Patent Publication Number: US-8522478-B1

Title: Ready to assemble shutter

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application relates to and claims the benefit of prior U.S. Provisional Application No. 60/552,547 entitled Full View Shutter, filed Mar. 13, 2004 and incorporated by reference herein. 
    
    
     BACKGROUND OF THE INVENTION 
     Shutters are a high quality interior window treatment, having a combination of style, functionality and elegance that sets them apart from other window coverings. Shutters provide warmth in the winter and protect from damaging heat and sunlight in the summer. Shutters also provide a convenient method of controlling view, privacy and light. Conventional shutters are typically custom made of an indigenous wood such as popular, oak or ash and are installed by professionals. 
     SUMMARY OF THE INVENTION 
       FIGS. 1-2  illustrate a conventional shutter window treatment  100  having a window frame  101  mounted around a window opening and a shutter  200  mounted within and hinged to the window frame  101 , allowing the shutter  200  to swing open or closed. The shutter  200  has stiles  210 , spreaders  220 , louvers  230  and a tilt bar  240 . The louvers  230  are rotatably mounted to the stiles  210  using standard louver pins  250 . The tilt bar  240  is linked to the leading edge of the louvers  230  with an interlocked tilt bar link  260  and louver link  270  and operable up and down so as to rotate the louvers  230  to various positions. The louvers  230  have a closed position with the tilt bar  240  in a fully up position and the louvers  230  overlapping along the edges so as to block light from passing through the opening  204 . The louvers  230  also have various open positions with the tilt bar  240  positioned away from the fully up position and the louvers  230  rotated away from the plane of the opening so as to allow light to pass. 
     Conventional shutters are assembled, pre-framed and hinged at a factory, boxed as fully assembled units, and transported to a job site. Typically, assembled shutters are professionally installed. As a result, conventional shutters are expensive, long-lead items for both assembly and installation. 
     Further, conventional shutters require tradeoffs with respect to viewing area. The stiles, spreaders and tilt bar block substantial areas of the window opening, reducing the viewing area and incoming light. The shutter can swing open on its hinges to increase the view, but this requires spreaders and stiles of sufficient dimension for mechanical strength and stability, contributing to the window blockage when the shutter is closed. The louver thickness, which is dictated by the use of louver pins for louver attachment, also reduces the viewing area. 
     In addition, conventional shutters do not provide perfect light control. The mechanical structure of conventional shutters only allows the louvers to close completely in one direction, up or down. Further, when the louvers are closed, light leakage occurs through the gap between the louvers and the stiles. 
     One aspect of a ready to assemble shutter is a shutter kit method providing frame components and louvers, the frame components being configured to assemble into a frame. Trees are assembled that are adapted to attach to the frame and are capable of removably and rotatably disposing the louvers within an opening of the frame. The frame components, trees and louvers are combined as a ready-to-assemble shutter. Tree assembly may comprise the steps of providing inserts adapted to insert into stiles of the frame components, rotatably attaching louver clips at regular intervals along the length of the inserts, and interconnecting at least a portion of the louver clips with at least one tilt bar. The interconnecting substep may comprise configuring leg portions of the tilt bars to fit into gaps between the frame and the louvers, and configuring cross bar portions of the tilt bars to fit across the gaps so as to block light from passing through the gaps. 
     Further steps of the shutter kit method may include determining window measurements and selecting the frame components and louvers, based upon the window measurements, from a frame component set and a louver set, where the frame component set comprises predetermined length stiles and predetermined length spreaders and where the louver set comprises predetermined length louvers. An additional step may be trimming the trees to a specific length based on at least one window measurement. Yet another step may be pre-inserting the trees into the stiles. 
     Another aspect of a ready to assemble shutter is a shutter kit comprising frame components, louvers, inserts, louver clips and tilt bars combined as a ready to assemble shutter. The frame components are configured to assemble into a shutter frame. The louvers are adapted to fit within the shutter frame. The inserts are adapted to attach to stiles of the frame components. The louver clips are capable of rotatably attaching at regular intervals along the length of the inserts and removably retaining the louvers. The tilt bars are adapted to rotatably interconnect the louver clips. In one embodiment, the inserts, louver clips and tilt bars are preassembled into trees adapted to insert into an assembled shutter frame. The shutter kit may further comprise light stop portions of the tilt bars adapted to block light between the assembled shutter frame and the louvers when the louvers are in a closed position. The frame components and louvers may be each selected from a set of frame components and louvers having predetermined lengths. The trees may be cut to a length corresponding to the assembled shutter frame and pre-inserted into stiles of the frame components. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1-2  are front perspective and exploded front perspective views, respectively, of a conventional shutter and window frame; 
         FIGS. 3A-D  are front, back, exploded and partially exploded perspective views, respectively, of a full view shutter; 
         FIGS. 4A-B  are front perspective views of an uninstalled and an installed full view shutter; 
         FIGS. 5A-B  are perspective views of ready-to-assemble (RTA) full view shutter kit embodiments; 
         FIG. 6  is a flow diagram of a full view shutter assembly and installation process; 
         FIGS. 7A-C  are front perspective, back perspective and back plan views, respectively, of a frame; 
         FIGS. 8A-C  are front perspective views of tree installation in the frame; 
         FIG. 9  is a front perspective view of louver installation; 
         FIGS. 10A-D  are top, left side, front and right side views, respectively, of a frame component embodiment; 
         FIGS. 11A-D  are top, front, side and bottom views, respectively, of an alternative frame component embodiment; 
         FIGS. 12A-C  are top, front and side views, respectively, of an insert; 
         FIGS. 13A-D  are front, top, side and back views of an unspaced louver clip; 
         FIGS. 14A-D  are front, top, side and back views, respectively, of a spaced louver clip; 
         FIGS. 15A-C  are top, front and side views, respectively, of a light stop tilt bar; 
         FIGS. 16A-C  are top, front and side views, respectively, of a louver; 
         FIG. 17  is a front perspective view of a multiple section full view shutter; 
         FIG. 18A-C  are top, front and side views, respectively, of a center post; 
         FIGS. 19A-F  are top, front, side, detailed, and exploded views of a spacer block and a detailed view of ganged spacer blocks, respectively; 
         FIGS. 20A-B  are front perspective and exploded front perspective views, respectively, of a full view shutter incorporating floating light blocks; 
         FIGS. 21A-B  are front perspective views of light stop shutter embodiments; 
         FIGS. 22A-B  are perspective views of ready-to-assemble (RTA) light stop shutter kit embodiments; 
         FIG. 23  is an exploded front perspective view of a light stop shutter illustrating assembly; and 
         FIG. 24  is a flow diagram of a light stop shutter assembly and installation process. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Full View Shutter 
       FIGS. 3A-C  illustrate a full view shutter  300  having a frame  700  that advantageously integrates the trim features of a conventional window frame with the mounting functionality of conventional stiles. This substantially increases the viewable area through the shutter. This also eliminates the necessity for a shutter panel that opens on hinges. As a result, the weight of the full view shutter  300  is significantly reduced as compared to that of a conventional window frame and shutter panel. This, along with easy assembly of the frame  700  supports a ready to assemble (RTA) kit embodiments of the full view shutter  300  that substantially reduces the lead-time and expense of factory assembled and professionally installed shutters. 
     As shown in  FIGS. 3A-C , the full view shutter  300  has frame components  1000  that are attached to form the frame  700 , as described in detail with respect to  FIGS. 7A-C , below. Inserts  1200  are adapted to be fitted within the frame components  1000  as described in detail with respect to  FIGS. 8A-C , below. Louvers  1600  are adapted to be removably attached to louver clips  1300 ,  1400 , as described in detail with respect to  FIG. 9 , below.  FIGS. 10-11  detail the frame components  1000 .  FIGS. 12A-C  detail the insert  1200 .  FIGS. 13-14  detail the louver clips  1300 ,  1400 .  FIGS. 16A-C  detail the louvers  1600 . 
     Further shown in  FIGS. 3A-C , there is no louver-mounted tilt bar to block the view through the shutter. Instead, louvers  1600  are opened and closed by moving an individual louver  1600 , which moves all the louvers  1600  via a light stop tilt bar  1500 . Advantageously, the light stop tilt bar  1500  fits between the louvers and the frame to block light from passing through that gap when the full view shutter  300  is closed. There may be one tilt bar  1500  on either side of the full view shutter  300  or two tilt bars  1500 , one on each side of the full view shutter  300 . The tilt bar or tilt bars  1500  may be located on the back of the full view shutter  300  (shown) or on the front of the full view shutter  300 . A tilt bar on the front of the full view shutter  300  advantageously functions as a handle for opening and closing the shutters. In one embodiment, an integrated grip is molded or separately attached to a tilt bar installed on the front of the full view shutter  300 . The light stop tilt bar  1500  is described in detail with respect to  FIGS. 15A-C , below. 
       FIGS. 4A-B  illustrate installation of the full view shutter  300 . Advantageously, the full view shutter is easy for the end user to size and install, eliminating the expense of professional shutter installation. The frame  700  is first sized to fit within a window opening  400 . Sizing is facilitated by the frame  700 , which has a trim  710  that fits around the periphery of the window opening and a support  720  that inserts into the window opening and rests along the window sill, supporting the shutter weight. Gaps between the support  720  and window opening  400  are covered by the trim  710 . Large gaps can be reduced by spacers, as described with respect to  FIGS. 19A-F , below. In one embodiment, the full view shutter  300  is removable. In particular, sections of Velcro® or other detachable securing mechanisms are fixedly attached around the outside periphery of the window opening  400 . Corresponding sections are fixedly attached around the backside periphery of the frame  700 . In another embodiment, the full view shutter  300  is semi-permanently installed with screws or similar fastening devices. Advantageously, the louvers can be removed prior to installation or removal of the shutter  300 , making the shutter significantly lighter and easier to handle. 
       FIGS. 5A-B  illustrate a shutter kit  500  that may be packaged, shipped and delivered as a ready-to-assemble (RTA) shutter that is easily built and installed by a layperson. Alternatively, the shutter kit components may be sold through outlets. The kit components may be cut to customer specifications or provided in standard sizes, as described in further detail below. As shown in  FIG. 5A , an unassembled kit embodiment has frame components  1000 , inserts  1200 , unspaced louver clips  1300 , spaced louver clips  1400 , one or more tilt bars  1500  and louvers  1600 . The frame components  1000  may come in two sizes, corresponding to vertical (stile) and horizontal (spreader) frame members, respectively. A partially assembled kit embodiment ( FIG. 5B ) has preassembled louver clip “trees”  310 ,  320  having unspaced and spaced louver clips  1300 ,  1400  pressed into the inserts  1200  and the tilt bar  1500  pressed onto the spaced louver clips  1400 . In one embodiment, the frame components  1000  and louvers  1600  are constructed of prefinished fiberboard and the inserts  1200 , tilt bars  1500  and louver clips  1300 ,  1400  are constructed of plastic. Prefinished fiberboard shutter components, inserts, louver clips (“end caps”) and removable louvers are described in U.S. Pat. No. 6,622,433 entitled Prefinished Medium Density Fiberboard Shutter, issued to the inventor of the current invention and incorporated by reference herein. 
       FIG. 6  illustrates a shutter kit assembly and installation process  600 . Initially, an end user determines their window size  610 . Based on window size, the end user purchases a set of shutter components  620 , such as illustrated in  FIGS. 5A-B . In one embodiment, shutter components may be pre-packaged according to various standard sizes. In another embodiment, shutter components may be individually selected and matched according to various standard sizes. A mechanical or electronic calculation device may be utilized that has window sizes as an input and that indicates corresponding component sizes as an output. The sizing can be further refined by cutting components to size or purchasing spacers  630 . In a particularly advantageous embodiment, the combination of a frame having a trim  710  ( FIGS. 7A-C ) that overlaps a window opening and spacers  1900  ( FIGS. 19A-F ) that fill in between standard sizes minimizes the number of stock keeping units (SKUs). Next, the frame is assembled  640 , as shown and described with respect to  FIGS. 7A-C . The frame can be assembled to enclosed standard louvers having pins. Alternatively, trees having louver clips are installed into the frame  650 , as shown and described with respect to  FIGS. 8A-C , and louvers are removably installed into the clips  660 , as shown and described with respect to  FIG. 9 . Spacers are added  670  if needed, and the assembled shutter is installed  680 , as shown and described with respect to  FIGS. 4A-B . 
       FIGS. 7A-C  illustrate the full view shutter frame  700 , which is advantageously constructed of two pairs  701 ,  702  of the same frame component  1000 , each pair differing, perhaps, only in length. Further, an end user can easily join the individual frame components  1000  along diagonal cut ends  1030  ( FIGS. 10A-D ) and fixedly attached the frame components  1000  together with press fit Hoffman keys  730 . Alternatively, or in addition to the keys  730 , screws or similar fasteners can be used to attach the frame components  1000 . The assembled frame  700  has a trim  710  and a corresponding support  720  defining a frame opening  709 . A frame groove  705  is defined by the support  720  proximate the opening  709 . The frame  700  is configured to encompass the louvers  1600  ( FIGS. 3A-B ) within the opening  709 . In a removable louver shutter embodiment described here and below, louvers are installed after frame assembly and installation. In a fixed louver shutter embodiment, the frame groove  705  is replaced with pin holes. Accordingly, an end user encloses louvers during frame assembly, and the louvers are held to the frame with louver pins inserted into the louver ends and the pin holes. 
       FIGS. 8A-C  illustrate assembly of the trees  310 ,  320  into the frame  700 . An unspaced tree  310  has an insert  1200  and unspaced louver clips  1300 . A spaced tree  320  has an insert  1200 , spaced louver clips  1400  and an attached light stop tilt bar  1500 . The spaced louver clips  1400  accommodate corresponding notches of the tilt bar  1500  so that, when the louvers are closed, the tilt bar is fully disposed between the louvers and the frame  700 . The louver clips  1300 ,  1400  are pressed into and rotatably retained by the inserts  1200 . As shown in  FIGS. 8B-C , the insert  1200  of each tree  310 ,  320  has a tongue  1220  extending the length of the insert  1200  that is pressed into the frame groove  705  so that the frame  700  retains the trees  310 ,  320 . 
       FIG. 9  illustrates louver installation into the frame  700 . In particular, louver ends  1620  slide into and are removably retained by the louver clips  1300 ,  1400 . 
       FIGS. 10A-D  illustrate a frame component  1000  that provides both the vertical and horizontal members of the frame  700  ( FIGS. 7A-C ). As such, each member of the frame  700  is advantageously manufactured by a common process and cut to size as a final process step. In one embodiment, unseparated and unsized frame components, louvers and trees are supplied as manufactured to wholesalers and distributors, for example, who then perform the final process step of cutting and sizing individual shutter parts. The frame component  1000  has a trim section  1010 , a support section  1020  and diagonal-cut ends  1030 . The trim section  1010  extends generally perpendicularly to the support section  1020  so as to form an L-shape cross-section. The diagonally-cut ends  1030  are adapted to fixedly attach to corresponding diagonally-cut ends  1030  of other frame components  1000  so as to fit into the corners of a window opening  400  ( FIG. 4A ). An inside edge  1003  is configured to align proximate an edge of the window opening  400  ( FIG. 4A ). A groove  1025  extends along the length of the support section  1020  and is configured to accept an insert  1200  ( FIGS. 12A-C ). In one embodiment, the frame component  1000  is constructed of prefinished fiberboard. 
       FIGS. 11A-D  illustrate an alternative frame component embodiment  1100  that accepts spacers  1900  for end user sizing of the frame  700  to a particular window opening  400  ( FIG. 4A ), as described with respect to  FIGS. 19A-F , below. The frame component has a trim section  1110 , a support section  1120 , a groove  1125  and diagonal-cut ends  1130  that function as described with respect to the frame component embodiment  1000  ( FIGS. 10A-D ), above. In addition, the frame component  1100  has a spacer groove  1127  configured to interlock with a spacer tongue  1920  ( FIGS. 19A-F ) so as to removably retain a spacer  1900 . 
       FIGS. 12A-C  illustrate an insert  1200 , which is an elongated tree component having a shelf  1210  and a tongue  1220 . The tongue  1220  provides a friction fit within a frame groove  705  ( FIGS. 7A-B ) and the shelf  1210  rests along the frame support  720  ( FIGS. 7A-B ). Multiple pin holes  1230  are evenly spaced along the shelf  1210  that rotatably retain unspaced louver clips  1300  ( FIGS. 13A-D ) or spaced louver clips  1400  ( FIGS. 14A-D ), as described below. In one embodiment, the insert  1200  is a single section of extruded plastic or similarly flexible material that is cut to size corresponding to a particular frame component length. 
       FIGS. 13A-D  illustrate an unspaced louver clip  1300 , which is adapted to removably retain a louver  1600  ( FIGS. 16A-C ), as described in detail below. The unspaced louver clip  1300  has a body  1310 , side flaps  1320 , end flaps  1330  and an insert button  1340 . The body  1310  is generally planar with an inside face  1301  and an outside face  1302  and is configured to cover a louver end  1620  ( FIGS. 16A-C ) so that the inside face  1301  is proximate the louver  1600  ( FIGS. 16A-C ) and the outside face  1302  ( FIGS. 16A-C ) is distal the louver  1600 . The side flaps  1320  and end flaps  1330  extend normally to the body  1310  from the inside face  1301  and are configured so that the side flaps  1320  grip the louver faces  1610  ( FIGS. 16A-C ) and the end flaps  1330  grip the louver edges  1630  ( FIGS. 16A-C ). Accordingly, an unspaced louver clip  1300  is constructed of a material having some flexibility, such as a thin plastic, so that one or more of the side flaps  1320  and end flaps  1330  can be deflected for attachment or detachment to a louver  1600 . 
     As shown in  FIG. 13B-D , the insert button  1340  is adapted to snap into and be rotatably retained inside an insert pin hole  1230  ( FIGS. 12A-C ) so that a louver  1600  ( FIGS. 16A-C ) can be rotatably retained within the frame  700  ( FIGS. 7A-C ). In one embodiment, the insert button  1340  extends normally from the louver clip outside face  1302  and has a catch that snaps inside a pin hole  1230  ( FIGS. 12A-C ). In an alternative embodiment, not shown, the side flaps  1320  or end flaps  1330  or both are replaced by a wedge, prongs or similar structure extending from the center of the inside face  1301  and adapted to insert into, and fixedly attached to, a louver end  1620  ( FIGS. 16A-C ). 
       FIGS. 14A-D  illustrate a spaced louver clip  1400 , which is adapted to removably retain a louver  1600  ( FIGS. 16A-C ), as described in detail below. The spaced louver clip  1400  has a body  1310 , side flaps  1420 , end flaps  1430 , which are the same in configuration and function as described for the unspaced louver clip  1300  with respect to  FIGS. 13A-D , above. The spaced louver clip  1400  also has an insert button  1440  formed on a spacer  1450 . The insert button  1440  functions as described for the unspaced louver clip  1300  with respect to  FIGS. 13A-D , above. The spacer  1450  is described below. 
     As shown in  FIGS. 14A-D , the spaced louver clip  1400  is also adapted to rotatably retain a tilt bar  1500  ( FIGS. 15A-C ), as described in detail, below. In particular, the spaced louver clip  1400  has a tilt bar button  1460  adapted to snap into a tilt bar hole  1530  ( FIG. 15C ) and be recessed within a tilt bar groove  1540 . In a closed position, the tilt bar  1500  ( FIGS. 15A-C ) has notches  1530  ( FIG. 15C ) that accommodate the spacers  1450 . In one embodiment, the tilt bar button  1460  extends normally from the louver clip outside face  1402  proximate one end and has a catch that snaps inside the tilt bar hole  1530  ( FIG. 15C ). In this manner, the tilt bar  1500  can connect multiple louvers  1600  ( FIGS. 16A-C ), as described with respect to  FIGS. 15A-C , below. Also, the tilt bar  1500  ( FIGS. 15A-C ) fits between the louvers  1600  ( FIGS. 16A-C ) and the frame  700  ( FIGS. 7A-C ). 
       FIGS. 15A-C  illustrate a light stop tilt bar  1500 , which advantageously functions both as a tilt bar to interconnect and rotate the louvers  1600  ( FIGS. 3A-B ) and as a mechanism for blocking light from “leaking” between the frame and the louvers on a closed shutter. The tilt bar  1500  is an elongated, generally T-shaped piece having a cross bar  1510 , a leg  1520  extending generally perpendicularly from the cross bar  1510 , tilt bar holes  1550  evenly distributed along the length of the tilt bar  1500  within a groove  1540  extending the length of the tilt bar  1500 , and notches  1530  evenly distributed along the leg  1520 . In particular, the leg  1520  is configured to fit in the gap between the frame  700  ( FIGS. 7A-C ) and the louver ends  1620  ( FIGS. 16A-C ), and the cross bar  1510  is configured to fit across that gap, effectively blocking light from passing through the gap. The notches  1530  accommodate corresponding louver clip spacers  1450  ( FIGS. 14B-D ) when the shutter is closed. 
       FIGS. 16A-C  illustrate a louver  1600 , which is a generally planar shutter component having louver faces  1610 , louver ends  1620  and louver edges  1630 . Multiple louvers  1600  are removably snapped into corresponding unspaced louver clips  1300  ( FIGS. 13A-C ) and/or spaced louver clips  1400  ( FIGS. 14A-C ) and extend parallel between frame components  1000  ( FIGS. 10A-D ). Advantageously, the louvers  1600  can be made substantially thinner than conventional louvers, which must accommodate a louver pin  250  ( FIG. 2 ). This allows more light to pass through an open shutter. In one embodiment, the louvers are manufactured at a thickness of less than ⅜ inch. 
       FIG. 17  illustrates a multiple section shutter  1700  having a frame  700 , trees  310 ,  320  and louvers  1600  as described above with respect to  FIGS. 8A-C . The multiple section shutter  1700 , however, has a center post  1800  that advantageously allows a single full view shutter to be placed within a wide window, typically greater than 4′ in length. Otherwise the shutter would have excessively long louvers prone to bowing and warping. The frame  700  is constructed around the center post  1800 , described with respect to  FIGS. 18A-C , below, which fits within the frame groove  705 . The center post  1800  can be held in place by the installed louvers  1600  or fixedly attached to the frame with Hoffman keys or other fastener or adhesive. 
       FIG. 18A-C  illustrate a center post  1800 , which is a generally elongated multiple section shutter  1700  component having a front  1810 , sides  1820 , ends  1830 , post grooves  1840  extending the length of each of the sides  1820  and post tongues  1850  extending generally perpendicularly from the ends  1830 . The center post  1800  is configured to be enclosed by the frame  700  ( FIG. 17 ) during frame assembly for the multiple section shutter  1700  ( FIG. 17 ), described above. In particular, the post tongues  1850  fit within the frame groove  705  at parallel sections of the frame  700 . The post grooves  1840  are configured for tree installation in a manner similar to that described for the frame groove  705  ( FIGS. 8B-C ), above. 
     In an advantageous embodiment, the frame components and louvers are selected from frame component sets and louver sets each having various standard or predetermined lengths. The selected lengths are based upon window measurements so that a standardized frame and corresponding louvers best fit the dimensions of a particular window. In this manner, cutting frame components and louvers to size is reduced or eliminated without requiring an excessive number of stock keeping units (SKUs). 
       FIGS. 19A-F  illustrate a spacer  1900  having a generally block-shaped body  1910 , a spacer tongue  1920  and a spacer groove  1930 . One or more spacers  1900  are advantageously utilized to fill a gap between a frame support  720  and the sides of a window opening. An end user utilizes the spacer  1900  to size a standardized frame to a particular window. The spacer tongue  1920  is configured to interlock with a spacer groove  1127 ,  1930  on either a frame component  1100  ( FIGS. 11A-D ) or another spacer  1900 . In this manner, one or more spacers  1900  can be used to fill various size gaps. One or more spacers  1900  may be placed along the bottom, sides and/or top of a frame  700  so as to stabilize and center a frame  700  within a window opening. In one embodiment, the frame components  1100  ( FIGS. 11A-D ) and louvers  1600  ( FIGS. 16A-C ) are provided in sets of predetermined lengths to best fit window dimensions, either height or width, of 4′, 4½′, 5′, 5½′, 6′, 6½′, etc., and spacers  1900  are provided in ½″ thicknesses and utilized to fit window dimensions in between these ½″ spacings. 
       FIGS. 20A-B  illustrate a light block shutter  2000  having frame components  1000 , inserts  1200 , clips  1300 ,  1400 , a tilt bar  1500  and louvers  1600  as described with respect to  FIGS. 3A-C , above. Further, the light block shutter  2000  has floating light blocks  2010  configured to fit within the frame groove  705  ( FIGS. 7A-B ). The light blocks  2010  are held in place at the top and bottom of the frame by the inserts  1200 . In particular, the inserts  1200  are sized to fit between the top and bottom light blocks  2010  within the grooves of the vertical frame components  1000 . Further, the light blocks  2010  are made substantially thinner than the width of the groove so that the light blocks “floats” within the groove, i.e. the light blocks can easily shift and/or tilt within the groove toward either the front or the back of the shutter. Advantageously, this floating light block feature allows the shutter to completely shut regardless of whether the louvers are closed in an upward or downward slanting direction. In contrast, prior art shutters can only close in one direction. The floating light blocks  2010  combined with the light block tilt bar  1500  provide a light block shutter  2000  with the ability to more effectively shut out light from entering a room. In one embodiment, a paper finish applied to the frame components  1000 , which is slit the length of the groove, advantageously acts as a gasket that holds the floating light blocks  2010  in place unless pressed upon by adjacent louvers. 
     Light Stop Shutter 
       FIGS. 21A-B  illustrate shutter embodiments  2100 ,  2105  that have easy assembly features supporting a ready to assemble (RTA) kit that substantially reduces the lead-time and expense of factory assembled and professionally installed shutters. The light stop shutter embodiments  2100 ,  2150  have frame components  2310 ,  2320  ( FIG. 23 ) configured to assemble into a shutter frame  700 , as described in detail with respect to  FIGS. 23-24 , below. Trees  320 , as described above, are adapted to be inserted into the shutter frame  2110 . Louvers  1600 , as described above, are adapted to be removably attached to the trees. 
     As shown in  FIGS. 21A-B , there are no louver-mounted tilt bars to block the view through the shutters  2100 ,  2105 . Instead, louvers  1600  are opened and closed by moving an individual louver  1600 , which moves all the louvers  1600  via light stop tilt bars  1500 . Advantageously, the light stop tilt bars  1500  fit in the gap between the louvers and the frame to block light from passing through that gap when the shutters  2100 ,  2105  are closed. There may be a tilt bar  1500  on either side of the shutter  2100 ,  2105  or two tilt bars  1500 , one on each side of the shutter  2100 ,  2105 , as shown. The tilt bar or tilt bars  1500  may be located on the back of the shutter  2100  or on the front of the shutter  2105 . Tilt bars on the back of the shutter  2100  are advantageously at least partially hidden. Tilt bars on the front of the shutter  2105  advantageously function as handles for opening and closing the shutters. The light stop tilt bar  1500  is described in detail with respect to  FIGS. 15A-C , above. 
       FIGS. 22A-B  illustrate light stop shutter kit embodiments  2200 ,  2205  that may be combined, packaged, shipped and delivered as a ready-to-assemble (RTA) shutter that is easily built and installed by a layperson. Alternatively, the shutter kit components may be sold through outlets. The kit components may be cut to customer specifications or provided in standard sizes. An unassembled kit has stiles  2310 , spreaders  2320 , trees  320  and louvers  1600 . The trees  320  may be pre-assembled ( FIG. 22B ) from inserts  1200 , tilt bars  1500  and louver clips  1400  as described above, or distributed unassembled ( FIG. 22A ). In one embodiment of the RTA kit, the trees  320  are pre-installed into the stiles  2310 , e.g. inserted into the stiles and held in place with tape or a similar temporary fastener. In one embodiment, the stiles  2310 , spreaders  2320  and louvers  1600  are constructed of prefinished fiberboard and the inserts  1200 , tilt bars  1500  and louver clips  1300 ,  1400  are constructed of plastic, as described in U.S. Pat. No. 6,622,433 cited above. 
       FIGS. 23-24  illustrate RTA shutter kit assembly. As shown in  FIG. 24 , window measurements are determined  2410 . In one embodiment, the shutter components are provided in standard sized sets and shutter components are selected based upon these measurements  2420 . In another embodiment, the shutter components are cut to a specified length. The shutter frame is then assembled  2430 . In particular, as shown in  FIG. 23 , the spreaders  2320  are fixedly attached to the stiles  2310  so that spreader tongues  2322  are inserted into stile grooves  2312 . The stiles and spreaders are held in place with glue and/or mechanical fasteners. 
     Further shown in  FIG. 24 , the assembled shutter frame is mounted to a conventional window frame  101  ( FIGS. 1-2 ). The window frame components may be included in the RTA light stop shutter kit or provided separately. In a particular embodiment, the shutter frame may have predrilled holes for screws or similar fasteners to attach hinges  110  ( FIG. 2 ) to the shutter frame. 
     Also shown in  FIG. 24 , trees are installed into the frame  2450 . In particular, as shown in  FIG. 23 , the tree inserts  1200  are inserted into the stile grooves  2312 . The trees may be provided in a general length and cut or otherwise trimmed to size for a specific frame or may be provided in standard sizes or pre-cut to size. The shutter assembly is completed by installing the louvers  2460  ( FIG. 24 ). In particular, the ends of the louvers  1600  ( FIG. 23 ) are removably attached to the louver clips  1400  ( FIG. 23 ). 
     A ready-to-assemble (RTA) shutter has been disclosed and described above in detail in connection with various embodiments, including a full view shutter and a light stop shutter. These embodiments are disclosed by way of examples only and are not to limit the scope of the claims that follow. One of ordinary skill in art will appreciate many variations and modifications.