Patent Publication Number: US-8109060-B1

Title: Storm shutter

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 protective window and portal coverings for use during hurricanes and high windstorms and more particularly to a uniquely configured transparent or translucent polycarbonate storm shutter which affords enhanced strength and impact resistance during heavy rains and windstorm conditions, particularly during hurricanes. 
     2. Description of Related Art 
     Hurricanes, heavy windstorms and tornado activity can produce winds easily capable of heavy property destruction. Windows and door openings may easily be shattered or destroyed which then leads to more severe wind damage due to the wind entering into the building structure and producing great interior pressure gradients against inside window and door surfaces as well as uplifting of the roofing structure which will rapidly to total building destruction. Therefore, initially protecting damage to these windows and portals during such severe storms may mean the difference between saving the entire building and a total loss of such buildings. 
     One well known method or technique for preventing window and door damage is to temporarily barricade them over with plywood material. However, the plywood should be removed promptly after storm conditions subside because the interior of the building is left completely light-blocked. Moreover, plywood is extremely heavy and difficult to deal with and the deployment and removal typically becomes a major task best left to a contractor. 
     U.S. Pat. No. 4,333,271 to DePaolo, et al. discloses a metal panel for door and window openings and Kostrzecha teaches a corrugated panel constructed from shatter-resistant and transparent plastic material in U.S. Pat. No. 5,457,921. 
     A method for adhering a flexible sheet to a polycarbonate sheet is taught by Sofie, et al. in U.S. Pat. No. 5,851,637. A storm panel formed of a film material in the form of two laminated sheets is taught by Motro in published U.S. Application 2003/0159372. 
     A penetration resistant window including a penetration layer sandwiched between transparent sheets is disclosed in U.S. Pat. No. 6,675,550 to Dlubak. Lewkowitz discloses an impact resistant glass and plastic pane attached to a flexible plastic sheet in U.S. Pat. No. 6,71,245 and Madden teaches a light transmitting storm shutter of corrugated aluminum and clear polycarbonate panels in U.S. Pat. No. 6,868,642. 
     A segmented storm shutter is taught in U.S. Pat. No. 5,345,716 to Caplan and Shaver discloses a partially transparent storm shutter of polycarbonate plastic sheet material in U.S. Pat. No. 6,079,168. Wade discloses plastic sheets have corrugated regions mounted on tracks in U.S. Pat. No. 6,974,622. 
     Reusable hurricane window film protection is taught in U.S. Pat. No. 6,705,054 to Pelton and Schoenberg discloses three-layered thermoplastic storm window film in U.S. Pat. No. 4,590,124. 
     The present invention provides a uniquely configured polycarbonate storm shutter which is easily deployable due to the light weight nature of the transparent or translucent panels and which affords by the nature of the corrugation, enhanced resistance to storm, wind and blown object impact. The preferred embodiment of the invention also includes an additional protective film attached thereto for added strength and may further or alternately include a sputter coated transparent metal or ceramic surface which greatly reduces ultraviolet and solar energy conveyance when the shutters are left in place for longer periods than simply the time period of a single hurricane or storm. 
     BRIEF SUMMARY OF THE INVENTION 
     This invention is directed to a transparent or translucent storm shutter for protectively covering a building portal, window and the like from hurricane and storm damage. A corrugated light transmitting polycarbonate panel is formed having continuous adjacent corrugation extending therealong. Each of the corrugations preferably has radiused side margins and a generally flattened or raised central portion offset from a neutral place of the panel. A central one of the corrugations extending along or adjacent to a centerline of the panel, preferably has a depth in a range of at least 10% greater than that of the edge corrugation of the panel, the central corrugations also preferably have a width in a range of at least 4% less than that of the edge corrugation wherein impact and wind resistance of the panel are enhanced. Protective transparent impact resistant film bonded to one panel surface preferably adds impact strength to the panel while sputter coating one panel surface with a transparent metallic or ceramic material enhances solar and UV rejection. 
     It is therefore an object of this invention to provide a translucent or transparent storm shutter for protectively covering building portals, windows and the like from hurricane and storm damage protection. 
     Yet another object of this invention is to provide a storm shutter for protecting a building from window or door damage which is formed of polycarbonate sheet material having a unique configuration for added impact resistance strength. 
     Yet another object of this invention is to provide a storm shutter having a uniquely configured corrugation structure and which may include a transparent hurricane-type film attached thereto for added strength. 
     Still another object of this invention is to provide a storm shutter formed of corrugated polycarbonate sheet material which may include a sputter coated ceramic or metallic surface layer for added solar and UV energy rejection when the panels are left onto the building while still allowing light to enter there into. 
     In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         FIG. 1  is a front elevation view of one embodiment of the invention. 
         FIG. 2  is an end elevation view of  FIG. 1 . 
         FIG. 3  is an enlarged end elevation view of another embodiment of the invention. 
         FIG. 4  is a simplified view of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to the drawings, one embodiment of the invention is there shown generally at numeral  10  in  FIGS. 1 and 2 . In this embodiment of the storm shutter  10 , a corrugated transparent or translucent polycarbonate panel  12  is formed having preferably continuous adjacent corrugations  14 ,  16 ,  18 ,  20  and  22  extending along the entire length of the panel  12 . However, overlapping of individual edge corrugations  14  and  16  for expanded width is envisioned. As best seen in  FIG. 3 , which includes the same corrugated panel  12  as shown in  FIGS. 1 and 2 , the corrugations  14  along the side margins  15 ,  17 ,  19  have a width of 3.000″ which is the greatest width of any of the corrugations. Corrugations  16  and  18  also has a corrugation width of 3.000 while the corrugations  20  are decreased in width to 2.875″ while the central corrugation  22  has the narrowest width of 2.75″. 
     The height of edge corrugations  14  is established at 1.00″ from the neutral plane B to a lateral portion  21  as are corrugations  16 , while the corrugations  18  have a height or depth of 1.08″, corrugations  20  having a height from the neutral plane B of 1.12″ as does the central corrugation  22 . These numerical results of corrugation height from the neutral plane and overall width with percentage comparisons are set forth in Table 1 herebelow. 
     
       
         
           
               
               
               
               
               
             
               
                 TABLE 1 
               
               
                   
               
               
                 Corrugation 
                 Width (in.)  
                 % Change 
                 Depth (in.) 
                 % Change 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
            
               
                 14 
                 3.000 
                 0 
                 1.000 
                 0 
               
               
                 16 
                 3.000 
                 0 
                 1.000 
                 0 
               
               
                 18 
                 3.000 
                 0 
                 1.080 
                  +8% 
               
               
                 20 
                 2.875 
                 −4% 
                 1.120 
                 +12% 
               
               
                 22 
                 2.750 
                 −8% 
                 1.120 
                 +12% 
               
               
                   
               
            
           
         
       
     
     By this arrangement, the central corrugation  22 , by virtue of its greatest depth of 1.10 from the neutral plane B and the greatest width, 2.750, affords the greatest resistance to impact against the panel  12 , that strength ratio gradually decreasing to the edge corrugations  14 . Further, the configuration of each of the corrugations affords added strength in that the central segment of each is flattened over a substantial width thereof which positions that material portion of the panel at the greatest distance from the neutral plane B for maximized strength. 
     To further enhance the strength characteristics of these panels  12 , it is preferred that a layer of transparent impact resistant film  24  be adhered to one of the surfaces of the panel  12 . These protective adhesively attached films are of uniform thickness and are well known in this industry. Such films are described in the prior art contained hereinabove. Because the surfaces of the polycarbonate panels  12  are not polished and free of manufacturing defects, it is preferred that they be treated with a plasma open air coating such as that as provided by PLASMATREAT of North America, Inc. located in Missagaua, Ontario, Canada under the trade name FLUME Plasma Systems This plasma system utilizes compressed air and power to generate atmospheric pressure plasma which is blasted onto the surface of the polycarbonate sheet  12  to prepare it for bonding application of the impact resistant film. 
     Referring lastly to  FIG. 4 , a simplified and clarified embodiment of the invention is there shown generally at numeral  10   a  and is substantially similar to that shown in  FIG. 2 . This corrugated panel  10   a  is defined as having an imaginary neutral plane B passing through and establishing the boundaries of each of the corrugations  14 ,  16 ,  18 ,  20  and  22 . The center valley corrugation  22  has the greatest depth (1.12″) from the neutral plane B while each of the peak corrugations  20  adjacent to the center corrugation  22  extend this same maximum distance or height (1.12″) from the neutral axis B as does the valley corrugation  22 . The next valley corrugations  18  further out from the center of the panel  10   a  have a smaller depth or distance (1.08″) from the neutral plane B while the next furthest from the center, peak corrugations  16 , have a yet smaller height (1.00″) from the neutral plane B than that of the valley corrugations  18 . The edge valley corrugations  14  are also smallest in height (1.00″) from the neutral plane B as highlighted by the phantom lines. 
     Because the polycarbonate panels  12  of this invention are transparent or translucent, the light transmitability is greatly enhanced over that of solid or opaque plywood. Therefore, leaving these protective panels in place during an entire hurricane season, for example, is not only feasible, but is highly practical. However, to reduce the amount of UV and solar radiation entering into the building through the protected window or portal, an additional coating of metal or ceramic material  26  deposited by the utilization of sputter coating techniques of one of the surfaces of these panels  12  is also preferred. The use of sputter coating for these plastic or polycarbonate panels  12  is also described in the Background hereinabove. 
     While the instant invention has been shown and described herein in what are conceived to be the most practical and preferred embodiments, it is recognized that departures may be made therefrom within the scope of the invention, which is therefore not to be limited to the details disclosed herein, but is to be afforded the full scope of the claims so as to embrace any and all equivalent apparatus and articles.