provide an overall structural integrity for the plurality of blades14which are only pin-to-cavity connected as above described, the metal female hinge half18is extruded at the full length of each of the blade assemblies12. Thus, the metal hinge half18spans all of the junctions of the end to end positioned and interlocked blades14to serve as a backbone along each margin between each of the segmented blades14after assembly.

While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permeations and additions and subcombinations thereof. It is therefore intended that the following appended claims and claims hereinafter introduced are interpreted to include all such modifications, permeations, additions and subcombinations that are within their true spirit and scope.