Abstract:
A shutter includes top and bottom frames as well as interconnecting perpendicular styles between which a plurality of louvers are pivotally mounted. Each louver has a first tap in its opposite ends for receipt of a pivot pin and a second tap in at least one end for receipt of a tilt pin for pivotal interconnection with a tilt bar. The tilt pins are positioned adjacent to one longitudinal edge of a louver whereby the tilt bar can be easily fastened thereto and positioned adjacent a longitudinal end of the louvers.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims the benefit of U.S. provisional application Ser. No. 60/607,038 filed Sep. 2, 2004, which application is hereby incorporated by reference as if fully disclosed herein. 

   FIELD OF THE INVENTION 
   The present invention relates generally to a tilt bar for controlling the louvers of a shutter for coverings for architectural openings and more particularly to a tilt pin for attachment of the tilt bar to the louvers. 
   DESCRIPTION OF THE RELEVANT ART 
   Generally, a tilt bar is used to control louvers in a shutter for a covering in an architectural opening. The tilt bar may be connected to the louvers in such a manner as to enable the louvers to be opened or closed simultaneously thereby maintaining an equal spacing and orientation among the louvers. 
   Several different means for attaching a tilt bar to the louvers in a shutter are well known. In one example, U-shaped staples are attached to the longitudinal louver edge with a complimentary U-shaped staple at the rear edge of a wooden shutter bar. These staple-like fasteners may be hammered into the louver at the center of the louver or applied from a staple gun. This type of fastening has several disadvantages. One being that the staple-like fastener may split the wood, requiring the louver to be discarded and replaced, at a loss of both time and expense. Another disadvantage is that the connection between the staple-like fastener in the louver and tilt bar is very loose. The loose attachment is noisy and allows the tilt bar to drop against the bottom bar causing wear thereto. 
   Another example of attachment of a tilt bar to the louvers is fixedly fastening the tilt bar to the inside longitudinal edge of the louver. A wood screw- or nail type fastener may be used to fixedly attach the tilt bar at an opening adapted to receive the screw fastener or nail at the longitudinal edge of the louver. In this example, the screw may loosen over time from use. Consequently, the tilt bar becomes loose enough to interfere with the stile causing unnecessary wear thereto. 
   It is to overcome such shortcomings in prior art connection systems that the present invention was developed. 
   SUMMARY OF THE INVENTION 
   The above discussed and other problems are solved by the shutter control system of the present invention. The invention provides an improved tilt bar with longitudinally-spaced connectors that may be efficiently clipped to tilt pins on the ends of the louvers in the shutter which are adapted to receive the connectors. The tilt bar is therefore attached at a longitudinal end of the louver rather than at the center of the louver, thus improving the view through the louvers. In addition, the tilt bar of the invention may be located adjacent to a rearward edge of the louvers. 
   Architectural openings typically have a frame therearound and the shutter is installed to fit within the frame. Shutters comprise two vertical stiles in parallel relationship to each other, a horizontal head bar, a horizontal bottom bar, and a plurality of horizontal louvers attached in spaced, parallel relationship to the stiles. The stiles, head bar and bottom bar cooperatingly fit within the frame of the architectural opening. 
   The system of the present invention in one embodiment comprises a combination of the tilt bar and dual headed pins that are used to control the position of the louvers. The tilt bar is positioned at one longitudinal end of the louvers and may be attached adjacent to the rearward edge of the louvers. Each louver is prepared for installation in the stiles. Preparation is completed by pre-drilling each louver at two locations to create a first tap opening and a second tap opening at each end of the louver. The end of the louver as used herein is defined as the end of the louver that is adjacent to the stile and perpendicular to the longitudinal axis of the louver. It is to be understood that the description of positioning the first and second taps in the louver is at both ends and to the plurality of louvers equally. Thus, the description at one end is understood to mean it is to be applied to the additional end of each louver and plurality of louvers as well. 
   The first tap is positioned at the center of the end of the louver for receiving a longitudinally-extending pivot shaft or dowel. The pivot shaft or dowel provides for pivotable attachment of the louver to the stile and is parallel to the longitudinal axis of the louver. The second tap is positioned at a location other than at the center of the end of the louver. The second tap is adapted for receiving a dual headed tilt pin. It will be appreciated the second tap is positioned so as to provide the best leverage to rotate the louver, namely at a position maximally spaced from the first tap. The louvers are then installed into the stiles. The assembly is completed when the head bar and bottom bar are connected to the stiles. Next, dual-headed tilt pins having first and second axially spaced heads are press fitted into the second tap at one end of the louver. The second head serves as a stop to limit the distance the pin may be inserted. Moreover, each dual headed pin has a knurled portion thereon which grips the wall of the second tap to prevent the pin from being easily withdrawn. Once the pin is inserted up to the extent of the second head, a portion of the pin remains exteriorly of the louver end. Thus exposed, the spacing between the first head and second head defines a neck. The neck has a diameter adapted to receive and cooperate with a connector on the tilt bar. 
   The tilt bar has open-ended connectors, preferably in the form of sockets, equally spaced thereon. The open ended sockets have a plurality of arms that form an oval opening for capturing the neck of the dual-headed pin. The arms are resilient to enable them to spread open so as to releasably capture the neck. As will be appreciated, the equal vertical spacing of the louvers in parallel relationship between the stiles also place the dual heads of the tilt pins on the louvers in a vertically spaced relationship. The spaced relationship of the pins is adapted to that of the spaced relationship of the open ended sockets on the tilt bar. Thus, in this relationship, the open ended sockets of the tilt bar “clip” to the necks of the dual headed tilt pins so as to form a releasable attachment therewith. Moreover, once the tilt bar is attached to the plurality of tilt pins, translation of the tilt bar tilts the plurality of louvers or pivots the louvers about longitudinal axes. 
   In another embodiment of the invention, the system comprises a single headed tilt pin and a tilt bar having a closed connector in the form of a socket. The combination of the tilt bar and tilt pins cooperate to control the positions of the louvers. The preparation of the louver is as was discussed above. However, in this embodiment, the tilt bar is attached to the louver by the single-headed tilt pin. The tilt bar accepts the tilt pin through an opening in the closed socket of the tilt bar. The opening of the closed socket is of oval shape and adapted to fit the neck of the single headed tilt pin. The tilt bar captures the pin at the socket in the tilt bar so as to attach the tilt bar to the louver. A raised surface adjacent the single head is adapted to be a bearing surface for movement of the tilt bar. Knurled surfaces of the single headed tilt pin grip the inside wall of the second tap to prevent the pin from being easily withdrawn from the second tap. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an isometric of a shutter showing a cut-away of the invention attached to the louvers. 
       FIG. 2  is a fragmentary front elevation of the louvers in the shutter of  FIG. 1  and their respective pivot points and fastener locations. 
       FIG. 3  is a section taken along line  3 - 3  of  FIG. 2 . 
       FIG. 4  is a section similar to  FIG. 3  showing translation of the louvers by the tilt bar. 
       FIG. 5  is a section similar to  FIG. 3  showing translation of the louvers by the tilt bar in a different direction. 
       FIG. 6  is a section similar to  FIG. 5  with the louvers in a different position. 
       FIG. 7  is a side elevation of the tilt bar. 
       FIG. 7A  is an enlarged fragmentary section showing a socket portion of the tilt bar. 
       FIG. 7B  is a front view of a socket in the tilt bar with a tilt pin therein. 
       FIG. 7C  is a front view similar to  FIG. 7B  with the tilt pin in a different location. 
       FIG. 7D  is a section through a louver with a tilt pin therein. 
       FIG. 8  is an exploded view of the tilt bar, tilt pin and louver. 
       FIG. 9  is a fragmentary isometric of the tilt bar and socket after attachment to the tilt pin. 
       FIG. 10  is an isometric of the tilt pin. 
       FIG. 11  is a longitudinal section of a tilt pin. 
       FIG. 12  is a fragmentary section showing two tilt bars connected to a tilt pin in a louver. 
       FIG. 13  is a front elevation of an alternative embodiment of tilt bar. 
       FIG. 14  is an enlarged fragmentary front elevation of a closed socket used in the tilt bar of  FIG. 13 . 
       FIG. 14A  is a view similar to  FIG. 14  with a tilt pin in the closed socket. 
       FIG. 15  is a side view of an alternative embodiment of the tilt pin. 
       FIG. 16  is a fragmentary side elevation of the head of the pin of  FIG. 15 . 
       FIG. 17  is a side elevation of a tilt pin similar to that of  FIG. 15  connecting a tilt bar to a louver. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIGS. 1-6  illustrate the tilt bar of the invention in relation to a shutter.  FIG. 1  shows the front of a shutter  50  for covering an architectural covering. Shutter  50  comprises stiles  10 , a head bar (not seen) a bottom bar  83 , a plurality of louvers  40  and a tilt bar  100 . The tilt bar  100  is shown in its closed position with louvers  40  tilted in a substantially vertical or closed position. As will be appreciated from  FIGS. 3-4 , movement of the tilt bar in an upward direction pivots the louvers in a clockwise direction through an open position and ultimately into a closed position. As seen in  FIG. 6  in the closed position, the louvers abut one another. 
   As shown in  FIG. 1 , the louvers  40  are pivotally attached to the stile  10  by pivot shafts or louver pins  60  preferably at the transverse center of the longitudinal ends of the louvers so as to enable pivotal rotation about the longitudinal axis of the louver upon movement of the tilt bar  100 . Each louver has two longitudinal ends. The length of the louver is variable as is necessary to span the distance between the stiles so that each end  45  of a louver can be pivotally supported by a stile. The ends  45  of the louver are adjacent to the stiles. For purposes of this description and the descriptions of the locations of drillings, hereafter referred to as taps, it will be assumed each end of the louver receives the same taps. Each louver receives a first tap  55  at each end  45  at its center of rotation so as to receive a pivot shaft or louver pin  60 . The first tap is preferably transversely centrally located at the ends  45  of the louver to enable the louver to rotate about a longitudinal axis. Next, as seen in  FIGS. 2 and 3  a second tap  65  is positioned in the ends  45  at a location proximal to the louver&#39;s longitudinal edge. The placement of second tap  65  is located on the ends  45  of a louver to provide a mechanical advantage when pivotal movement of the louver is desired. The second tap  65  at one end of the louver is adapted to receive a tilt pin  90 . The attachment of the tilt pin will be discussed below. The second taps are provided in both ends of a louver to provide a choice as to which end will receive the tilt pin therefore determining on which end the tilt bar will be mounted. 
   In  FIGS. 8 and 9 , the tilt bar  100  can be seen to be releasably attached to a tilt pin  90 . The means for attachment is a clipping socket  120  formed on the tilt bar  100 . The point of attachment for socket  120  to tilt pin  90  is at a neck  93  defined on the tilt pin ( FIG. 11 ). The socket  120  of the tilt bar  100  will be discussed below. 
   As is shown in  FIGS. 10 and 11 , the tilt pin  90  is generally cylindrical having a first head  91  and an axially spaced second head  92  at one end. The tilt pin  90  may be constructed from metal, polycarbonate, or other suitable material. A neck  93  is defined in the longitudinal space between the first head  91  and the second head  92 . Further, the neck  93  is kept cylindrical so as to provide a bearing surface for a socket  120 . As will be appreciated, the second head  92  serves to limit the extent that the tilt pin  90  may be inserted into the second tap  65 . Pressing the tilt pin  90  into the second tap  65  may only be up to the second head  92 . Thus, as the tilt pin  90  is pressed to the limit of the second head  92 , the first head  91  and the second head  92  as well as the neck  93  remain exteriorly of the second tap  40 . In this position, the neck  93  is exposed to receive a socket  120  of the tilt bar  100  as will be discussed below. 
   As can be seen in  FIGS. 10 ,  11 , and  11 A to the left of the second head  92 , are two sets of diamond knurled projection surfaces  94 . The knurls  94  are raised above the surface of tilt pin  90 , for example 0.095 inches. Thus, as was discussed above, pressing a tilt pin  90  into the second tap  65  to the extent of second head  92  enables the knurls to frictionally engage the inner wall of the second tap  65 . The frictional engagement of the knurls with the inner wall of the second tap  65  prevents the tilt pin from easily working free in the second tap upon repeated use of the tilt bar  100 . 
   The tilt bar  100  is best shown in  FIGS. 7 and 7A  and may be constructed of metal, polycarbonate, or any other suitable material. In a preferred embodiment, spring tempered steel was used to create resiliency of arms  121  formed on the bar as will be discussed below. The tilt bar is a longitudinal strip or flat bar having a thickness substantially the same as the distance between first head  91  and second head  92 , i.e. the width of the neck  93 . As seen in  FIG. 12 , the width of the bar  100  can be made thinner or the width of the neck wider in the event two opposed ends of a pair of tilt bars are connected at one neck. Returning to  FIG. 7 , the tilt bar  100  includes a plurality of longitudinally spaced sockets  120  extending perpendicularly from the length of the bar in equally spaced increments off one side. 
   The spacing of the sockets is dependent upon the spacing of the louvers. The sockets  120  are C-shaped in cross-section having at least two of the resilient arms  121 . Between the arms  121  an oval opening  125  is defined. As seen in  FIGS. 3-6 , the tilt bar must be closely adjacent to the louvers as the tilt bar is translated in an up or down movement to fully open and close the louvers. Upon fully closing the louvers as seen in  FIG. 3 , the tilt bar remains at some minimal distance from the louvers. Thus, the distance of projection of the sockets away from the tilt bar is one of a relationship of the distance necessary for the tilt bar to close the louvers yet not interfere with the louvers. 
   As seen in  FIG. 7B , the arms  121  extend arcuately partly around the oval opening  125  but do not connect so as to form entry opening  130  at their distal ends. At their distal ends, the distance between each arm  121  is slightly less than the diameter of the neck  93 . As will be appreciated, upon clipping the socket to the neck  93 , the arms are adapted to expand from their static position to allow the oval opening  125  to accept the diameter of the neck  93  via entry opening  130 . However, once inside the oval opening  125 , the neck  93  is captured within the oval opening. The capture of the neck  93  is facilitated by the smaller entry opening between the arms  121  and the resiliency of the arms to return to their static position. Resiliency of the arms is due to the spring steel or other material from which the tilt bar is made and the cooperation with a channel  122  and an opening  123  to be discussed below. As will be appreciated, the resiliency of the arms is necessary to expand so as to accept neck  93  and then return to their static or neutral position so as to retain neck  93  within oval opening  125 . Moreover, the resiliency of the arms enables the socket to be removed or be re-captured if that is desired. Thus, the tilt bar may be considered to be removably or releasably attached to the tilt pins. 
   Referring to  FIGS. 7A and 7B , it can be seen that the oval opening  125  allows the neck  93  some amount of movement once captured. While every attempt to maintain proper positioning of the first and second taps is necessary, some errors in the locations of the taps will occur. These errors become a concern when multiplied by the number of taps, especially in a larger shutter having a larger number of louvers. Thus, the allowance of a minimal amount of movement of the neck within the socket reduces binding that may in part be attributable to these miss-measurements as between the plurality of first taps and second taps. Therefore, due to the fixed spacing of the sockets along the length of the tilt bar, the opening  125  is preferably oval in shape. This enables a neck  93  to have a range of movement or “float” within its associated socket. Thus, a smoother movement is provided along the tilt bar provided by the shape of the oval opening  125 . This further reduces binding of the tilt bar when the tilt bar is translated. 
   As shown in  FIGS. 7B and 7C , opposite to entry opening  130  is the channel  122  having the expansion opening  123 . As was described above, the resilient arms  121  expand to allow entry of a neck  93  into the oval opening  125  and then retract to the spacing defined at the entry opening  130 . The channel  122  and the opening  123  cooperate to act as a cantilevered beam to enable the resilient arms  121  to expand upon engagement with the neck  93 . Once the neck  93  is positioned within the oval opening  125 , the arms return to their pre-determined separation. 
   In practice, the louvers  40  are tapped at their ends  45  so as to have the aforenoted first and second taps. A pivot shaft or dowel (not shown) is pressed into the first tap  55 . A tilt pin  90  is pressed into the second tap  65  at one end of the louvers up to the extent of the second head  92  leaving the first head  91 , the second head  92 , and the neck  93  projecting outwardly away from the associated end of the louvers. The louvers are inserted into the stiles and the head and bottom bars are attached to the stiles. The tilt bar  100  with its sockets  120  are clipped to the necks of the exposed tilt pins. After attachment of the tilt bar  100 , the louvers may be pivoted about the pivots by translation of the tilt bar in an up or down movement. 
   Another embodiment of a tilt pin can be seen in  FIG. 15 . In this embodiment, the tilt pin  250  is generally cylindrical in shape having a main body  255 . The body of the pin may have a diameter, for example, of 0.850 inches. A head  260  is formed at one end thereof as seen in  FIG. 15 . The tilt pin  250  may be constructed from metal, polycarbonate, or any other suitable material. Adjacent to the head (to the left of the head as viewed in  FIG. 15 ) is a curved or arcuate portion  265  having a width, for example, of 0.010 inches between the head and a cylindrical bearing surface  270 . The purpose of this curved portion will be explained below. The bearing surface  270  is slightly greater in diameter than the main body of the pin having a diameter, for example, of 0.100 inches. It will be appreciated the bearing surface  270  is cylindrical so as to provide a suitable surface for receiving a socket  220  as will be more fully explained below. Adjacent to the bearing surface  270 , is an angular or beveled portion  275 . This embodiment shows that the angular portion  275  tapers at a 45° angle, for example, in relationship to the bearing surface  270 . In another embodiment shown in  FIG. 16 , the angular portion is shown as ninety degrees. The angle provides a transition from the bearing surface  270  to the main body  255  of the pin. In either event, the angular portion  275  functions as a stop to prevent the pin  250  from being over-inserted into the second tap  65 . Moreover, pressing the tilt pin  250  into the second tap  65  may only be up to the angular portion  275  due to its greater diameter than that of the diameter of the second tap  65 . Thus, as the tilt pin  250  is pressed to the limit of the angular portion  275 , bearing surface  270 , curved portion  265  and head  260 , remain exteriorly of the opening of the second tap at the end of a louver  40 . 
   The tilt pin  250  can be seen in  FIG. 15  having a plurality of diamond knurls  280 . The knurls  280 , for example, project 0.010 inches above the main body  255 . As the pin  250  is inserted into the second tap  65 , the knurls  280  frictionally engage the inner wall of the second tap  65  due to their projection outwardly from the main body  255 . The frictional engagement of the knurls with the inner wall of the second tap  65  serves to prevent the tilt pin from working free from the second tap upon repeated use of the tilt bar  200 . 
   The tilt bar  200 , as seen in  FIGS. 13 and 14 , may be constructed of metal, polycarbonate, or any other suitable material. The thickness of the tilt bar is slightly less than the width of the bearing surface  270 . The tilt bar is generally described as a longitudinal strip or thin bar having thereon equally spaced closed sockets  220 . The spacing between the closed sockets is dependent upon the spacing of the louvers. The closed sockets  220  project laterally from a side of the tilt bar so as to enable engagement with the tilt pins  250 . The closed sockets have an oval shaped opening  230  therein adapted to accept a tilt pin  250 . The smallest dimension of the oval opening is, for example, 0.110 inches. As was discussed above, the diameter of bearing surface  270  is, for example, 0.100 inches in diameter. Thus, the smallest dimension of oval opening  230  closely approximates but is slightly greater than the diameter of bearing surface  270 . The close approximation between the two dimensions enables some vertical movement of the tilt bar within the oval-shaped opening. Moreover, the closeness between the bearing surface and the smallest dimension of the oval opening serves to limit horizontal movement. It will be appreciated that enabling vertical movement allows for a better closure in larger shutter panels. 
   In use, louvers  40  are tapped at their ends  45  so as to have the first and second taps. A pivot dowel (not shown) is pressed into the first tap  55 . The louvers are inserted into aligned holes (not seen) in the stiles and the head and bottom bars are attached to the stiles. Each louver is turned outwardly so as to provide access to the second tap  65 . The tilt bar  200  is aligned with the second tap  65  so as to place openings  230  over the second taps  65 . The tilt pin  250  is first inserted into an opening  230  and subsequently into an aligned second tap  65 . The tilt pin  250  is press fitted into the second tap  65  to the extent of angular portion  275 . It will be appreciated the bearing surface  270  fits substantially within the opening  230  so as to act as a bearing surface for the tilt bar. 
   As seen in  FIG. 17 , upon receipt of the tilt pin fully within the second tap  65 , the tilt bar  200  is captured adjacent to the end  45  of the louver. In this captured position, the tilt bar  200  is held against the end  45  of the louver. However, it may move toward head  260  to the extent allowed by the curved surface  265 . As seen in  FIG. 15 , the curved surface  265  increases the diameter of bearing surface  270  toward head  260 . In this example, the close tolerances between the opening  230  in the tilt bar and the bearing surface  270 , permits some movement of the tilt bar toward the head  260  to the extent that the increase in diameter at the curved surface  265  exceeds the dimensions of the opening  230 . 
   Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example, and changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims.