Patent Publication Number: US-8533996-B1

Title: Shutter drive apparatus

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This nonprovisional utility patent application claims the benefit under 35 USC §119(e) of U.S. provisional application No. 61/626,195 filed Sep. 22, 2011 and of U.S. provisional application No. 61/632,049 filed Jan. 17, 2012 both of which are incorporated, in their entirety, by this reference. 
    
    
     BACKGROUND 
     The present invention relates generally to window covering shutters such as plantation style shutters and their respective drive systems. More particularly, the present invention relates to “tilt-rod-less” shutters and drive systems that are adapted such that the movement of (any) one shutter louver (e.g. the opening or closing of one louver) results in the corresponding movement (slaved movement) of all of the shutter louvers. 
     RELATED ART 
     Window cover type shutters are well known and have long been used to not only improve home décor, but to allow for the amount and direction of light allowed to pass through a cover window and into a room (see appendix A to this specification). While such use of shutters have been both decorative and functional, a problem with many such shutters is that the tilt rod used to position the louvers of such shutters has restricted the range of motion of such louvers such that the louvers of the shutter are not completely closeable. Various solutions to the problem of incomplete louver closure, such as creating pockets in the rails to receive the ends of a tilt rod, and thus allow for a greater range of motion of the louvers have been devised. Moreover, a preferred method of increasing the range of motion and an especially aesthetically pleasing solution, is to completely eliminate the tilt rod from the shutter. However, in such “tilt-rod-less” configurations, unless each louver is to be separately adjustable (a very cumbersome and impractical configuration), a drive mechanism is required such to adapt the shutter such that the movement of (any) one shutter louver (e.g. the opening or closing of one louver) results in the corresponding movement (slaved movement) of all of the shutter louvers. 
     SUMMARY 
     The invention is a shutter drive apparatus adapted such that the movement of (any) one shutter louver (e.g. the opening or closing of one louver) results in the corresponding movement (slaved movement) of all of the shutter louvers. The shutter defines a preferably tilt-rod-less shutter comprising a shutter frame having at least top and bottom horizontal rails, at least a first side stile and a second side stile, and a plurality of louvers (slats or blades) rotatably mounted within the stiles such that a first end of the louvers are freely rotatable within the first side stile, and such that a second end of the louvers are drivably engaged to the shutter drive apparatus. The shutter drive apparatus is preferably mounted within the second stile and preferably includes a plurality of pinion gears, a face strip, opposing drive strips, and a retainer strip. Each louver is drivably engaged to a different pinion gear and each pinion gear is drivably engaged to the drive strips such that movement of (any) one shutter louver (e.g. the opening or closing of one louver) results in the corresponding movement (slaved movement) of all of the shutter louvers. The shutter drive apparatus is adapted to require minimal (different) parts and to be of low manufacturing cost. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which: 
         FIG. 1  is a substantially trimetric view of a first embodiment of the present invention with the louvers shown in phantom lines; 
         FIG. 2  is a substantially exploded trimetric view of a first embodiment of the present invention; 
         FIG. 3  is an enlarged scale view of the pinion gear shown in  FIG. 2 ; 
         FIG. 4  is an enlarged scale view of a portion of the face strip shown in  FIG. 2 ; 
         FIG. 5  is an enlarged scale view of a portion of the face strips shown in  FIG. 2 ; 
         FIG. 6  is an enlarged scale view of a portion of the retainer strip shown in  FIG. 2 ; 
         FIG. 7  is an enlarged scale view of a portion of the stile shown in  FIG. 2 ; 
         FIG. 8  is an enlarged scale view of the louver shown in  FIG. 2 ; 
         FIG. 9  is a front orthographic view of a first embodiment of the present invention with the stile and the louvers shown in phantom lines and with the louvers shown in a horizontal position; 
         FIG. 10  is a top orthographic sectional view of a first embodiment of the present invention taken at the location of the section arrows shown in  FIG. 9  and with without the louvers being shown; 
         FIG. 11  is a front orthographic view of a first embodiment of the present invention with the louvers shown adjusted to a first angled position; 
         FIG. 12  is a front orthographic view of a first embodiment of the present invention with the louvers shown adjusted to a second angled position; 
         FIG. 13  is a substantially trimetric view of a second embodiment of the present invention; 
         FIG. 14  is a substantially exploded trimetric view of a second embodiment of the present invention; 
         FIG. 15  is an enlarged scale view of a portion of the front case member shown in  FIG. 14 ; 
         FIG. 16  is an enlarged scale view of a portion of the rear case member shown in  FIG. 14 ; and 
         FIG. 17  is a top orthographic sectional view of a second embodiment of the present invention taken at the location of the section arrows shown in  FIG. 13 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. 
     Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are included to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention. 
     The invention is a shutter drive apparatus adapted such that the movement of (any) one shutter louver (e.g. the opening or closing of one louver) results in the corresponding movement (slaved movement) of all of the shutter louvers. The shutter defines a preferably tilt-rod-less shutter comprising a shutter frame having at least top and bottom horizontal rails, at least a first side stile and a second side stile, and a plurality of louvers (slats or blades) rotatably mounted within the stiles such that a first end of the louvers are freely rotatable within the first side stile, and such that a second end of the louvers are drivably engaged to the shutter drive apparatus. The shutter drive apparatus is preferably mounted within the second stile and preferably includes a plurality of pinion gears, a face strip, opposing drive strips, and a retainer strip. Each louver is drivably engaged to a different pinion gear and each pinion gear is drivably engaged to the drive strips such that movement of (any) one shutter louver (e.g. the opening or closing of one louver) results in the corresponding movement (slaved movement) of all of the shutter louvers. 
     In order to facilitate the understanding of the present invention in reviewing the drawings accompanying the specification, a feature list is provided below. It is noted that like features are like numbered throughout all of the figures. 
     
       
         
           
               
            
               
                   
               
               
                 FEATURE TABLE 
               
            
           
           
               
               
               
               
            
               
                 # 
                 Feature 
                 # 
                 Feature 
               
               
                   
               
            
           
           
               
               
               
               
            
               
                 10 
                 Shutter drive apparatus 
                   
                   
               
               
                 20 
                 Pinion gear 
                 22 
                 Engagement cleat 
               
               
                 23 
                 Prong 
                 24 
                 Bearing surface 
               
               
                 26 
                 Gear 
                 28 
                 Axle 
               
               
                 30 
                 Face strip 
                 32 
                 Gear reception socket 
               
               
                 40 
                 Drive strip 
                 41 
                 Load flange 
               
               
                 42 
                 Drive opening 
                 43 
                 Drive teeth 
               
               
                 44 
                 Punch index hole 
                   
                   
               
               
                 45 
                 Drive strip 
                 46 
                 Load flange 
               
               
                 47 
                 Drive opening 
                 48 
                 Drive teeth 
               
               
                 49 
                 Punch index hole 
                   
                   
               
               
                 50 
                 Retainer strip 
                 52 
                 Retention opening 
               
               
                 54 
                 Flexible flange 
                   
                   
               
               
                 60 
                 Stile 
                 62 
                 Backing strip 
               
               
                 64 
                 Axle reception socket 
                   
                   
               
               
                 70 
                 Louver 
                 72 
                 Stiffener 
               
               
                 74 
                 Cleat reception socket 
                 76 
                   
               
               
                 100 
                 Shutter drive apparatus 
                   
                   
               
               
                 110 
                 Front case member 
                 112 
                 Gear reception socket 
               
               
                 114 
                 Engagement groove 
                   
                   
               
               
                 120 
                 Rear case member 
                 122 
                 Gear reception socket 
               
               
                 124 
                 Engagement ridge 
               
               
                   
               
            
           
         
       
     
     Referring now to the drawings and in particular to  FIGS. 1 through 12 , a first embodiment of the invention is a shutter drive apparatus  10  comprising a pinion gear  20 , a face strip  30 , a first drive strip  40 , a second drive strip  45 , and a retainer strip  50 . Pinion gear  20  defines a preferably injection molded plastic gear having an engagement cleat  22  having a plurality of prongs  23 , a bearing surface  24 , a gear  26 , and an axle  28 . Face strip  30  defines a substantially elongated generally rectangular strip having a plurality of gear reception sockets  32 . Face strip  30  may for instance be formed from wood, plastic, metal (e.g. aluminum) or, a composite thereof. Drive strip  40  defines a substantially generally elongated rectangular strip having general “L” cross-sectional shape and having a load flange  41 , a plurality of drive openings  42 , each drive opening  42  having a plurality of drive teeth  43 , and a plurality of punch indexing holes  44 . Drive strip  40  is preferably formed from an aluminum extrusion. Drive strip  45  defines a substantially generally elongated rectangular strip having general “L” cross-sectional shape and having a load flange  46 , a plurality of drive openings  47 , each drive opening  47  having a plurality of drive teeth  48 , and a plurality of punch indexing  49 . Drive strip  45  is preferably formed from an aluminum extrusion. It is noted that in order to reduce the number of different parts required for shutter drive apparatus  10 , drive strips  40  and  45  are preferably substantially identical in geometry, material, and construction. It is further noted that long lengths of aluminum extrusion may be obtained with drive openings pre-punched such that a drive strip may be cut to custom lengths. Retainer strip  50  defines a preferably plastic substantially elongated generally rectangular strip having a plurality of retention openings  52 , with each retention opening  52  having a plurality of flexible flanges  54 . It is noted that retainer strip  50  is adapted such that retainer strip  50  may be manufactured from rolls of blank plastic strip that in turn has a plurality of retention openings  52  punched into the strip at predetermined intervals. The punched strip may then be cut to length to form retainer strip  50 . Reference stile  60 , defines a generally elongated stile having a backing strip  62 , with backing strip  62  having a plurality of axle reception sockets  64 . Reference stile  60  may be formed of wood, plastic, metal, or other materials. It is noted that backing strip  62  may be formed integrally with stile  60  or may be formed separately and then assembled to stile  60  (e.g. a wood, plastic or composite stile  60  having an assembled aluminum backing strip  62 ). Reference louver  70 , defines a generally elongated louver having a generally centrally located stiffener  72 , with stiffener  72  forming a cleat reception socket  74  on each end of louver  70 . Reference louver  70  may be formed of wood, plastic, metal, or other materials. It is noted that stiffener  72  may be formed integrally with louver  70  or may be formed separately and then assembled to louver  70  (e.g. a wood, plastic or composite louver  70  having an assembled aluminum stiffener  72 ). 
     Shutter drive apparatus  10  is assembled such that pinion gears  20  are inserted into gear reception sockets  32  of face strip  30  such that bearing surfaces  24  are in rotatable engagement with gear reception sockets  32 . Drive strip  40  is positioned in a first orientation against assembled face strip  30  and pinion gears  20  such that drive teeth  43  of drive strip  40  are meshed with gear  26 . Drive strip  45  is positioned in a second orientation against assembled face strip  30  and pinion gears  20  such that drive teeth  48  are meshed with gear  26 . With drive strips  40  and  45  thus assembled, retainer strip  50  is snappingly engaged to pinion gears  20  such that flexible flanges  54  of openings  52  are engaged to axles  28  of pinion gears  20  to retain assembled drive strips  40  and  45  while allowing for the rotation of pinion gear  20 . It is noted that axles  28  may be optionally staked to assure retention of pinion gears  20 . It is further noted that the assembly of Shutter drive apparatus  10  allows for the free floatation of pinion gears  20 . Shutter drive apparatus  10  is preferably mounted into stile  60  and prongs  23  of engagement cleats  22  are preferably engaged in sockets  74  of louvers  70 . It shall be noted that stile  60  and louver  70  preferably form a portion of an overall shutter frame (e.g. having at least two stiles, at least two rails, and a plurality of louver blades). It shall be further noted that the unique assembly of drive strips  40  and  45  provides that side separation loading of drive strip  40  is reacted by load flange  46  and side separation loading of drive strip  45  is reacted by load flange  41  such that drive strips  40  and  45  do not separate under a drive load, such that drive strips  40  and  45  move smoothly when functioning to open and close shutters, and such that the side loading of drive strips  40  and  45  is substantially evenly distributed between drive strips  40  and  45 . It shall be yet further noted that with shutter drive apparatus  10  thus assembled, louvers  70  are slaved engagement to one another. 
     In practice, with shutter drive apparatus  10  thus assembled, shutter drive apparatus  10  functions such that a movement of any one of louvers  70  results in a like or corresponding movement of the other louvers  70 . Thus in order for a user to open, close or reposition the louvers  70  of a shutter that employs shutter drive apparatus  10 , the user merely grasps any one of louvers  70  and moves louver  70  to the desired position resulting in the simultaneous movement of all of louvers  70 . It shall be noted that not only is shutter adjustment simple and easy but a shutter thus configured can be readily completely closed without a tilt rod inhibiting the range of motion of the shutter. 
     Referring now to the drawings and in particular to  FIGS. 13 through 17 , a second embodiment of the invention is a shutter drive apparatus  100  comprising a pinion gear  20 , a front case member  110 , a first drive strip  40 , a second drive strip  45 , a retainer strip  50 , and a rear case member  120 . Front case member  110  defines a substantially generally elongated rectangular member having general “C” cross-sectional shape and having a plurality of gear reception sockets  112  and a plurality of engagement grooves  114 . Front case member  110  is preferably formed from an aluminum extrusion. Rear case member  120  defines a substantially generally elongated rectangular member having general “C” cross-sectional shape and having a plurality of gear reception sockets  122  and a plurality of engagement ridges  124 . Rear case member  120  is preferably formed from an aluminum extrusion. 
     Shutter drive apparatus  100  is assembled such that pinion gears  20  are inserted into gear reception sockets  112  of front case member  110  such that bearing surfaces  24  are in rotatable engagement with gear reception sockets  112 . Drive strip  40  is positioned in a first orientation against assembled front case member  110  and pinion gears  20  such that drive teeth  43  of drive strip  40  are meshed with gear  26 . Drive strip  45  is positioned in a second orientation against assembled front case member  110  and pinion gears  20  such that drive teeth  48  are meshed with gear  26 . With drive strips  40  and  45  thus assembled, retainer strip  50  is snappingly engaged to pinion gears  20  such that flexible flanges  54  of openings  52  are engaged to axles  28  of pinion gears  20  to retain assembled drive strips  40  and  45  while allowing for the rotation of pinion gear  20 . It is noted that axles  28  may be optionally staked to assure retention of pinion gears  20 . Rear case member  120  is further snappingly engaged to front case member  110  such that engagement ridges  124  seat within engagement grooves  114  and such that pinion gears  20  are free to rotate within gear reception sockets  122 . It is noted that the assembly of Shutter drive apparatus  100  allows for the free floatation of pinion gears  20 . Shutter drive apparatus  100  is preferably mounted into stile  60  and prongs  23  of engagement cleats  22  are preferably engaged in sockets  74  of louvers  70 . It shall be noted that stile  60  and louver  70  preferably form a portion of an overall shutter frame (e.g. having at least two stiles, at least two rails, and a plurality of louver blades). It shall be further noted that the unique assembly of drive strips  40  and  45  provides that side separation loading of drive strip  40  is reacted by load flange  46  and side separation loading of drive strip  45  is reacted by load flange  41  such that drive strips  40  and  45  do not separate under a drive load, such that drive strips  40  and  45  move smoothly when functioning to open and close shutters, and such that the side loading of drive strips  40  and  45  is substantially evenly distributed between drive strips  40  and  45 . It shall be yet further noted that with shutter drive apparatus  100  thus assembled, louvers  70  are slaved engagement to one another. 
     In practice, with shutter drive apparatus  100  thus assembled, shutter drive apparatus  100  functions such that a movement of any one of louvers  70  results in a like or corresponding movement of the other louvers  70 . Thus in order for a user to open, close or reposition the louvers  70  of a shutter that employs shutter drive apparatus  100 , the user merely grasps any one of louvers  70  and moves louver  70  to the desired position resulting in the simultaneous movement of all of louvers  70 . It shall be noted that not only is shutter adjustment simple and easy but a shutter thus configured can be readily completely closed without a tilt rod inhibiting the range of motion of the shutter. 
     The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.