Patent Publication Number: US-7716884-B2

Title: Shutter assembly

Description:
RELATED APPLICATIONS 
   This continuation-in-part patent application claims priority to U.S. parent patent application Ser. No. 10/264,477, filed Oct. 4, 2002, now issued U.S. Pat. No. 7,062,884, issue date Jun. 20, 2006, which claims priority to U.S. provisional patent application Ser. No. 60/404,016, filed Aug. 16, 2002. 

   FIELD OF THE INVENTION 
   The subject invention generally relates to a shutter assembly and more particularly to a reinforced, locking, shutter assembly that withstands inclement weather. 
   BACKGROUND OF THE INVENTION 
   Various locking assemblies for shutters are known in the art. It is generally known that locking assemblies are utilized, when necessary, to lock pairs of shutters in a closed position on a dwelling. Shutters are used for both aesthetic and function purposes on the dwelling. In the closed position, the shutters function to protect windows, doors, and other openings of the dwelling during inclement weather, such as precipitation storms, wind storms, and hurricanes. 
   During such inclement weather, it is pertinent to lock, or retain, the shutters in the closed position such that the shutters can continue to provide adequate protection to the windows, doors, and other openings during and throughout the inclement weather. If the weather causes the shutters to open then the functional purpose of the shutters is defeated. 
   Conventional assemblies for locking pairs of shutters in the closed position are deficient for many reasons. For instance, the locking assemblies of the prior art do not adequately retain the shutters in the closed position throughout the inclement weather. In these assemblies, wind either bends or breaks the assembly and then causes the shutters to open. Also for instance, many conventional locking assemblies require direct drilling into and through the shutters to adequately retain the shutters in the closed position. In these assemblies the fastener extends through at least a portion of the shutters. As a result, to one degree or another, these conventional locking assemblies damage the shutters such that, after the inclement weather, the aesthetic purpose of the shutters is negatively impacted. 
   Furthermore, some conventional locking assemblies, also referred to in the art as storm or locking bars, create an emergency egress issue that prevents occupants of the dwelling from escaping during an emergency, such as a fire. More specifically, a conventional storm bar is mounted across the shutters once the shutters have been closed. The storm bar is secured, typically screwed, into the dwelling on each side of the closed shutters to prevent the shutters from opening during the inclement weather. Screws are also used to connect the shutters to the storm bar such that the shutters can not be blown, or otherwise deflected, inward, i.e., toward the dwelling, during the inclement weather. With the storm bar screwed to the dwelling and the shutter screwed to the storm bar, the occupants of the dwelling cannot open a window or door from within the dwelling to release the storm bar and escape. 
   Due to the deficiencies in the locking assemblies of the prior art, including those described above, it is desirable to provide a novel locking assembly for shutters that adequately retains the shutters in a closed position on a dwelling such that protection to a window, door, or other opening is maximized throughout any inclement weather. It is also desirable to provide a locking assembly for shutters that does not physically damage the shutters to retain the shutters in a closed position. More specifically, it would be ideal to provide a locking assembly that retains the shutters in a closed position without a fastener extending through the shutters. 
   SUMMARY OF THE INVENTION AND ADVANTAGES 
   A shutter assembly having at least one shutter and a security bar device for locking closed and providing additional rigidity to the shutter when covering an opening in a dwelling. The bar device has an elongated member preferably releasably engaged to the dwelling in the opening. The member traverses the opening and prevents the shutters from collapsing into the opening when closed. A retention bracket co-extends with and is spaced from the member with a portion of the shutter layered there-between when in the closed position. As such, the retention bracket prevents the shutter from opening when in the closed position. A locking portion of the retention bracket projects laterally to releasably engage the member. 
   Preferably, the elongated member is engaged releasably to the dwelling by at least one leg of a mounting bracket that projects into the opening and engages the member at an end. The locking portion of the retaining bracket is preferably removably secured to the member at the leg utilizing a common fastener that preferably extends through aligned apertures in the leg, the retaining bracket, and the member. With the retention bracket locked to the member and leg, the shutters are retained in the closed position. 
   Accordingly, the subject invention provides a shutter assembly having shutters that adequately remain in a closed position on a dwelling during harsh environmental conditions to protect an opening, yet has a security bar device that can be quickly released by an occupant to open the shutters if need be. It is also advantageous that the shutters of the shutter assembly do not require unsightly modification to work with a security bar device of the assembly. Hence, fasteners used for the assembly do not visually affect or physically damage the shutters in any way. Other advantages include a relatively simple and robust design that is inexpensive to manufacture and in service has a long and useful life. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
       FIG. 1  is a perspective view of a dwelling having the shutter assembly embodying the present invention with one pair of shutters in an open position and another pair of shutters in a closed position; 
       FIG. 2  is an exploded perspective view of the shutter assembly; 
       FIG. 3  is a perspective view illustrating a locking assembly of the subject invention mounted to a sill of the dwelling and a locking assembly of the subject invention mounted to a header of the dwelling, both retaining the shutters in the closed position on the dwelling; 
       FIG. 4  is a perspective view illustrating a first backing component according to the subject invention; 
       FIG. 5  is a perspective view illustrating a second backing component according to the subject invention; 
       FIG. 6  is a perspective view illustrating a retention bracket according to the subject invention; 
       FIG. 7  is a perspective view illustrating an occupant of the dwelling opening a window to access the locking assembly from within the dwelling; and 
       FIG. 8  is a partially cross-sectional side view of an alternative locking assembly according to the subject invention adapted to be mounted to the header of the window. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a shutter assembly is generally disclosed at  10  and mounts to a dwelling  14  such as a home or industrial building to open and close over an opening  11  in the dwelling such as a doorway or window. When closed, the shutter assembly  10  protects the windows and/or doors from inclement weather, such as precipitation storms, wind storms, and hurricanes. To accomplish this protection, the shutter assembly  10  has a lockable storm bar device  13  that reinforces and locks closed a pair of shutters  12  of the assembly  10  hinged along respective pivot axes  15  that are preferably parallel to one-another. 
   As best illustrated in  FIGS. 2-3 , the storm bar device  13  has lower and upper mounting brackets  16 A,  16 B, an elongated backing member  17 , an elongated retention bracket  18  that generally co-extends with the backing member  17 , and a plurality of quick release fasteners  20 . For ease of explanation, the shutter assembly  10  will be described as if installed over the opening  11  of a window of the dwelling, however, one skilled in the art would know that such an assembly could be installed over any opening in a structure requiring protection from inclement weather. Preferably, the shutters  12  are hinged to an external surface of the dwelling  14  and swing in opposite rotational directions about respective axes  15  to close, thus forming a relatively small and substantially vertical gap  19  between distal portions  21  of the respective shutters  12  spaced radially outward from the respective axes  15 . When the shutters  12  are closed, the gap  19  substantially bisects and is located in front of the opening  11  or window at the exterior of the dwelling  14 . 
   The lower and upper mounting brackets  16 A,  16 B are located generally external to the window and in the opening  11  of the dwelling  14  and remain attached fixedly to the dwelling whether or not the shutters  12  are open or closed. The lower mounting bracket  16 A (see  FIGS. 3 and 4 ) attaches rigidly to a sill  22  of the window and the upper mounting bracket  16 B attaches rigidly to the header  24  of the window. When the shutter assembly  10  is closed and locked, the elongated backing member  17  of the storm bar device  13  is located inside of the shutters  12  (i.e. between the shutters  12  and the window, yet inside the opening  11 ) and extends between and fastens to the lower and upper mounting brackets  16 A,  16 B. The elongated retention bracket  18  is located externally of the shutters  12  and projects laterally through the gap  19  to engage the elongated backing member  17  and preferably the brackets  16 A,  16 B via the quick release fasteners  20 . The backing member  17  and thus the lower and upper brackets  16 A,  16 B are adapted to be fixedly mounted to the dwelling  14  for keeping the shutters  12  spaced from the dwelling  14  when the shutters  12  are in the closed position. That is, the backing member  17  keeps the shutters  12  in a spaced relationship relative to the dwelling  14 . 
   Referring to  FIG. 6 , the retention bracket  18  is preferably a T-bar having a generally T-shaped cross section that includes a retention portion  26  and a locking portion  28  that longitudinally bisects the retention portion  26  and projects laterally there-from at a substantial right angle. When the shutters  12  are closed, the retention portion  26  is generally co-planar to the shutters  12  and the locking portion  28  extends laterally through the gap  19  between the distal portions  21  of the closed shutters  12  to secure to the backing member  17 . As best shown in  FIG. 3 , at least the distal vertical portions  21  of the closed shutters  12  are layered snuggly between the retention portion  26  of the retention bracket  18  and the backing member  17 . During inclement weather, the retention portion  26  of the retention bracket  18  prevents the shutters  12  from moving away from the dwelling  14  into an open position. 
   The elongated backing member  17  preferably has a U-channel section  55  having opposite side walls  57 ,  59  and a bottom wall  61  that extends laterally between the two side walls  57 ,  59 . A channel  56  is defined by walls  57 ,  59 ,  61  and receives a distal edge  63  of the locking portion  28  of the retention bracket  18  that projects inward through the gap  19  and beyond the shutters  12 . The U-channel section  55  is flanked on both sides by first and second lateral flange sections  52 ,  54  that project laterally outward and extend longitudinally along the respective side walls  57 ,  59 . Each side wall  57 ,  59  extends laterally between the bottom wall  61  and respective flange sections  52 ,  54 . When the shutter assembly  12  is closed and locked, the distal portions  21  of the respective shutters  12  are layered between the retention portion  26  of the retention bracket  18  and the respective flange sections  52 ,  54  of the backing member  17 . 
   Referring more specifically to  FIGS. 2-4 , the lower and upper brackets  16 A,  16 B each have a base plate  36 , a first support leg  46  and a second support leg  48 . The legs  46 ,  48  project outward from a common side of the plate  36 , are substantially parallel to one another and define a slot  50  there-between. The slot  50  is preferably opened at an outward end with respect to the dwelling  14  that is generally defined by outward lateral edges  38 ,  40  of respective legs  46 ,  48 . The base plates  36  secure to the respective sill  22  and header  24  by at least one fastener or screw  42  that extend through holes  44  in the plate  36 . Although not required, it is preferred that molded plastic inserts, or anchors, are disposed in the sill  22  or the header  24  to receive the fasteners. The molded plastic inserts, or anchors, are disclosed in phantom in  FIG. 3 . 
   During operation of the shutter assembly  10 , and when the shutters  12  are generally open, the exterior retention bracket  18  and the interior backing member  17  are preferably removed from the dwelling  14  with only the lower and upper brackets  16 A,  16 B attached. Opposite ends of the backing member  17  are placed transversely into the slots  50  of the respective brackets  16 A,  16 B. Prior to closing the shutters  12  and prior to locking the storm bar device  13 , the lower end of the backing member  17  can rest upon the base plate  36  and in the slot  50  of the lower bracket  16 A. When so positioned, the flange sections  52 ,  54  of the backing member  17  are butted against the respective edges  38 ,  40  of the respective legs  46 ,  48  of the brackets  16 A,  16 B. This pre-alignment will generally assure that the channel  56  is aligned to the gap  19  and that the shutters  12  when closed will be properly spaced from the dwelling  14 . 
   With the backing member  17  positioned, the shutters are then closed upon the flange sections  52 ,  54  of the backing member  17 . The locking portion  28  of the retention bracket  18  is then inserted laterally through the gap  19  and into the channel  56  of the backing member  17 . When so inserted, the longitudinal ends or distal corners of the locking portion  28  are located in the slots  50  of the respective mounting brackets  16 A,  16 B thus vertically aligning the retention bracket  18 . With the retention bracket  18  in the channel  56 , one of the fasteners  20  is inserted through aligned apertures  30  in the support leg  46  of the lower mounting bracket  16 A, then through the first side wall  57  of the lower end of the interior backing member  17 , then through the locking portion  28  of the exterior retention bracket  18 , through the second sidewall  59  and then through the second support leg  48 . Likewise, another fastener  20  is inserted through apertures  30 , first in the leg  48  of the upper mounting bracket  16 B, then through the first side wall  57  of the upper end of the interior backing member  17 , then through the locking portion  28 , through the second sidewall  59  and then through the support leg  46 . Preferably providing further rigidity and strength to the storm bar device  13  are at least one intermediate fastener  58  that is spaced between the lower and upper mounting brackets  16 A,  16 B and extends through the U-channel section  55  of the member  17  and the locking portion  28  of the retention bracket  18 . With the retention bracket  18  locked to the backing member  17  and the mounting brackets  16 A,  16 B, the shutters  12  are retained in the closed position. 
   When the shutter assembly  10  is fully closed and locked, the retention bracket  18  is locked to the backing member  17 , and the shutters  12  are retained in the closed position without the fasteners  20  physically damaging the shutters  12  themselves. Preferably, the fastener  20  is a cotter pin. The cotter pin may include a separate locking needle or may be a more modern-type cotter pin with spring loaded bearings embedded in the cotter pin that retract upon insertion through the components (not shown). The fasteners  20  are not limited to cotter pins and may include many other types of fasteners including, but not limited to, a nut-and-bolt assembly, other locking pins, and the like. 
   Referring now to  FIG. 7 , in the event an emergency egress issue arises, such as during a fire, an occupant  60  can still exit the dwelling  14  through the window, door, or other opening even when the shutter assembly  10  is closed and locked. That is, from within the dwelling  14 , the occupant  60  simply opens the window, door, etc., that the shutters  12  are protecting to access the storm bar device  13 . More specifically, the occupant  60  disengages the fasteners  20 ,  58  to release the backing member  17  and the retention bracket  18  from each other and from the mounting brackets  16 A,  16 B. With the shutter assembly  10  unlocked, the occupant  60  can then easily force the shutters  12  from the closed position into the open position and exit the dwelling  14  as necessary. 
   One skilled in the art would now know that modifications to the preferred embodiment of the invention could include the omission of the elongated backing member  17  although this could potentially weaken the resistance of the shutters  12  from blowing into the opening or toward the window during high or hurricane wind scenarios. In such a modification, the slot  50  defined between the legs  46 ,  48  of each mounting bracket  16 A,  16 B, receives the respective lower and upper ends of the locking portion  28 . Hence, the first and second support legs  46 ,  48 , and not the first and second flange sections  52 ,  54 , maintain the shutters  12  spaced from the dwelling  14  when the shutters  12  are in the closed position. 
   Moreover, one skilled in the art would now know that the mounting brackets  16 A,  16 B could be omitted and the ends of the elongated backing member  17  could be mounted directly to the sill and header. Furthermore, the locking portion  28  and the U-channel section  55  could be interchanged between the exterior retention bracket  18  and the interior backing member  17 . However, the fasteners  20  would then be installed from the outside of the dwelling  14  and not the inside. 
   It is preferred that the shutters  12  of the shutter assembly  10  are impact resistant when used in combination with the lockable storm bar device  13 . Such impact-resistant shutters are commonly referred to as storm-proof or storm-rated shutters. One such shutter is disclosed in commonly assigned U.S. patent application Ser. No. 10/264,476, now U.S. Pat. No. 7,174,683 issued Feb. 13, 2007, entitled “Impact-Resistant Shutter Assembly” which was filed on the same day as the parent of this application, the disclosure of which is herein incorporated by reference in its entirety. However, the shutter assembly  10  of the subject invention may use any type of shutter  12 , including conventional aluminum shutters that are primarily utilized for decorative purposes and are not impact-resistant. The security bar device  13  is preferably made of metal for strength and can be made of aluminum and/or stainless steel to resist corrosion in salty environments. 
   As best illustrated in  FIG. 8 , an alternative shutter assembly  10 ′ is disclosed wherein like elements have the same identifying numerals of the first embodiment except with the addition of a prime symbol. A backing member  17 ′ of the shutter assembly  10 ′ has a notch or channel  30 ′ at an upper end that receives a pin or rod  64  extending across a slot  50 ′ of the mounting bracket  16 B′. The ends of the rod  64  are supported by respective legs  46 ′,  48 ′ of the mounting bracket  16 B′ that define in-part the slot  50 ′. The arrow identified as  62  in  FIG. 8  represents the direction of engagement of the backing member  17 ′ to the upper bracket  16 B′. 
   Shutter assembly  10 ′ is beneficial when used in a single hung window application, wherein the upper mounting bracket  16 B′ is inaccessible from inside the dwelling with the shutters in their closed position because of interference by the upper non-moving window pane. When assembly  10 ′ is used in this application, the occupant  60  simply raises the lower pane of the single hung window and disengages a lower fastener  20 ′ from the lower mounting bracket  16 A′ to unlock the shutter assembly  10 ′. After removing pin  20 ′, the occupant pulls the lower end of the backing member  17 ′ inwardly toward oneself and then downward to release the top end from the pin  64 . 
   Although the preferred embodiments of the present invention have been disclosed, various changes and modifications may be made thereto by one skilled in the art without departing from the scope and spirit of the invention as set forth in the appended claims. It is also understood that the terms used herein are merely descriptive, rather than limiting, and that various changes may be made without departing from the scope and spirit of the invention.