Shutter assembly

A shutter assembly including a plurality of shutter panels arranged side-by-side. Each shutter panel has a respective plurality of louvers and a respective operable tilt mechanism configured to adjust the tilt angle of the respective plurality of louvers. A control shaft operates the tilt mechanisms. The control shaft is configured to drive simultaneously the respective tilt mechanisms of all of the plurality of shutter panels.

CROSS-REFERENCE TO RELATED APPLICATION

This application is claims priority to European Patent Application No. 14179373.7, filed Jul. 31, 2014, entitled “Shutter Assembly”, which is hereby incorporated by reference herein in its entirety for all purposes.

TECHNICAL FIELD

The present invention relates to a shutter assembly, in particular having a plurality of shutter panels arranged side-by-side with each shutter panel including a set of adjustable louvers, and a method of adjusting the tilt angle of respective sets of louvers in respective shutter panels of a shutter assembly.

BACKGROUND

It is known from the prior art to provide a plurality of shutter panels, each shutter panel having a set of louvers for which the tilt angle may be adjusted. US 2003/0159355 A describes an automatic louver actuating system including a plurality of louvered panels and a respective plurality of motors installed in those panels for controlling tilt of respective sets of louvers.

Motorising the louvered panels in this way is expensive, the weight of each panel is increased and available space for the louvers within the panel is reduced.

SUMMARY

It is an object of the present invention at least to reduce the problems associated with the previous motorised louvered panels.

According to the present invention, there is provided a method of adjusting the tilt angle of respective sets of louvers in respective shutter panels of a shutter assembly including operating a control shaft to drive simultaneously all of the respective tilt mechanisms of all of the plurality of shutter panels. When one or more sets of louvers are out of relative orientation with the single control shaft, because of one or both of them having been manually tilted or having been pivoted away from the control shaft with opening of the respective shutter panel, the method may include operating the control shaft between its two opposite ends of operation so as to relocate with any respective tilt mechanisms that have become out of relative orientation.

According to the present invention, there is provided a shutter assembly including a plurality of shutter panels arranged side-by-side, each shutter panel having a respective plurality of louvers and a respective operable tilt mechanism configured to adjust the tilt angle of the respective plurality of louvers. A control shaft may be provided for operating the tilt mechanisms. The control shaft may be configured to drive simultaneously all of the respective tilt mechanisms of all of the plurality of shutter panels.

In this way, the shutter panels themselves need not contain a motor. Instead, each tilt mechanism of a respective shutter panel is driven by the control shaft, the control shaft being shared by all of the plurality of shutter panels and being provided to drive all of the tilt mechanisms of the shutter panels. Because the individual shutter panels need not contain a respective motor, the weight of an individual shutter panel may be reduced. Similarly, space is not required within the shutter panel for a motor such that more of the area of the shutter panel may be taken up by the tiltable louvers.

Each shutter panel is a respective self-supporting structure. It includes the tilt mechanism and pivotable support for all of its louvers. It may include at least one edge member for partially or completely surrounding its louvers. The control shaft is provided externally of and separate to the plurality of shutter panels and may extend adjacent to all of the shutter panels and beside each of the shutter panels in their side-by-side arrangement.

With the plurality of shutter panels arranged side-by-side, the control shaft may extend either along the top or along the bottom of the side-by-side arrangement, thereby extending along the tops or bottoms of each of the plurality of shutter panels. The control shaft may preferably be rotatable about its own axis. The louvers may tilt/rotate about axes extending in the side-by-side direction substantially parallel with the control shaft.

The shutter assembly may further include a plurality of respective actuators for the plurality of respective shutter panels. Each respective actuator may be configured to engage with a respective tilt mechanism. Each respective actuator may also be operable by the control shaft to drive the respective tilt mechanism of the respective actuator.

In this way, although a single control shaft is provided for operating all of the tilt mechanisms of the plurality of shutter panels, individual respective actuators, each operable by the control shaft, may be provided to drive the respective tilt mechanisms of the plurality of shutter panels.

The shutter assembly may further include a respective gear mechanism for each respective shutter panel for converting rotational movement of the control shaft to translation of a respective actuator.

Translation of an actuator, in other words movement in a longitudinal or lateral direction, may be used to operate a respective tilt mechanism so as to tilt the plurality of louvers of the respective shutter panel.

Each respective actuator may extend towards the respective shutter panel. Each respective actuator may be configured to translate parallel to a plane defined by the respective shutter panel and thereby drive the respective tilt mechanism.

Each respective tilt mechanism of each respective shutter panel may include a respective tab which extends towards a respective actuator. The tab is provided for engagement with a respective actuator and is operable by the respective actuator to drive the respective tilt mechanism.

The shutter assembly may further include a frame supporting the plurality of shutter panels. In this case, the actuators may be provided extending from the frame towards the respective shutter panels.

The control shaft may extend within a portion of the frame, for instance at the top or bottom of the side-by-side arrangement of the shutter panels. Also, the plurality of respective gear mechanisms, if provided, may be provided within that portion of the frame.

Thus, a plurality of respective actuators, operable by the control shaft, may be provided extending to each of the respective shutter panels to operate the respective tilt mechanisms. Each actuator may translate parallel to a plane defined by the respective shutter panel, namely the plane of the frame when a frame is provided for the plurality of shutter panels. In one arrangement, the actuator may translate towards and away from a respective shutter panel along its own length substantially perpendicular to the side-by-side arrangement and the axes of rotation of the louvers. Each actuator may engage with a respective tab provided on a tilt mechanism for operating that respective tilt mechanism.

Although the control shaft enables simultaneous operation of all respective tilt mechanisms, it may be desirable for a user to change manually the tilt angle of the set of respective louvers of a respective shutter panel.

In this respect, the shutter assembly may further include a plurality of respective clutches formed between the respective tilt mechanisms and the control shaft. Each respective clutch may provide engagement or allow selective relative slip between a respective tilt mechanism and the control shaft. In one embodiment, respective clutches selectively provide output from the control shaft to respective shutter panels. The clutches may provide engagement between the control shaft and the tilt mechanism until a breakaway resistance has been overcome or may selectively provide engagement. In one arrangement, the clutches may be provided as electromagnetic clutches for selectively providing engagement. Where the control shaft is driven by a motor, the respective clutches can be configured to provide engagement when the motor is operated.

Where respective actuators, as defined above, are provided in the shutter assembly, the clutches may be provided respectively between the control shaft and the actuators, for example between the control shaft and respective gears for operating the respective actuators. Alternatively, the clutches may be formed respectively between the actuators and their respective tilt mechanisms. The respective clutches may thus form respective engagements between the respective tilt mechanisms and the respective actuators.

In this way, a user may manually/directly adjust the tilt angle of a respective plurality of louvers during engagement of the clutches or by forcing movement of the tilt mechanism against the resistance of the respective clutch so that the respective tilt mechanism operates/moves relative to the control shaft.

The clutches may provide a breakaway resistance at all respective relational positions between the tilt mechanism and the control shaft. Alternatively, a clutch may provide substantially no breakaway resistance at any relational position other than one particular relational position. Thus, when the position of the control shaft and the state of a respective tilt mechanism for a particular tilt angle has a predetermined relationship, then the clutch engages the control shaft with the respective tilt mechanism up to a breakaway resistance. Providing a force to the louvers to overcome the breakaway resistance allows the respective tilt mechanism and the tilt of the louvers to change relative to the control shaft and then freely move.

Each respective clutch may include a mechanical engagement. Additionally or alternatively, each respective clutch may include a magnetic engagement. The engagement may alternatively be electromagnetic and be controlled to selectively allow slip.

Respective clutches may be provided between respective actuators and respective tilt mechanisms, selectively connecting actuators to respective tilt mechanisms. Respective clutches may also or alternatively be provided at the output of the control shaft between the control shaft and the respective actuators.

Where respective actuators are provided for respective shutter panels and those actuators operate respective tilt mechanisms by translating towards and away from a respective shutter panel substantially perpendicular to the axes of the louvers, each respective actuator may include one of a recess or a protrusion for engaging with a mating protrusion or recess respectively in a portion of the respective tilt mechanism. Where the tilt mechanism is provided with a tab, the mating respective protrusion or recess may be provided by that tab. This arrangement is useful for when the tilt mechanism, with its respective shutter panel, pivots away from its frame or architectural support. The tilt mechanism and actuator easily disengage and can re-engage when the shutter panel is swung shut again.

During operation of the shutter assembly, by operating the control shaft between two opposite limits for opposite tilts of the plurality of louvers, it is possible to ensure that any disengaged mating protrusions and recesses are reengaged so that, once again, the control shaft can operate the respective tilt mechanisms and louvers.

While the mating protrusion and recess are engaged with one another, translation of the actuator under control of the control shaft will operate the respective tilt mechanism. However, manual direct operation of the louvers and the respective tilt mechanism can be used to overcome the breakaway resistance of the mated protrusion and recess so that the protrusion and recess become disengaged from one another, thereby allowing the respective plurality of louvers and tilt mechanism to operate independently of movement of the control shaft. Alternatively, if clutches are provided at the output of the control shaft, the protrusions and recesses may remain engaged whilst manual operation is achieved by slip of the respective clutches.

One or both of the respective protrusion and recess may be a magnetic component. This improves positive engagement between the protrusion and recess.

At least one shutter panel of the plurality of shutter panels may be pivotably supported. Where the shutter assembly includes a frame for supporting the plurality of shutter panels, that at least one shutter panel may be pivotably supported by the frame. The at least one shutter panel may be pivotable, with respect to the frame where appropriate, from a closed position in which the at least one shutter panel defines a plane and an open position with the at least one shutter at least partially extending from the plane. Where the shutter panels are supported by a frame, the plane will also be the plane of the frame.

Preferably, when the at least one shutter is in a position pivoted from the closed position, the respective tilt mechanism of the at least one shutter panel is pivoted away from the control shaft so that the respective tilt mechanism of the at least one shutter panel and the control shaft are disengaged.

In this way, the control shaft and any associated components need only be configured to operate louvers of shutter panels which are in their closed positions within the plane of the frame.

Where a plurality of respective actuators are provided, when the at least one shutter is in a position pivoted from the closed position, the respective tilt mechanism of the at least one shutter panel is preferably pivoted away from the respective actuator so that the respective tilt mechanism of the at least one shutter panel and the respective actuator are disengaged.

Engagement between a respective tilt mechanism and the respective actuator may be provided by the means as explained above. In other words, when a shutter panel is in the closed position, the clutch may be engaged by the respective actuator engaging with the respective tilt mechanism, for example its tab. Pivoting the shutter panel away from its closed position preferably results in the tilt mechanism, for example its tab, pivoting away from the actuator and, hence, becoming disengaged. For example, the respective mating protrusion and recess are moved apart in the direction in which the protrusion protrudes into the recess and there is no need to overcome the breakaway resistance.

In addition or alternatively, each respective shutter panel may be provided with a respective connector for operably connecting drive of the control shaft to the respective tilt mechanism when the shutter panel is in the closed position and to disconnect drive of the control shaft to the respective tilt mechanism when the respective shutter panel is in a position pivoted away from the closed position.

Each respective connector may be constructed similarly to the clutch described above and may include one or both of a mechanical engagement and a magnetic engagement.

Although the control shaft could be operated manually, the shutter assembly may include a motor configured to rotate the control shaft. The motor may be provided within a portion of the frame, for example in the same portion as that in which the control shaft is provided.

Each louver may be tiltable about a respective longitudinal axis extending longitudinally along the louver and the louvers of a respective plurality of louvers may be arranged in a side-by-side array with the respective longitudinal axes parallel. The side-by-side array of louvers may be perpendicular to the side-by-side arrangement of the shutter panels.

Each louver may include, at one longitudinal end of the louver, a louver gear rotatable with the louver and rotatable about the respective longitudinal axis of the louver for tilting the louver. Each respective tilt mechanism may include a rack bar extending substantially perpendicular to the louvers of a respective plurality of louvers and engaging with the respective louver gears of the respective plurality of louvers such that the louvers of the respective plurality of louvers tilt together.

The tab, where provided, may be provided on or as an extension of the rack bar.

Each respective shutter panel of the plurality of shutter panels may include a respective edge member. The respective tilt mechanism of the respective shutter panel may be housed within the respective edge member.

The tab, where provided, may extend through and protrude from a face of the respective edge member, for example for selective engagement with a corresponding respective actuator.

DETAILED DESCRIPTION

A shutter assembly can be constructed with a plurality of shutter panels, each shutter panel having a plurality of slats or louvers mounted in stiles of the shutter panel.

FIG. 1illustrates three such shutter panels2arranged side-by-side. Each shutter panel2includes a respective plurality of louvers4and respective edge members6forming stiles for supporting the louvers4. As illustrated, the louvers4have a longitudinal extent in a horizontal direction and are arranged as a side-by-side array in a vertical direction. Thus, in the illustrated arrangement, the respective side-by-side arrays of louvers4are perpendicular to the side-by-side arrangement of shutter panels2. The louvers4are pivotable about longitudinally extending axes so as to open or close respective shutter panels.

The shutter panels2may be individually mounted adjacent to one another in an architectural opening or may be provided within a frame8as illustrated inFIG. 2.

So that all of the slats or louvers4of a respective shutter panel2operate/tilt together/simultaneously, a tilt rod may be provided to connect together all of the louvers4of a respective shutter panel2. Such a tilt rod may be provided centrally with respect to the longitudinal extent of the louvers4or offset to one side. This type of tilt mechanism may also be provided hidden from view, for example behind the louvers, whereby a user manually operates the plurality of louvers4of a shutter panel2by manually adjusting one of the louvers4(and thereby adjusting the tilt of all of the louvers4for that respective shutter panel2). The tilt mechanism may be hidden inside the edge member or stile of the shutter panel2. One such tilt mechanism is described in US 2005/0252086.

FIG. 3illustrates an appropriate tilt mechanism10. Rack gear portions12are provided at appropriate intervals along opposing respective rack bars14. At one longitudinal end of each respective louver4, a respective louver gear16is rotatable with the louver4. In other words, by rotating a louvered gear16by a certain angle, the corresponding respective louver4will be tilted by that same angle. At least one of the two rack bars14is moveable/translatable along its length so as to rotate simultaneously all of the louver gears16and, hence, tilt all of the corresponding louvers4. As illustrated, the tilt mechanism10can be housed within a stile18forming an edge member6supporting the corresponding respective plurality of louvers4.

FIG. 4illustrated schematically an embodiment of the present invention in which a single control shaft20is operable to drive simultaneously the tilt mechanisms of each one of a plurality of shutter panels2.

As illustrated, the control shaft20extends alongside each one of the plurality of shutter panels2. In this way, it is able to interact with and drive the tilt mechanisms housed within each of the shutter panels2. The control shaft20, in other words, extends alongside the side-by-side arrangement of shutter panels2.

The control shaft20may provide drive to the respective tilt mechanisms of the shutter panels2by itself moving in any effective manner, for example up/down, left/right or back/forward along its elongate length. However, in a preferred embodiment, as illustrated, the control shaft20is rotatable about an axis extending along its length.

The control shaft may be provided as a single integral unit or may be provided as a plurality of co-operating parts, optionally interlocking with each other. For example, each shutter panel2could have a respective sub-shaft or piece which co-operates and/or interlocks with the other sub-shafts or pieces to form the control shaft.

In the illustrated embodiment, the control shaft20extends above a horizontal side-by-side arrangement of shutter panels2, but it could also be arranged below this arrangement. Also, for a vertical side-by-side arrangement of shutter panels, a control shaft could be arranged vertically on either the left or right side of the arrangement.

As illustrated, respective transfer mechanisms22are provided for transferring drive from the control shaft20to each respective one of the shutter panels2.

In accordance with the description ofFIG. 2, the shutter panels2can be supported in a frame8. With such an arrangement, the control shaft20may be housed within a portion of the frame8, for example the upper portion as illustrated schematically inFIG. 5. Each transfer mechanism22may then extend between and be distributed across the interface between the frame8and the respective shutter panels2.

In some embodiments, the control shaft20could be manually operated, for instance by means of a user-operable control rod or looped control cord or chain.

FIG. 6illustrates schematically a preferred embodiment where a control motor24is additionally provided within the frame8. This is a significant advantage over arrangements where individual respective motors are provided in each respective shutter panel.

A gear box26may be provided for transferring rotation of the motor24to movement of the control shaft. Where the control shaft rotates, it is possible that the gear box need only provide 0.5 revolutions for the control shaft.

As illustrated, the motor24is provided in the same portion of the frame8as the control shaft20. It will be understood that, with an appropriate transfer mechanism, the control motor24could be provided in any other portion of the frame8.

It should also be understood that the arrangement described with reference toFIG. 4could also use a motor to operate the control shaft20.

FIG. 7(a)illustrates a possible arrangement for each respective transfer mechanism22. For each respective shutter panel2, there is provided a pinion gear27rotatable with the control shaft20. A respective actuator or actuator arm28engages with and is driven by the pinion gear27by virtue of a series of teeth30on one side of the actuator arm28transforming the actuator arm28into a rack. By rotating the control shaft20and pinion gear27in one direction or the opposite direction, it thus becomes possible to translate the actuator arm28up or down respectively. The actuator arm28drives a respective tilt mechanism so as to tilt the louvers4of a corresponding respective shutter panel2.

FIG. 7(b)illustrates a development of the arrangement ofFIG. 7(a)in which a clutch device29is provided between the pinion gear27and rotation of the control shaft20. The clutch device29may selectively transfer rotation between the control shaft20and the pinion gear27or may allow relative rotation. In one example, the clutch may be an electromagnetic clutch which is controllable to selectively transfer rotation or allow relative slip. Where a motor is provided to drive the control shaft20, the clutch device29may be controllable with the motor so that, when the motor is operated to rotate the control shaft20, the clutch device29locks the rotation of the control shaft20to rotation of the pinion gear27and, when the motor is not operated, the pinion gear27is free to rotate relative to the control shaft20. In this way, when the motor is not operated, a user may freely adjust the tilt of louvers manually. After a set of louvers has been tilted manually and then the motor and control shaft20is operated, in order to bring all of the louvers of the shutter panels back into alignment, the motor may operate the control shaft20beyond full tilt of the louvers so that the respective clutch devices29allow slip between the control shaft20and the louvers until the louvers of all the shutter panels are all aligned.

In certain embodiments, in particular where shutter panels are fixed within an architectural opening and manual operation of the louvers is not required, a respective actuator arm28can be formed integrally with the respective tilt mechanism, for example as an extension of part of the tilt mechanism, such as a rack bar14in the arrangement ofFIG. 3.

For ease of assembly, it may be preferable for the actuator arm28and a portion of the tilt mechanism to be provided separately and engaged with one another during installation. There are also advantages in some arrangements for allowing the actuator arm28to engage and disengage with the tilt mechanism.

FIG. 8illustrates schematically an actuator arm28extending from a frame8, together with a tab32extended from a respective tilt mechanism and for engagement with the actuator arm28. A similar arrangement may be provided for the example ofFIG. 4where shutter panels are mounted directly in an architectural opening.

As illustrated, the actuator arm28includes a recess34and the extended tab32includes a corresponding respective protrusion36. It will be appreciated that this arrangement can be reversed with a protrusion provided on the actuator arm28and the recess formed in the extended tab32. The extended tab32engages with the actuator arm28by inserting the protrusion36into the recess34. When rotation of the control shaft20causes the actuator arm28to translate up and down parallel with its longitudinal extent, engagement of the protrusion36in the recess34causes the extended tab32similarly to translate up and down and operate the respective tilt mechanism.

One or both of the actuator arm28and extended tab32may be configured to allow some movement away from each other, so as to allow the protrusion36to disengage from the recess34. The mounting mechanism for one or both of the actuator arm28and extended tab32may allow for this relative movement and/or the components may have sufficient resilient qualities to provide this.

FIGS. 9(a) and 9(b)illustrate schematically the arrangement in an engaged and disengaged state respectively.

In the engaged state ofFIG. 9(a), rotation of the control shaft20and the pinion gear27clockwise or anticlockwise will cause the actuator arm28to move downwards or upwards respectively. The protrusion36of the extended tab32engages in the recess of the actuator arm28and is similarly moved downwards or upwards respectively. In this way, the respective tilt mechanism is operated.

With this illustrated arrangement, the extended tab32can disengage from the actuator arm28. This is useful for embodiments as described below with reference toFIGS. 10 and 11where a shutter panel2is swung open. Also, once a sufficient force is applied to the extended tab32, it may force the protrusion36and recess34to become disengaged from one another, eg by resiliently flexing away from one another, such that the extended tab32and corresponding respective tilt mechanism may operate independently of the control shaft20. This allows a user manually to tilt a set of louvers4of a respective shutter panel2irrespective of use of the control shaft20. As illustrated, the actuator arm28includes a surface38upon which the protrusion36can slide in the disengaged state as illustrated inFIG. 9(b).

In order for the control shaft20once again to regain control of all of the respective tilt mechanisms, it is sufficient to operate the control shaft20and all of the respective pinion gears27and actuator arms28between the full range of operation. In this way, all of the actuator arms28will inevitably re-engage with any of the extended tabs32which have been placed in a disengaged state as illustrated inFIG. 9(b).

Engagement between the actuator arm28and extended tab32may alternatively or additionally be achieved using one or more magnetic components. In the arrangement illustrated inFIGS. 9(a) and (b)a magnet40is provided at the base of the recess34and the protrusion36is formed from a magnet. One of these respective magnets could be replaced with a non-magnetised ferrous material.

The actuator arm28and extended tab32described above may not only form a respective connector connecting drive of the control shaft20to the respective tilt mechanism, but may also, with functions as described above forFIG. 7(b), provide a respective clutch allowing, where required, relative movement between the control shaft20and the tilt mechanism. The functions of the clutch could alternatively be provided at some other position between drive of the control shaft20and the tilt mechanism such as described with reference toFIG. 7(b)where a respective clutch is provided between each respective pinion gear27and the control shaft20. In the clutch formed between the protrusion36and recess34as described with reference toFIGS. 8 and 9, engagement is provided at one position and slip is allowed in all other positions. It is also possible to provide a clutch where engagement is provided in all relative positions, but slip becomes possible in all of these relative positions once a required predetermined force is applied. To return to a state where the control shaft20has full control of all of the louvers of all of the shutter panels2in the same orientation, it would be sufficient for the control shaft20to rotate enough to tilt all of the louvers4from one extreme angle to the other. In this way, the respective sets of louvers4will be tilted until they reach their full angular tilt. Further rotation of the control shaft20will cause slip at the respective clutch for a set of louvers4that has reached its full tilt angle and remaining sets of louvers4will continue to tilt until they also reach their full tilt angle.

It may be desirable for individual shutter panels2to be pivoted from the plane of their normally closed orientation, for example the plane of the frame8, to an open position with that shutter panel2extending out of the plane. This is illustrated inFIG. 10. Although it would be possible to provide an actuator arm which translates along the pivot axis of a shutter panel2so that the control shaft20is able to operate the louvers4of a shutter panel2irrespective of its position (between closed and open positions), this may be an unnecessary level of complication noting that, usually, when a shutter panel2is open, a user will not require operation of the respective set of louvers by the control shaft20.

FIG. 11illustrates an arrangement using a connection between an actuator arm28and an extended tab32similar to that described with reference toFIG. 8. In the illustrated arrangement, the extended tab32is housed within an edge member or stile6of the shutter panel2. The edge member6defines an elongate aperture42through which the protrusion36extends. The protrusion36of the extended tab32is able to move up and down along the extent of the aperture42so as to operate the tilt mechanism housed within the shutter panel2. When the shutter panel2is pivoted to its closed position, the protrusion36swings into engagement with the recess34of the actuator arm28. In particular, movement of the shutter panel2immediately into or out of its closed position is substantially parallel with the axis of protrusion between the protrusion36and recess34. In the manner described above, if the protrusion36happens to be out of alignment with the recess34, operation of the control shaft20between its full opposite rotational positions will cause the protrusion36to become engaged in the recess34. The arrangement may additionally provide the feature of a clutch allowing a user to manually operate a set of louvers4irrespective of the control shaft20or, alternatively, the arrangement may be intended merely to re-engage the protrusion36of the extended tab32with the recess34of the actuator arm28.

In the illustrated arrangement, the transfer mechanism formed by the actuator arm28and extended tab32is provided at a portion distant from the pivot of the shutter panel2. In this way, the extended tab32and actuator arm28become disengaged with only a small angular opening of the shutter panel2. Arrangements are possible with the transfer mechanism located closer to the pivot of the shutter panel2, but larger opening angles may be required to ensure full disengagement.

FIGS. 12(a) to (d)illustrate an example of a practical arrangement of a transfer mechanism22providing the features of connector and clutch described above.