Abstract:
An end cap for an H-shaped header bar used to secure a corrugated hurricane shutter attachable to a window frame and having a generally inverted U-shaped pocket adapted in size to receive an upper margin of the hurricane shutter and the end cap at each end of the header bar. The header bar cooperates with a lower support channel also attached to the window frame to support and secure the hurricane shutter over the window. An end cap is positionable and attachable within an inner upright side of the pocket to engage with the upper corner of the hurricane shutter preventing substantial lateral expansion movement or corrugation deformation from being struck by flying objects during heavy hurricane wind.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not applicable 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable 
     INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
     Not applicable 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to removable storm and hurricane shutters, and more particularly to an end cap dependently engagable within each end of an upper H-header for supporting the corners of a corrugated hurricane shutter. 
     2. Description of Related Art 
     Hurricane shutters have become extremely popular and useful in the hurricane prone sections of the country. Such hurricane shutters are typically deployed prior to an area coming under the influence tropical storm and hurricane weather conditions and serve to prevent damage to the glass windows and portal doors as a result of high winds and flying debris. 
     An example of such a storm shutter installation is disclosed in U.S. Pat. No. 4,685,261. This invention is primarily directed to a hurricane shutter which includes a lower support channel or bracket which is readily adaptable to a range of lower sill angles to which this portion of the storm shutter is attached. 
     A critical aspect with respect to this type of hurricane shutter, and with all hurricane shutters, is that it must meet stringent impact testing requirements before becoming approved for use as a hurricane damage preventative. One such test such hurricane shutters must pass is to withstand substantial deformity and damage from heavy object high speed impact. It has been shown that, although the polycarbonate corrugated hurricane shutter structure is generally adequate to withstand such impact, when incorporated into conventional H-headers for support, impact in the vicinity of the upper portions of the hurricane shutter results in excessive deformation of the corrugations and expansion of those corrugations, causing the structure to fail building code testing. 
     The present invention affords a simple end cap structure which is positionable within each end of an upper H-header for strengthening and stabilizing the shape of the upper corners of a corrugated polycarbonate hurricane shutter to eliminate excessive corrugation deformation in the upper corner areas and lateral expansion movement of the hurricane shutter which otherwise results in failure to comply with current building code testing procedure. 
     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 an end cap for an H-shaped header bar used to secure a corrugated polycarbonate hurricane shutter attachable to a window frame. The H-header has a generally inverted U-shaped pocket adapted in size to receive an upper margin of the hurricane shutter, with the end cap positioned in each end of the header bar. The H-header cooperates with a lower support channel also attached to the window frame to support and secure the hurricane shutter over the window. The end cap is dependently positionable within an inner upright side of the pocket to engage with the upper corner of the hurricane shutter, strengthening and preventing substantial movement from flying object impact during heavy hurricane wind conditions and building code testing therefor. 
     It is therefore an object of this invention to provide an end cap securable around each upper corner of a polycarbonate corrugated hurricane shutter and dependently positionable within the ends of the header to strengthen and prevent unacceptable upper corner deformation and expansion movement of the hurricane shutter during hurricane and tropical storm conditions. 
     It is therefore an object of this invention to provide an end cap securable around each upper corner of a polycarbonate corrugated hurricane shutter and dependently positionable within the ends of the header to strengthen and prevent unacceptable upper corner deformation and expansion movement of the hurricane shutter during hurricane and tropical storm conditions during building code testing procedures. 
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         FIG. 1  is a perspective exploded view of the present invention incorporated into each end of an H-header and supporting the upper corner of a corrugated hurricane shutter. 
         FIG. 2  is a simplified exploded top plan view of the upper right-hand corner of  FIG. 1  showing the H-header in phantom. 
         FIG. 3  is an exploded top plan view similar to  FIG. 2  showing another embodiment of the invention. 
         FIG. 4  is a perspective view of a third embodiment of the invention. 
         FIG. 5  is an end elevation view of  FIG. 4 . 
         FIG. 6  is a rear elevation view of  FIG. 4 . 
         FIG. 7  is a front elevation view of  FIG. 5 . 
         FIG. 8  is a perspective view of a fourth embodiment of the invention. 
         FIG. 9  is an end elevation view of  FIG. 8 . 
         FIG. 10  is a front elevation view of  FIG. 8 . 
         FIG. 11  is another end elevation view of  FIG. 8 . 
         FIG. 12  is a side elevation view of  FIG. 8 . 
         FIGS. 8A and 12A  show an alternate embodiment to that shown in  FIGS. 8 and 12 . 
         FIG. 13  is a perspective view of a fifth embodiment of the invention. 
         FIG. 14  is a top plan view of  FIG. 13 . 
         FIG. 15  is a front elevation view of  FIG. 14 . 
         FIG. 16  is a bottom plan view of  FIG. 14 . 
     
    
    
     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, and firstly to  FIG. 1 , a typical hurricane shutter is there shown generally at numeral A which includes a corrugated polycarbonate transparent hurricane shutter D supported along a lower horizontal margin thereof by an upright U-shaped lower channel E and, along an upper margin of the hurricane shutter D within an inverted downwardly extending H-header B. 
     The header B includes a pair of spaced apart side walls. The side walls are elongated in the width direction of the hurricane shutter A. An elongated traverse wall connects the pair of side walls to form the inverted downwardly extending channel. An end wall is positioned at either end of the pair of side walls to define a cavity formed in the H-header B. 
     Referring additionally to  FIG. 2 , absent the present invention which is shown generally at numeral  10 , the corrugations F of the hurricane shutter D simply sit within the upright side walls of the header B and are somewhat free to move laterally as well as front to back absent substantial support. However, the present invention  10  is positionable within the ends of the header B and fitted downwardly and entrappingly around the upper corner of each of the edge corrugations J. Note that the end cap  10  is not shown at the lower end of the header B for simplicity, but may be added. 
     The end cap  10  is formed of either extruded or roll-formed thin wall plastic or sheet metal material, and preferably polycarbonate for strength having an overall width that slidably engages into the header B shown in phantom in  FIG. 2 . The end cap  10  includes a housing  12  having a flat front wall  24  extending into an arcuate inner side wall  14  and an outer side wall  22  having an offset forming end stop  18 , the purpose of which is described herebelow. The housing  12  also includes an upright back wall  20  which, in combination with the end of the arcuate side wall  12 , forms an upright access slot  16  extending over the entire height of the housing  12 . The access slot  16  extends generally normal to the longitudinal direction of the pair of side walls of the header B. Further, the end cap  10  is positioned within the cavity of the H-header B adjacent the end wall. 
     The above housing configuration is sized and adapted to downwardly slide over the corner of the edge corrugation J as shown. The access slot  16  is slidable downwardly over the second arcuate portion K of corrugation J, the first flat corrugation J bearing against the inner surface of the back wall  20 , while the first arcuate portion L terminating at edge C, bears against the end stop  18 . The small gap  26  between the neutral portion N of the first corrugation provides very limited clearance or no clearance at all with a biased engagement against the arcuate portion  14  so as to establish a non-movable non-deforming arrangement laterally, while the front wall  24  and the rear wall  20  bearing against the corresponding upright sides of the H-header B prevent any fore and aft (or front-to-back) movement, thus fully entrapping the upper corner of the hurricane shutter D. Appropriate fasteners (not shown) may further interengage these mating upright front and back surfaces with the side walls of the H-header B as desired. 
     Referring now to  FIG. 3 , a second embodiment of the invention is there shown wherein the front upright surface  44  extends across a more substantial length of the housing  32  while still maintaining an end stop  38  for supportingly bearing against the upright edge C of the hurricane shutter D. As previously described, the flat M of the first corrugation J bears against the rear upright wall  40  while the first neutral portion N is closely spaced at  46  with respect to the arcuate inner side wall  34 . The outer side wall  42 , in combination with stop surface  38 , entraps the edge C of the hurricane shutter D. 
     Referring now to  FIGS. 4 to 7 , a third embodiment of the invention is there shown generally at numeral  50  and also includes a molded or extruded plastic or metal housing  52  having an arcuate inner side wall  54  which in combination with the upright back panel  60  forms the access slot  56  which functions as previously described. The combination of the stop surface  58  and the outer side wall  62  define an entrapment means similar to that previously described. The front upright surface  64  is again elongated similar to that shown in  FIG. 3 . 
     Referring now to  FIGS. 8 to 12 , a fourth embodiment of the invention is there shown generally at numeral  70  and also includes a molded plastic or metal housing  72  having an inner arcuate surface  74  blending uniformly from the front upright surface  84 . The back upright surface  80  defines, in combination with the end of the inner side wall  74 , the access slot  76 . The front upright wall  84  is of a length similar to that in  FIG. 3 , while the combination of outer upright side wall  82  and stop surface  78  define the entrapment means for the edge C of the upper corner of the hurricane shutter D as previously described. In this embodiment of the housing  72 , a solid top surface  86  is also provided as an end stop for the upper end corner of the first corrugation J of the hurricane shutter D for added stability. 
       FIGS. 8A and 12A  show an alternate embodiment of the invention shown at numeral  70  in  FIGS. 8 and 12 . This embodiment  70 ′ includes all of the features previously described in  FIGS. 8 and 12  with respect to embodiment  70 , except for the addition of a lead-in ramp  88  which extends diagonally into panel  88   a . This enlarges the size and breadth of the slot  76 ′ defined from the inner arcuate surface  74 ′. This lead-in ramp  88  and enlarged access slot  76 ′ greatly facilitate the assembly of this embodiment  70 ′ over the upper corner of the corrugated panel D. 
     Referring lastly to  FIGS. 13 to 16 , a fifth embodiment is there shown at numeral  90  having a molded plastic or metal thin wall housing  92  similar to that previously described. The front upright surface  104  blends into the convex arcuate inner side wall surface  94  and, in combination with the upright back wall  100 , defines the corrugation access slot  96  for the upper corner of the corrugated hurricane shutter D as previously described. 
     In this embodiment  90 , the housing  92  includes a reinforcing gusset  108  which does not interfere with the entrapment functioning of the outer end wall  102  in combination with the stop surface  98 . A panel  106  is positioned centrally along the height of this embodiment  92  which bears against the upper end of either of the corners of the corrugated hurricane shutter D so as to achieve ambidextrous structure, that is, this embodiment  90  will fit on either upper end of the corners of the hurricane shutter D. 
     All of the above described embodiments provide two important strengthening and building code qualifying aspects necessary for these polycarbonate corrugated hurricane shutters to both meet building code requirements and to adequately protect the contents and people within a so-protected building window structure. The first aspect is with respect to the deformation of the corner areas of the corrugated storm shutter which otherwise occurs causing test failure when struck by a high impact flying object. Additionally, when the corrugated hurricane shutter is struck in a central upper portion, the collapse of the corrugations in the impact area has been shown to otherwise lead to the lateral expansion of the structure in the vicinity of the upper corners causing test failure as well. The present invention both restrains the upper corners from corrugation deformation and restrains the overall corrugation structure from excessive lateral expansion by semi-rigidly restraining these corner areas from such outward lateral movement. 
     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.