Abstract:
An apparatus and method for a window shutter system are disclosed. A window shutter system ( 100 ) is disclosed that includes a plurality of shutter frames ( 106, 108 ). Each shutter frame ( 106, 108 ) includes a plurality of elongate members ( 126, 130 ). Each of these elongate members ( 126, 130 ) has two ends, and each end has a receiver ( 204, 208 ). The shutter frames ( 106, 108 ) also include a plurality of couplers ( 128, 120, 132, 140 ). Each coupler ( 128, 120, 132, 140 ) has at least two extensions ( 202, 206 ) for connecting adjacent elongate members. These extensions ( 202, 206 ) are adapted to interlock with the receiver ( 204, 208 ) of an associated elongate member ( 126, 130 ) such that the elongate members ( 126, 130 ) and the couplers ( 128, 120, 132, 140 ) cannot rotate relative to one another. In addition to the shutter frames ( 106, 108 ), the shutter system ( 100 ) also includes at least one hinge ( 112, 114 ) that may be used to couple one of the elongate members ( 126, 130 ) to a window frame ( 110 ). The shutter system ( 100 ) further includes at least one joint ( 132, 136 ) that is used to hingedly connect the various frames ( 106, 108 ). 
     A method for assembling a window shutter system ( 100 ) is also disclosed. The method entails assembling at least one frame ( 106, 108 ) by connecting a plurality of elongate members ( 126, 130 ) using a plurality of couplers ( 128, 120, 132, 140 ). The connections between the elongate members ( 126, 130 ) and the couplers ( 128, 120, 132, 140 ) are made such that the elongate members ( 126, 128 ) and the couplers ( 128, 120, 132, 140 ) cannot rotate relative to one another. The method also entails attaching at least one hinge ( 112, 114 ) to the frame ( 106 ) for mounting the shutter system ( 100 ) to a window ( 110 ).

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 09/225,177, filed Jan. 4, 1999, now U.S. Pat. No. 6,170,554, by Jean A. Turner and entitled “APPARATUS AND METHOD FOR A WINDOW SHUTTER SYSTEM”. 
    
    
     TECHNICAL FIELD OF THE INVENTION 
     This invention relates generally to the field of window treatments and more particularly to an apparatus and method for a window shutter system. 
     BACKGROUND OF THE INVENTION 
     Window shutters have been used for many years to cover window openings. Purposes of such window shutters include functional purposes such as blocking out light and maintaining privacy, and aesthetic purposes such as decorating the home or office. Originally, window shutters were constructed completely of wood. Such shutters typically include a wood frame with wood blinds mounted inside the frame. There are several disadvantages to this approach. These wooden window shutters are usually purchased pre-assembled, and are often bulky and expensive. Such shutters also are often required to be custom made and must usually be installed by a professional. 
     Later, window shutters were developed that consisted of a frame made of wood with a fabric insert. While this type of shutter is typically less expensive than the all-wood type, it suffers from the other disadvantages of the previous wood shutters. 
     Window shutters have also been provided that are sold to the user in un assembled component form. The purchaser then has the option of customizing some portions of the shutter before assembly so as to fit a desired window. An example of such a window shutter can be found in U.S. Pat. No. 5,307,858. The frame of the shutters is typically made of metal. The various tubular members that form the frame may be connected with corner connectors that are shaped to receive the circular cross-section of the frame members. While this type of modular shutter system provides a relatively inexpensive window shutter that can be installed by the purchaser, it still has some disadvantages. First, the use of a metal frame makes sizing of the frame members more difficult, and it makes the frame heavy and relatively expensive. In addition, the circular cross-section of the frame members allows the members to rotate inside the corner connectors, and thus causes the frame to bend. Finally, while the use of corner connectors allows for ease of assembly, such connectors do not provide a means to securely connect the frame members in such a way that the shutter can be easily assembled and disassembled. 
     Therefore, a need has arisen for a new apparatus and method for a window shutter system that overcomes the disadvantages and deficiencies of the prior art. 
     SUMMARY OF THE INVENTION 
     An apparatus for a window shutter system is disclosed. The window shutter system includes a plurality of shutter frames. Each shutter frame includes a plurality of elongate members. Each of these elongate members has two ends, and each end has a receiver. The shutter frames also include a plurality of couplers. Each coupler has at least two extensions for connecting adjacent elongate members. These extensions are adapted to interlock with the receiver of an associated elongate member such that the elongate members and the couplers cannot rotate relative to one another. The frames are also configured so as to allow the vertical and horizontal sections of the frame to be uncoupled and recouped without the use of an adhesive or other permanent coupling means. In addition to the shutter frames, the shutter system also includes at least one hinge that may be used to couple one of the elongate member to a window frame. The shutter system further includes at least one joint that is used to hingedly connect the various frames. 
     In another embodiment, a method for assembling a window shutter system in accordance with the invention comprises two steps. The method entails assembling at least one frame by connecting a plurality of elongate members using a plurality of couplers. The connections between the elongate members and the couplers are made such that the elongate members and the couplers cannot rotate relative to one another. In addition, the horizontal and vertical sections of the frame can be disconnected and reconnected without the use of an adhesive or other permanent coupling means. The method also entails attaching at least one hinge to the frame for mounting the shutter system to a window. 
     A technical advantage of the present invention is that a method for assembling a window shutter system is provided. Another technical advantage of the present invention is a modular construction that allows for user customization. Furthermore, shutter systems incorporating teachings of the present invention may be made from plastic, so as to make the shutter systems lightweight and easy to size. 
     Further technical advantages of the present invention include the ability of the various parts of the shutter system to be interconnected by a male/female connection that provides a secure fit, prevents rotation of the various parts, and can be easily connected and disconnected. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     For a more complete understanding of the present invention, the objects and advantages thereof, reference is now made to the following descriptions taken in connection with the accompanying drawings in which: 
     FIG. 1 is a schematic diagram of a window shutter system incorporating teachings of the present invention; and 
     FIG. 2 is an exploded view of a portion of the window shutter system of FIG.  1 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The preferred embodiment of the present invention and its advantages are best understood by referring to FIGS. 1 and 2 of the drawings, like numerals being used for like and corresponding parts of the various drawings. 
     FIG. 1 is a schematic diagram of a window shutter system  100  incorporating teachings of the present invention. Window shutter system  100  includes a pair of shutter assemblies  102  and  104 . Since the configurations of shutter assemblies  102  and  104  are similar, only shutter assembly  104  will be described in detail. It should be noted, however, that shutter assembly  102  is illustrated to include components that comprise an alternate embodiment of the present invention, which is described below. 
     Shutter assembly  104  is comprised of an outer shutter frame  106  and an inner shutter frame  108 . It will be understood, however, that other embodiments of the present invention may include a larger or smaller number of shutter frames. Each shutter frame  106  and  108  is formed of modular and interconnect able components. Outer frame  106  is disposed adjacent a window frame side  110 . Outer frame  106  is coupled to window frame side  110  through the use of an upper hinge  112  and a lower hinge  114 . 
     Upper hinge  112  includes an upper wall mount  118  and an upper hinge post  120 . Upper wall mount  118  is mounted to window frame side  110 . Upper hinge post  120  is coupled to upper wall mount  118 . The means by which these components are coupled is described below in conjunction with FIG.  2 . Likewise, lower hinge  114  includes a lower wall mount  122  and a lower hinge post  124 . Lower wall mount  122  is mounted at a point on window frame side  110  that is lower than the point at which upper wall mount  118  is mounted. Lower hinge post  124  is coupled to lower wall mount  122  as described below in conjunction with FIG.  2 . In addition, the interconnections of all other parts of shutter assembly  104  are described in detail below in conjunction with FIG.  2 . 
     A vertical elongate member  126   a  is disposed between and coupled with upper hinge post  120  and lower hinge post  124  such that it is generally parallel to window frame side  110 . Vertical elongate member  126   a  and hinge posts  120  and  124  form a vertical section of outer frame  106 . Vertical elongate member  126   a  is preferably made of plastic, however other appropriate materials may be used. Vertical elongate member  126   a  also may be sized by the user by cutting away any undesired length. In so sizing, vertical elongate member  126   a  may be fitted to a desired distance between upper hinge  112  and lower hinge  114 . Likewise, all other vertical and horizontal elongate members  126  and  130  of shutter system  100  are also preferably made of plastic and also may be sized. 
     A corner piece  128   a  is connected to the upper end of upper hinge post  120 . Likewise, corner piece  128   b  is connected to the lower end of lower hinge post  124 . A horizontal elongate member  130   a  is coupled at one end to corner piece  128   a  such that horizontal elongate member  130   a  extends generally perpendicular to vertical elongate member  126   a . Corner piece  128   c  is coupled to the opposite end of horizontal elongate member  130   a . Likewise, horizontal elongate member  130   b  is coupled at one end to corner piece  128   b  such that horizontal elongate  130   b  extends generally perpendicular to vertical elongate member  126   a . Corner piece  128   d  is coupled to the opposite end of horizontal elongate member  130   b . Horizontal elongate member  130   a  and corner pieces  128   a  and  128   c  form a horizontal section of outer frame  106 . Likewise, horizontal elongate member  130   b  and corner pieces  128   b  and  128   d  form another horizontal section of outer frame  106 . 
     It should be noted that the corner pieces  128  are used to transition from the horizontal sections of outer frame  106  to the vertical sections of outer frame  106 , and vice versa. Furthermore, the combination of a corner piece  128  and a post, such as upper hinge post  120 , form a coupler that can be used to connect a vertical elongate member  128  to a horizontal elongate member  130 . 
     Still referring to FIG. 1, an upper joint post  132  is coupled to corner piece  128   c  such that upper joint post  132  extends downward, generally perpendicular to horizontal elongate member  130   a . Likewise, lower joint post  134  is coupled to corner piece  128   d  such that lower joint post  134  extends upward, generally perpendicular to horizontal elongate member  130   b . As is described below, upper and lower joint posts  132  and  134  are used to hingedly connect outer frame  106  to inner frame  108 . To complete outer frame  106 , vertical elongate member  126   b  is disposed between and coupled to upper and lower joint posts  132  and  134  such that it is generally parallel to vertical elongate member  126   a.    
     Shutter assembly  104  also includes inner frame  108 . Inner frame  108  is hingedly coupled to outer frame  106  through the use of two joints. Upper joint post  136  of inner frame  108  is hingedly coupled to upper joint post  132  of outer frame  106  to form one joint. Likewise, lower joint post  138  of inner frame  108  is hingedly coupled to lower joint post  134  of outer frame  106  to form the second joint. 
     Vertical elongate member  126   c  is disposed between and coupled to upper joint post  136  and lower joint post  138 . Corner pieces  128   e  and  128   f  are coupled to upper and lower joint post  136  and  138 , respectively. As described above, corner pieces  128  serve as a transition from the vertical to the horizontal sections of inner frame  108 , and vice-versa. 
     Horizontal elongate member  130   c  is coupled at one end to corner piece  128   e  such that it extends generally perpendicular to vertical elongate member  126   c . Likewise, horizontal elongate member  130   d  is coupled at one end to corner piece  128   f  such that it extends generally perpendicular to vertical elongate  126   c . Corner pieces  128   g  and  128   h  are coupled to the other ends of horizontal elongate members  130   c  and  130   d , respectively, in order to transition from the horizontal sections to the vertical sections of inner frame  108 . 
     An upper end post  140  is coupled to corner piece  128   g  such that upper end post  140  extends downward, generally parallel to vertical elongate member  126   c . Likewise a lower end post  142  is coupled to corner piece  128   h  such that it extends upward, generally parallel to vertical elongate member  126   c . One end of vertical elongate member  126   d  is coupled to upper end post  140  such that vertical elongate member  126   d  is generally parallel to vertical elongate member  126   c . Likewise, one end of vertical elongate member  126   e  is coupled to lower end post  142  such that vertical elongate member  126   e  is generally parallel to vertical elongate member  126   c . Vertical elongate members  126   d  and  126   e  extend towards each other, but they do not meet. Disposed between and coupled to vertical elongate members  126   d  and  126   e  is a latching component  144 . Latching component  144  may be used in conjunction with a latch  126  to connect shutter assembly  102  with shutter assembly  104 . 
     Although shutter assembly  104  has been described as comprising outer frame  106  and inner frame  108 , shutter assembly  104  may also include one or more intermediate frames (not explicitly shown). Such intermediate frames may be coupled between inner frame  108  and outer frame  106  in a similar fashion as inner frame  108  is coupled to outer frame  106 . On the other hand, shutter assembly  104  may only include outer frame  106 . In such an embodiment, upper end post  140  would replace upper joint post  132 , and lower end post  142  would replace lower joint post  134 . In addition, vertical elongate member  126   a  could be replaced by vertical elongate members  126   d  and  126   e , so as to accommodate latching component  144 . 
     Still referring to FIG. 1, shutter assembly  102  illustrates an alternate embodiment of the present invention. In this embodiment, horizontal elongate members  130   e  and  130   f  are added to the above-described assembly to provide additional support to the shutter. In order to accommodate horizontal elongate members  130   e  and  130   f , various other additional components must be included. Horizontal elongate member  130   e  is disposed between a latching component  146  and an intermediate joint post  148 . Intermediate joint post  148  is hingedly coupled to intermediate joint post  150 , in a similar manner as the joint posts in shutter assembly  104 . Horizontal elongate member  130   f  is disposed between intermediate joint post  150  and an intermediate hinge post  152 . Intermediate hinge post  152  is hingedly coupled to intermediate wall mount  154 . In this manner, a third hinged connection is made between shutter assembly  102  and a window frame side  156 . 
     As shown in FIG. 1, shutter system  100  may also include a balance  158 . Balance  158  is mounted to window frame side  110  through the use of a right wall mount  160 . Likewise, balance  158  is mounted to window frame side  156  through the use of left wall mount  164 . Right hinge post  162  and left hinge post  166  are hingedly coupled to right wall mount  160  and left wall mount  164 , respectively. Corner piece  128   i  is coupled to the top of right hinge post  162 . Likewise, corner piece  128   j  is coupled to top of left hinge post  164 . A horizontal elongate member  130   g  is disposed between corner pieces  128   i  and  128   j  to complete balance  158 . It should be understood that horizontal elongate member  130   g  may be replaced by two separate horizontal elongate members (not explicitly shown). In such an embodiment, one horizontal elongate member is coupled to corner piece  128   i , and the other horizontal elongate member is coupled to corner piece  128   j . In this configuration, the horizontal elongate members are permitted to pivot about window sides  110  and  156 . 
     Still referring to FIG. 1, shutter assemblies  102  and  104  and balance  158  preferably include a fabric covering  170 . Fabric covering  170  preferably includes sleeves (not explicitly shown) that fit over the horizontal and vertical elongate members of shutter system  100 . When fabric covering  170  is placed over the horizontal and vertical elongate member of shutter assemblies  102  and  104 , fabric covering  170  is operable to cover the interior areas of the frames of shutter assemblies  102  and  104 . Likewise, fabric covering  170  can be used to cover balance  158 . Fabric covering  170  is operable to inhibit the propagation of light and air through a window incorporating shutter system  100 . 
     It should be understood that although shutter system  100  includes balance  158 , alternate configurations of the shutter system may have balance  158  replaced by another set of window assemblies  102  and  104 . In such a configuration, the window could be almost entirely covered by the shutter system. 
     Referring now to FIG. 2, illustrated is an exploded view of a portion of window shutter system  100  of FIG.  1 . FIG. 2 shows the means by which each part of shutter assembly  104  of shutter system  100  is connected. It should be noted that the various components shown in FIG. 2 are connected in either a hinged or fixed configuration. Each of these means of connection will be described below. 
     One means of connecting the various components of shutter system  100  is a fixed connection using complimentary male extensions and female receivers. Such a connection is used between the various vertical and horizontal elongate members and the hinge posts, joint posts, end posts, and corner pieces to which they are coupled. For example, vertical elongate member  126   a  is coupled to upper hinge post  120  through the interconnection of an extension  202  with a receiver  204 . The cross-sections of extension  202  and receiver  204  are formed such that extension  202  securely fits inside receiver  204 , and such that the relative rotation of the two coupled parts is prevented. The parts are further fastened together using solvent welding or some other suitable fastening technique. 
     Another example of such a male/female connection is the coupling of horizontal elongate member  130   b  to corner piece  128   b . In this case, extension  206  of corner piece  128   b  interlocks with receiver  208  of horizontal elongate member  130   b . The cross-sections of extension  206  and receiver  208  are formed as described above. 
     A final example of the male/female connections in shutter system  100  is the coupling of upper joint post  132  to corner piece  128   c . In this case, extension  210  of upper joint post  132  interconnects with receiver  212  of corner piece  128   c . Receiver  212  can be clearly seen on corner piece  128   h . The cross-sections of extension  210  and receiver  212  are formed as described above. In addition to this male/female interconnection, corner piece  128   c  is secured to upper joint post  132  with a fastener  214 . Fastener  214  may be a bolt or screw that threads into upper joint post  132 , or it may be any other type of fastening means. The above three examples of male/female interconnections represent all the fixed connections of the components of shutter system  100 . The means by which the other fixed components of shutter system  100  are coupled can be understood from these examples. 
     As described above, the cross-sections of the male extensions and female receivers of shutter system  100  are formed such that the relative rotation of the coupled parts is prevented. Although, a particular cross-section is shown in FIG. 2, any cross-section may be used that prevents rotation. Examples include, but are not limited to, rectangular, triangular, and square cross-sections. 
     The various male extensions and female receivers used to connect the components of shutter system  100  may also incorporate snap-fit connections (not explicitly shown). In such a case, the extension locks into place when it is inserted into the receiver. The operation of such a snap-fit connection is well known in the art and will not be described in further detail here. 
     Due to the use of the various male/female connections described above, shutter system  100  can be delivered to the user in disassembled modular form. The user can then size the various horizontal and vertical elongate member and then assemble the shutter system by snapping the various components into place. The user can also easily disassemble the system by unsnapping the various components. In this manner, a shutter system is provided that is relatively light weight, inexpensive, and easy to assemble and disassemble. 
     Shutter system  100  also includes a series of hinged connections. Such hinged connections are represented by the following two examples. The first example is the connection of upper wall mount  118  to upper hinge post  120 . Upper hinge post  120  includes a extension arm  216 . Extension arm  216  is inserted into a receiver  218  of upper wall mount  118 . Extension arm  216  and receiver  218  have complimentary circular cross sections that allow the rotation of extension arm  216  inside receiver  204 . Such a connection allows shutter assembly  104  to rotate about the side of a window frame. It should be noted that upper wall mount  118  may be mounted to a window frame (not explicitly shown) with a fastener  219 . Fastener  219  may be a bolt, screw, nail, or any other appropriate fastening means. 
     The second example of a hinged connection in shutter system  100  is the connection of lower joint post  134  to lower joint post  138 . Lower joint post  134  includes extension arm  222  that is inserted into a receiver  224  of lower joint post  138 . The cross sections of extension arm  222  and receiver  224  are circular so that extension arm  222  may rotate inside the receiver  224 . This hinged connection allows the various shutter frames of shutter system  100  to pivot relative to one another about a generally vertical axis. The other hinged connections in shutter system  100  are represented by one of the two examples described above. 
     In using the window shutter system described in conjunction with FIGS. 1 and 2, the user first identifies the window in which the shutter system is to be placed. The user then determines which components of the shutter system he or she wishes to install on the window. For example, the user may decide the number of frames that will comprise each shutter assembly. In addition, the user may determine whether a balance is to be used. The user then measures the dimensions of the window in which the shutter system is to be placed, and purchases the various components in a size that most closely matches the dimensions of the window. Once the components are obtained, the user may then trim length off the various horizontal and vertical elongate members included in the shutter system to better fit the dimensions of the window. The user then assembles and installs the window shutter system as described above. 
     In addition, the user may buy a fabric covering to be used with the window system. A separate fabric covering is preferably included for each frame of the window shutter system, and for the balance, if desired. These fabric coverings are typically fabricated so that they will fit over the various shutter frames and balance after the horizontal and vertical elongate members of the frames and balance have been shortened. The fabric covering preferably includes stitched sleeves that can be fitted around the elongate members of the shutter system. In such a case, the user preferably slides the fabric covering over the elongate members before they are coupled together. However, other means, such as Velcro, may be used to allow the user to put the fabric covering on the shutter system after the shutter frames have been assembled and mounted on the window. 
     While the invention has been particularly shown and described by the foregoing detailed description, it will be understood by those skilled in the art that various other changes in form and detail may be made without departing from the spirit and scope of the invention.