Patent Publication Number: US-2019195007-A1

Title: Gear Driven Louver Shutter System

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     The present application is a Continuation in Part of U.S. Ser. No. 15/726,328, filed on Oct. 5, 2017 and entitled “Gear Driven Louver Shutter System”, the entire disclosure of which is incorporated by reference herein. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     The present invention relates to the field of shutter systems, and more specifically to shutter systems which utilize a plurality of adjustable louvers. 
     2. Description of Related Art 
     Louvers were first seen in the Middle Ages to allow ventilation, while still offering protection against natural elements such as rain, snow, or heavy wind. These louver systems were primarily comprised of fixed louvers and were commonly placed onto roof holes in kitchens to allow smoke and steam to escape. 
     Modern shutter systems, which utilize a plurality louvers, first started appearing in the early 1900s. The louvers of the shutters were adjustable and could be open or closed when a user pulled a handle or turned a hand-crank. All of the louvers in the shutter system would be connected with a tilt bar, such that all of the louvers in the system would remain parallel as they were adjusted. The louvers were commonly made from wood, glass, vinyl, PVC, or aluminum. 
     Many louver assemblies seen today do not come equipped with a handle or hand crank, instead the user simply adjusts the tilt bar or one of the louvers to adjust the angle of all of the louvers in the assembly. While a tilt bar can successfully keep all louvers of a shutter assembly in a parallel with one another, it can be an unsightly feature which some users prefer not to look at. Hidden tilt bars may be used which nest inside the stile of the shutters, however their implementation prevents the louvers from fully closing in both direction. 
     Based on the foregoing, there is a need in the art for a shutter assembly wherein the tilt of the louvers may be controlled by a hidden apparatus. What may be further desired is a hidden apparatus to control the tilt of the louvers and allows for the louvers to be closed in both directions without obstruction of the view. 
     SUMMARY OF THE INVENTION 
     In an embodiment, a louver shutter system is provided as two frame members separated by a plurality of louvers. Two gear tracks are disposed within at least one of the frame members. Each gear track is formed a gear strip having a plurality of apertures with a plurality of gear racks inserted into the apertures. 
     In an embodiment, a plurality of pinions is removably engaged with the gear racks of the gear tracks via a plurality of teeth provided on a portion of the pinion. The pinons are further provided with one or more connector pins. Each of the pinions engages with one end of a louver via the connector pins. 
     When one louver is adjusted, all the louvers in the shutter system will move accordingly, due to the movement of the gear strip rotating the pinions in that frame member at the same rate. 
     The foregoing, and other features and advantages of the invention, will be apparent from the following, more particular description of the embodiments of the invention, the accompanying drawings, and the claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present invention, the objects and advantages thereof, reference is now made to the ensuing descriptions taken in connection with the accompanying drawings briefly described as follows. 
         FIG. 1  is a front elevational view of the gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 2  is a perspective view of the frame component of the gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 3  is a perspective view of the pinion component of the gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 4  is a cross-section view of the gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 5  is a cross-section view of the gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 6  is an exploded view of the gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 7  is an exploded view of the gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 8  is a perspective view of the connector pin of the gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 9  is a front elevational view of the gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 10  is a cut away of the frame member gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 11  is a cross-section view of the gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 12  is a cross-section view of the gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 13  is a perspective view of the frame component of the gear driven louver shutter system, according to an embodiment of the present invention; 
         FIG. 14  is a perspective view of the pinion component of the gear driven louver shutter system, according to an embodiment of the present invention; and 
         FIG. 15  is a perspective view of the gear strip component of the gear driven louver shutter system, according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Embodiments of the present invention and their advantages may be understood by referring to  FIGS. 1-15 , wherein like reference numerals refer to like elements. 
     In reference to  FIG. 1 , a complete shutter assembly is shown, wherein a plurality of louvers  5  have been mounted to the frame members (not shown) and the frame members have been inserted into the stiles  9 . In the embodiment, the louvers  5  are positioned horizontally, in another embodiment, the louvers  5  may be positioned vertically (as shown in  FIG. 9 ). In the embodiment, the shutter assembly if further comprised of a midrail  15 , a bottom rail  16 , and a top rail  20 . In another embodiment, the shutter assembly may contain more midrails, bottom rails, top rails, or none at all. 
     In reference to  FIG. 2 , according to an embodiment of the present invention, a frame member  10  is shown with two gear strips  25  inserted into the gear track  11  of the frame member  10 . The frame member  10  is further comprised of a shaft cavity  12 , a neck cavity  13 , and drilled holes  14  such that the frame member is able to receive a pinion (not shown). 
     In an embodiment, the frame member  10  is comprised of aluminum which is created via extrusion. In another embodiment, the frame member  10  may be any metal, wood, plastic, or other material deemed suitable. 
     In reference to  FIG. 3 , according to an embodiment of the present invention, a pinion  30  is comprised of a gear drive shaft  35  and connector pin  40 . In an embodiment, the shaft  35  is further comprised of a guide washer  36 , to retain the pinion  30  inside the frame member (not shown). The shaft  35  further comprises of a plurality of gears  37  to engage with a gear strip (not shown). 
     In an embodiment, the connector pin  40  is further comprised of a line-up joint  41  to retain the position of the pinion  30  when inserted into a frame member (not shown). The connector pin is further comprised of two louver pins  42  to adapted to engage with a louver or louver clip (not shown). In another embodiment, the connector pin may have one louver pin with teeth or more than two louver pins. 
     In the embodiment shown in  FIG. 3 , the gear drive shaft  35  and connector pin  40  are fastened together to form the pinion  30 , via a connector screw  45 . The connector screw  45  is received by a counter-sunk aperture  43 , provided in the connector pin  40 , and a threaded aperture  38  provided on the gear drive shaft  40 . In the embodiment, a Philips type screw is used, however the screw used may be any type. In another embodiment, attachment of the shaft and pin may be achieved using a nut and bolt, snap on, or other connection deemed appropriate. In an embodiment, the end of the gear drive shaft  35  is a hexagonal shape provided to engage with the line-up joint  41  to prevent slipping between the pin and shaft. In another embodiment, the end of the gear drive shaft may be provided with teeth, be square, or another shape to prevent slipping between the pin and the shaft. 
     In reference to  FIG. 4-5 , a cross-sectional view of a pinion to be inserted into a frame member  10  is shown. In the embodiment shown, the frame member  10  has been drilled with four holes  14  to accommodate the pinion. The same four holes will be drilled at any location along the length of the frame member  10  in which a pinion is to be placed. In the embodiment, the gear drive shaft  35  and connector pin  40  are inserted separately into the holes  14  on opposing sides of the frame member  10 , then assembled or connected via the preferred method of attachment. 
     When properly assembled, the gears  37  of the pinion are engaged with the gear strips  25 , such that rotation of a pinion causes the gear strips to slide within the gear track. The rotation of one pinion, will then cause all other pinions assembled in the frame member to rotate in the same manner. In an embodiment, the assembled frame member is then inserted into a stile  9 . The stile is provided to retain the frame members and hide the conceal the components of the assembly. 
     In reference to  FIG. 6 , according to an embodiment of the present invention, a shutter assembly is shown in an exploded state, having pinions and gear strips (not shown) assembled into the frame members  10 . In the embodiment shown, louver clips  50  are provided to be inserted into the louvers  5  and attached to the connector pins  40  of the pinion. In the embodiments, the louver clips  50  are snapped onto the connector pins  40  and snapped into the louvers  5 . In other embodiments, the louver clips  50  may be adhered into the louvers  5  or fit into the louvers with a transitional tolerance. In another embodiment, the louvers may contain holes which allow for direct insertion of the connector pins  40  into the louvers  5  without a louver clip. 
     In an embodiment, each the frame members  10  are inserted into a stile  9  after they are assembled. The stiles  9 , are provided to conceal the components of the frame member which may be considered unsightly. When utilized, the stiles  9  give the shutter system a clean appearance without a tilt bar. 
     In the embodiment, the louvers are assembled in position to be parallel with one another. The assembly is provided to allow a user to tilt one louver, twisting its pinions and moving the gear strip to tilt all the louvers in the assembly, such that they remain parallel with one another. This arrangement relinquishes the need for a tilt bar, as seen in most shutter assemblies. 
     In reference to  FIG. 7 , according to an embodiment of the present invention, a shutter assembly similar to the shutter assembly of  FIG. 6  is shown, wherein louvers  5  are shown having a curved profile as a variation. The curved profile allows for light for complete blocking of light when the louvers  5  are arranged with a slight overlap. It could be appreciated, that the profile of the louvers may be further varied to achieve a desired aesthetic. In the embodiment, one side of the shutter assembly is provided with a support frame  210  having louver supports  140 . In the embodiment, the louver supports are comprised of a single pin which is inserted into one end of each louver. In another embodiment, the louver supports are each inserted into a louver clip and the louver clips are inserted into each louver. In an embodiment, the louver supports are an integrated component of the support frame. In another embodiment, the louver supports are removably inserted into through holes provided in the support frame. In an embodiment, the louver supports have a smooth circumference such that the louvers or louver clips may rotate freely about the support. In the embodiment, the support frame is not provided with a gear system. 
     In reference to  FIG. 8 , according to an embodiment of the present invention, a variation of the connector pin is shown have four pins to engage with a louver clip or louver. In the variation shown, the connector pin does not have an aperture for a fastening component such as a screw, however one can consider additional variations of the connector pin in which an aperture for a fastener is provided. In another embodiment, varying pin numbers and shapes may be used. 
     In reference to  FIG. 10-11 , according to an embodiment of the present invention, a frame member  100  is shown with a gear strip  102  inserted into the frame member  100 . A low-friction glide strip  104  is interposed between the gear strip  102  and a wall  115  of the frame member. The frame member  100  is further comprised of a shaft cavity  108 , an optional neck cavity  110 , and pinion holes  112  such that the frame member is able to receive a pinion  114 . The pinion  114  may be inserted through a pinion hole  112  to interface with the gear strip  102  within the frame member  100 . 
     In an embodiment, the glide strip  104  has two protrusions  116  forming a channel  118 , within which the gear strip  102  may glide, without contacting the walls of the frame member  100 . The glide strip may be made of a low-friction plastic material known in the art, that reduces the friction between a sliding gear strip  102  and channel  118 . 
     The glide strip may be held within the gear track with a friction fit, and/or may have one or more protrusions  120  on the reverse to interface with a clamp or groove  122  on the inside wall of the frame member. 
     In an embodiment, the frame member  10  and frame member  100  are comprised of aluminum, which is created via extrusion. In another embodiment, the frame member  10  or  100  may be any metal, wood, plastic, or other material deemed suitable. 
     In an embodiment, the louvers are comprised of wood. In other embodiments, the louvers may be comprised of vinyl, polyvinyl chloride (PVC), composite, acrylic, aluminum, or any material deemed suitable. In an embodiment, the pinions and gear strips are comprised of plastic. In another embodiment, the pinions and gear strips may be comprised of vinyl, polyvinyl chloride (PVC), composite, acrylic, aluminum, or any material deemed suitable. 
     With reference to  FIGS. 12-15 , another embodiment of the gear driven louver shutter system is depicted. In an embodiment, the system is provided with two gear tracks  211  to be inserted into the lower portion of the frame member  200 . In an embodiment, each gear track is comprised of a gear strip  202  having a plurality of apertures to receive gear racks  212 . In the embodiment, the connector pins  240 , collar  241 , and drive shaft  235 , which are all integrated as a single, integrated pinion component  230 . A plurality of pinions  230  are provided for the system and each pinion is inserted into a through hole  214 . A plurality of through holes  214  are provided along the length of the frame member  200 . In the embodiment, each through hole is provided with the same diameter throughout the frame member. 
     With reference to  FIG. 12 , a cross section view of the frame member  200  is shown according to an embodiment. In the embodiment shown, pinion  230  has been inserted into one of the through holes on one side of the frame member. The pinion is provided with a collar  241  below the connector pins  240 . The collar is provided with a larger diameter than the through hole and the drive shaft  235 , such that the collar rests against one side of the frame member. In the embodiment, two gear tracks have been inserted into the frame member. However, an embodiment using only one gear track would still produce a functional system. Each gear track has a gear strip  202  with a plurality of apertures to receive removable gear racks  212 . The gear racks engage the teeth of each pinion. In an embodiment, the gear strips  202  are provided with two protrusions  216  and have a substantially ‘I’ shaped cross-section. In the embodiment, the protrusions are provided to reduce the surface area of the gear strip against the frame member, such that friction is reduced. In an embodiment, the end of the gear shaft, opposite of the connector pin, is provided with a reduced diameter portion  245  to decrease friction against the frame member. In an embodiment, the frame member  200  is provided with indentations  209 , such that a decorative stile may engage with and cover the frame member (similar to the depiction in  FIG. 5  of stile  9  engaging with the frame member). 
     In an embodiment, with reference to  FIG. 13 , a portion of a frame member  200  is depicted. The frame member is provided with a plurality of through holes  214  to receive a pinion. Each through hole consists of the same diameter throughout the frame member. In the embodiment, two gear tracks have been inserted into the frame member. Each gear track has a gear strip  202  with a plurality of apertures to receive removable gear racks  212 . The gear racks engage the teeth of each pinion. In an embodiment, the gear strips  202  are provided with two protrusions  216  at each end and have a substantially ‘I’ shaped cross-section. In an embodiment, the frame member  200  is provided with indentations  209 , such that a decorative stile may engage with and cover the frame member (similar to the depiction of stile  9  engaging with the frame member in  FIG. 5 ). 
     With reference to  FIG. 14 , an embodiment of the pinion component  230  is shown. In the embodiment, the connector pins  240 , collar  241 , and drive shaft  235 , which are all integrated as a single, integrated pinion component. In the embodiment, the drive shaft  235  includes a plurality of teeth  237  to form a gear. In the embodiment, the plurality of teeth are formed by a plurality of reductions in diameter, and not by protrusions. In an embodiment, the pinion is further provided with a tolerance collar  242 . The tolerance collar provides a tight fit with the outer aperture of the frame member to prevent the attached louvers from wiggling. In an embodiment, the end of the gear shaft, opposite of the connector pin, is provided with a reduced diameter portion  245  to decrease friction against the frame member. In an embodiment, the pinion is comprised of plastic or another polymer which is both lightweight and cost effective. The pinion may also be provided with an aperture or through hole in the center to further reduce weight. 
     With reference to  FIG. 15 , an embodiment the gear track  211  is formed by a gear strip  202  with a plurality of apertures  222  to receive removable gear racks  212 . The gear racks engage the teeth of each pinion. In an embodiment, the gear racks are provided with a stop  214  at the ends to prevent the pinions from disengaging with the gear racks. In an embodiment, the gear strips  202  are provided with two protrusions  216  and have a substantially ‘I’ shaped cross-section. In the embodiment, the protrusions are provided to reduce the surface area of the gear strip against the frame member, such that friction is reduced. In an embodiment, one side of the gear racks  212  are provided with a bevel  213  to allow easier insertion into the apertures  222 . The embodiment having a gear strip with apertures to receive the gear racks allows for the gear strips and gear racks to be comprised of different materials. In an embodiment, the gear racks are comprised of a plastic or polymer to be both light weight and cost effective. In an embodiment, the gear strips are comprised of aluminum which is lightweight but more resistant to bending within the frame member, as the aluminum has a higher tensile and compressive strength than plastic. In an embodiment, the aluminum used for the gear strip is provided with a polymeric coating to reduce the frictional when the gear strip is in contact with a frame member. 
     In an embodiment of the present invention, an electric motor with a pinon adapted to engage with the gear strips can be implemented to create an electrically driven shutter system. In the embodiment, a remote system may be added to control the motor via remote control, allowing the shutters to be open and closed using a remote. Furthermore, this system could be adapted to an internet of things to allow a user to open and close shutter systems in their home using their mobile device. 
     The invention has been described herein using specific embodiments for the purposes of illustration only. It will be readily apparent to one of ordinary skill in the art, however, that the principles of the invention can be embodied in other ways. Therefore, the invention should not be regarded as being limited in scope to the specific embodiments disclosed herein, but instead as being fully commensurate in scope with the following claims.