Patent Publication Number: US-2023160257-A1

Title: Slat for roller shutters, shutter comprising such a slat and plant for manufacturing such a shutter

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of Application No. 102021000029336, filed 19 Nov. 2021 in Italy, and which application is incorporated herein by reference. To the extent appropriate, a claim of priority is made to the above disclosed application. 
    
    
     FIELD OF APPLICATION 
     The present invention relates to a slat for roller shutters, a shutter comprising such a slat and a plant for manufacturing such a shutter. 
     PRIOR ART 
     A roller shutter for windows and glass doors consists of a plurality of slats which are identical to one another and coupled to one another along respective longitudinal edges. The slats are shaped so as to be able to be mutually coupled to one another. The coupling zones are configured to allow partial rotation between the slats about the longitudinal direction. As a result of this freedom of rotation between the slats, the roller shutter may roll up on itself. In this way, the shutter may be completely or partially raised or lowered by rolling one or more slats into a suitable container arranged above the window or glass door space, depending upon the opening requirements of the space itself. 
     Generally, as shown in  FIG.  1   , a traditional slat D consists of an elongated body E, in a metal or plastic material, which in use will face the outside of the compartment with a first face E 1  (outer face) and towards the inside of the compartment with a second face E 2  (inner face). The elongated body E comprises a coupling appendage A, extending along the whole of an upper longitudinal edge BS, and a hollow seat C extending along the whole of a lower longitudinal edge BI. The hollow seat C is delimited by a first portion C 1  arranged on the outer face E 1  of the elongated body E and by a second portion C 2  of the elongated body, which is arranged on the inner face E 2  of the elongated body E and is generally L-shaped. The two portions C 1  and C 2  are connected by a bottom wall C 3 . 
     The hollow seat C and the coupling appendage A are shaped so as to allow mutual coupling. In particular, the coupling appendage A engages with the L-shaped second portion C 2 . As shown in  FIG.  2   , in an assembled shutter, the coupling appendage of a first slat is inserted into the hollow seat of a second slat arranged above, while the hollow seat of this first slat receives therein the coupling appendage of a third slat (not shown) arranged below. 
     The hollow seat C of each slat is open at both longitudinal ends of the slat itself. In this way, one slat may be coupled to another by longitudinally sliding the coupling appendage of one slat inside the hollow seat of the other slat starting at one of the two ends. 
     To prevent the slats from slipping out of one another as a result of longitudinal sliding between appendages and hollow seats, it is known to provide the slats with end caps that, by coupling to the end profile of the slat, retain the coupling appendage inside the relevant hollow seat. 
     The adoption of end caps is however expensive insofar as it involves the supply of additional components (the caps) and requires a specific step for the application during the production process of the shutters. 
     As an alternative to the application of end caps, it is known to lock the coupling appendage inside the relevant hollow seat by deforming two opposite end portions of the hollow seat itself, so as to close the hollow seat at the two longitudinal ends and thus retain the coupling appendage therein which was previously shaped by removing two end portions having a width corresponding to the deformed portions of the hollow seat. 
     In more detail, as shown in  FIG.  3   , in the hollow seat C to be deformed is a flap of the first portion  01  arranged on the outer face E 1  of the elongated body E. Before the coupling between the slats, the flap to be deformed is separated from the rest of the first portion  01  by means of a transverse notch that extends in depth up to the bottom wall C 3 . The same notch also partially affects the second portion C 2 , limited to the base of the L, in such a way as to implement a separate flap also in this second portion C 2 . Once the coupling appendage A has been inserted (suitably shaped), the aforementioned flap of the first portion  01  engages with the flap of the second portion C 2 , deforming it in turn. In particular, the base of the L is bent against the vertical portion of the L. In this way the hollow seat C 1  is completely closed. This operation is carried out at both ends of the slat. 
     This technical solution  1 , while allowing for the closure of the hollow seat C and therefore the locking of the coupling appendage inside the hollow seat C, has some drawbacks. 
     A first drawback is in relation to the fact that if the two coupled slats are rotated in relation to one another by an angle beyond 90°, it may happen that the coupling appendage A is forcibly inserted between the two deformed portions C 1  and C 2  and may slide out of the hollow seat C, at least partially, thereby compromising the complete functionality of the shutter. 
     A second drawback is related to the fact that the deformation of the flap of the first portion  01  modifies the outer face E 1  of the elongated body E. This is at the expense of the aesthetic appearance of the slat itself on the most visible side and therefore the value of the same slat. 
     In the field of production of roller shutters there is therefore a need to have a slat that may be assembled to form a shutter while ensuring a more stable and secure coupling between the coupling appendage and the hollow seat, without at the same time requiring changes to the external face of the slat itself. 
     DISCLOSURE OF THE INVENTION 
     Therefore, the main object of the present invention is to eliminate all or part of the drawbacks of the aforementioned prior art, in providing a roller shutter slat that may be assembled to form a shutter while ensuring a more stable and safe coupling between the coupling appendage and the hollow seat, without at the same time requiring modifications to the external face of the slat itself. 
     A further object of this invention is to provide a slat for roller shutters that is simple and cost-effective to produce. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The technical features of the invention, according to the aforementioned objectives, may be clearly seen in the content of the claims below, and the advantages thereof will become more readily apparent in the detailed description that follows, made with reference to the accompanying drawings, which represent one or more purely exemplifying and non-limiting embodiments thereof, wherein: 
         FIG.  1    is a cross-sectional view of a traditional slat for roller shutters; 
         FIGS.  2  and  3    show two slats of  FIG.  1    coupled together and shown respectively before and after the deformation of the hollow seat; 
         FIG.  3   a    shows an enlarged detail of  FIG.  3    relating to the coupling area between two slats with deformation of the coupling hollow seat; 
         FIG.  4    shows a perspective view of a slat for roller shutters according to a preferred embodiment of this invention, seen from the inner face; 
         FIG.  5    shows a perspective view of a slat for roller shutters according to a preferred embodiment of this invention, seen from the outer face; 
         FIG.  6    shows an orthogonal lateral view of the slat of  FIG.  4   ; 
         FIGS.  7  and  8    show two orthogonal views of the slat of  FIG.  4   , respectively seen from the inner face and from the outer face; 
         FIG.  9    shows a lateral orthogonal view of a shutter according to a preferred embodiment of the invention, assembled with the slats shown in  FIG.  4   ; 
         FIGS.  10  and  11    show two orthogonal views of the shutter of  FIG.  9   , respectively seen from the inner side thereof and from the outer side thereof; 
         FIGS.  12  and  13    show two perspective views of the shutter in  FIG.  9   , respectively seen from the inner and outer sides thereof; 
         FIGS.  14  to  17    show the main operational steps for the manufacture of a slat and a shutter according to the invention; and 
         FIG.  18    shows a lateral orthogonal view of a section of a shutter production plant according to the invention, comprised between a second cutting unit and a first crushing unit; 
         FIG.  19    shows a top-down orthogonal view of the section of the plant shown in  FIG.  18   ; and 
         FIG.  20    shows a front orthogonal view of an assembly station of a shutter production plant according to the invention. 
     
    
    
     DETAILED DESCRIPTION 
     The slat  1  for roller shutters according to the invention has been indicated as a whole by the reference number  1  in the accompanying figures. 
     Herein and in the following description and claims, reference will be made to the slat  1  in an assembled condition inside a shutter. Therefore, any references to a lower or upper position or to a horizontal or vertical orientation should be interpreted in this sense. 
     According to a general embodiment of the invention, the roller shutter slat  1  comprises an internally hollow elongated body  10 , which extends along a longitudinal direction X and comprises a first face  10 e and a second face  10 i, opposite the first, which in use are designed to be turned respectively towards the outside and inside of the compartment closed by the shutter of which said slat  1  is designed to form a part. 
     The elongated body  10  comprises:
         a coupling cavity  20 , which is formed along a first longitudinal edge  11  of said elongated body  10     a coupling appendage  30  which extends from a second longitudinal edge  12  of said elongated body  10 , opposite the first edge  11 .       

     Preferably, the elongated body  10  consists of a box-shaped body made by bending and profiling a metal sheet. The coupling cavity  20  is obtained integrally within the box-shaped body by bending the metal sheet; the coupling appendage  30  may also be obtained integrally within the box-shaped body (as shown in the attached figures) or alternatively it may constitute a separate piece applied to the box-shaped body. 
     As shown in  FIG.  9   , the coupling cavity  20  is designed to be engaged by the coupling appendage  30  of a first slat, identical to said slat  1 , while the coupling appendage  30  is designed to engage the coupling cavity  20  of a second slat that is identical to said slat  1 . 
     In more detail, as shown in particular in  FIG.  6   , the coupling cavity  20  is delimited by a first appendage  21  of the elongated body  10  obtained on the first face  10   e  and by a second appendage  22  of the elongated body  10  obtained on the second face  10   i.  These two appendages  21 ,  22  are connected to one another by means of a connecting portion  23  that defines the bottom of said coupling cavity  20 . 
     As shown in particular in  FIGS.  7  and  8   , the coupling appendage  30  has a longitudinal extension L 1  that is smaller than the longitudinal extension L 2  of the elongated body  10  so as to define two recesses  15 ,  16  at the ends of the second longitudinal edge  12  of the elongated body  10 . 
     According to a first aspect of the invention, as shown in particular in  FIGS.  4  and  7   , the slat  1  comprises two notches ( 24 ′,  24 ″ which are obtained on said second appendage ( 22 ) near the two opposite longitudinal ends  10 ′ and  10 ″ of said elongated body  10  and extend transversely to said first longitudinal edge  11 . 
     These two notches  24 ′,  24 ″ define, on said second appendage  22 , a first tab  25  and a second tab  26  which are placed at the two opposite longitudinal ends  10 ′ and  10 ″ of said elongated body  10 . 
     Each tab  25  and  26  is in a transversely opposite position (in relation to the longitudinal direction X) to one of said two recesses  15 ,  16  and has a longitudinal extension equal to or less than the respective recess. 
     In use (as shown in the attached figures, and in particular in  FIGS.  4 ,  6 ,  7 ,  9  and  12   ), each tab  25 ,  26  is designed to be bent against the first appendage  21  so as to close the coupling cavity  20  at the two opposite longitudinal ends  10 ′ and  10 ″ of the elongated body  10  once the coupling appendage  30  of an adjacent slat has been inserted into the coupling cavity ( 20 ) with the respective recesses  15  and  16  placed at the tabs  25  and  26 . 
     According to a further aspect of the invention, the first appendage  21  develops continuously from one end of the elongated body  10  to the other, without interruption. 
     It was possible to verify in the field that closing the coupling cavity by bending only two end portions of the second appendage  22  (tabs  25  and  26 ) provides more stable and secure locking of the coupling appendage  30  of an adjacent slat within the coupling cavity  20 . 
     Furthermore, such a technical closure solution leaves the first face  10 e of the elongated body  10 , i.e., the face of the slat  1  having a higher aesthetic value, unchanged. This significantly improves the aesthetic appearance of a shutter manufactured by assembling slats according to the invention. 
     The slat for roller shutters according to the present invention may therefore be assembled to form a shutter while ensuring a more stable and secure coupling between the coupling appendage and the hollow seat, without at the same time requiring changes to the external face of the slat itself. 
     Preferably, as shown particularly in  FIG.  6   , the aforementioned two notches  24 ′,  24 ″ extend transversely up to the connecting portion  23  which connects the two appendages  21  and  22  that define the coupling cavity  20 . In this way, both tabs  25 ,  26  extend up to said connecting portion  23  and may be bent from the base starting from said connecting portion, maximizing the dimensions thereof within the coupling cavity when bent against the first appendage  21 . This benefits the closure capacity of the coupling cavity on the part of the tabs. 
     Preferably, the second appendage  22  is L-shaped. In this way both of the tabs  25 ,  26  are L-shaped. The L-shaped configuration maximizes the dimensions of the tabs  25  and  26  within the coupling cavity when bent against the first appendage  21 . This benefits the closure capacity of the coupling cavity on the part of the tabs. 
     Advantageously, as shown in the accompanying figures, the aforementioned two recesses  15 ,  16  have the same longitudinal extension. As will be clear from the following description, this simplifies the production process of the slat  1 . 
     Advantageously, as shown in the accompanying figures, the two tabs  25 ,  26  have the same longitudinal extension. As will be clear from the following description, this simplifies the production process of the slat  1 . 
     The subject of the present invention is also a roller shutter  50  comprising a plurality of slats coupled with one another in pairs. Each of said slats is a slat  1  according to the invention, and in particular as described above. 
     In the shutter  50 , the two tabs  25 ,  26  of each slat  1  are bent against the first appendage  21  so as to close the coupling cavity  20  at the two opposite longitudinal ends  10 ′ and  10 ″ of the elongated body  10  and thus retain the coupling appendage  30  of the adjacent slat inside said coupling cavity  20 . 
     As shown in particular in  FIGS.  11  and  13   , the shutter  50  manufactured by assembling slats  1  according to the invention does not show any machining marks on the external side associated with the assembly of the slats. This benefits the aesthetic appearance of the shutter. 
     Preferably, both tabs  25 ,  26  of each slat  1  extend to the connecting portion  23  connecting the first appendage  21  to the second appendage  22 . Both tabs  25 ,  26  are bent in the vicinity of the connecting portion  23 . 
     Preferably, both tabs  25 ,  26  are L-shaped and are bent at the portion defining the L-shaped vertical section. 
     The production process of the slat  1  according to the invention and the relative shutter  50  will now be described. 
     As shown in  FIG.  14   , the process starts from an elongated body preferably consisting of a box-shaped body obtained by bending and profiling a metal sheet. This elongated body corresponds to the elongated body  10  of the slat one according to the invention. By means of cutting operations transverse to the longitudinal direction X of the elongated body, sections corresponding to a slat  1  will be obtained. 
     Before cutting the elongated body, at the two longitudinal edges  11  and  12  of this elongated body, two pairs of notches  24 ′,  24 ″ and  24 ′″,  24   iv  are formed. A first pair of notches  24 ′,  24 ″ is made at the first longitudinal edge  11  and involves only the second appendage  22  implemented on the second face  10   i  (inner face) of the elongated body. A second pair of notches  24 ′″,  24   iv  is made at the second longitudinal edge  12  and involves only the coupling appendage  30  of the elongated body. The two pairs of notches are aligned transversely to one another in relation to the longitudinal direction X and straddle the cutting line T (or separation line) between two slats  1 ′ and  1 ″ obtainable by cutting the elongated body. 
     The portion of the second appendage  22  arranged between the first pair of notches  24 ′ and  24 ″ defines two tabs  25  and  26  of two contiguous slats  1 ′ and  1 ″ along the longitudinal development of said elongated body. These two tabs  25  and  26  will be separated from one another when the elongated body is cut in order to separate the two slats  1 ′ and  1 ″ from one another. 
     Subsequently, as shown in  FIG.  15   , the portion of the coupling appendage  30  arranged between the second pair of notches  24 ′″,  24   iv  is removed by cutting in order to create one of said two recesses  15 ,  16  on two contiguous slats  1 ′ and  1 ″ along the longitudinal development of said elongated body. These two recesses  15  and  16  will be separated therebetween when the elongated body is cut in order to separate the two slats  1 ′ and  1 ″ from one another. 
     Subsequently, as shown in  FIG.  16   , the two contiguous slats  1 ′ and  1 ″ are separated by cutting the elongated body along the cutting line T. After cutting, the tab  25  of one of the two slats  1 ′ is bent against the relative first appendage  21 . In this way, the coupling cavity  20  of this slat  1 ′ will then be closed at one longitudinal end before the coupling appendage of another slat is inserted into the aforementioned coupling cavity. Said bent tab  25  will act as an abutment element for the insertion of the coupling appendage  30  of said second slat. 
     The last slat obtained in succession by cutting the elongated body is ready to be coupled to the slat that was previously obtained by cutting the elongated body, as shown in  FIG.  17   . Once the coupling appendage of the penultimate slat has been inserted into the coupling cavity of the last slat produced, the tab  26  of the last slat produced is also bent by pressing, thus completing the locking of the coupling appendage just inserted. 
     The operations described above are repeated in sequence until a shutter  50  of a predefined length is completed. 
     The subject of the present invention is also a plant  100  for the production of a shutter  50  according to the invention, by assembling slats  1  according to the invention itself. 
     As shown in  FIGS.  18 ,  19  and  20   , said plant  100  comprises, in sequence in the direction of advancement V indicated in  FIG.  18   , the following:
         a feeding unit for a continuous profile (not shown in the attached figures);   a bending and profiling station for said continuous profile (not shown in the attached figures) for obtaining an elongated body corresponding to the elongated body  10  of the slat  1  according to the present invention;   a first cutting unit  110  movable at the advancement speed of the continuous profile, programmed to cut the elongated body  10  into slats  1  of a predefined length;   an assembly station  120  of said slats  1  for forming a sheet of said shutter  50 .       

     The assembly station  120  is arranged downstream of said first cutting unit  110 . 
     According to the invention, the plant  100  further comprises a second cutting unit  130  movable at the advancement speed of the continuous profile, which unit operates between said bending and profiling station and said first cutting unit  110  and is programmed to implement the following:
         a first pair of transverse notches  24 ′,  24 ″ on the first longitudinal edge  11  of the elongated body  10  at said second appendage  22  and   a second pair of transverse notches  24 ′″,  24   iv  on the second longitudinal edge  12  of the elongated body  10  at said coupling appendage  30 .       

     These two pairs of notches straddle the cutting line T between two slats. 
     According to the invention, the plant  100  further comprises a shearing unit  140  movable at the advancement speed of the continuous profile, which unit operates between said second cutting unit  130  and said first cutting unit  110  and is programmed to remove the portion of the continuous profile arranged between the second pair of notches  24 ′″,  24   iv  in order to make one of said two recesses  15 ,  16  on two contiguous slats along the longitudinal development of said elongated body. 
     According to the invention, the plant  100  further comprises:
         a first crushing unit  150 , which operates between said first cutting unit  110  and said assembly station  120  and is programmed to bend, against the first appendage  21  of said elongated body  10 , the profile portion that is comprised between one notch of said first pair of notches  24 ′,  24 ″ and the cutting line T between two slats and which defines a first tab  25 ,  26  of said slat  1  so as to close the coupling cavity  20  at a first longitudinal end of said slat  1 ; and   a second crushing unit  160 , which is integrated into said assembly station  120  and is programmed to bend, against the first appendage  21  of said slat ( 1 ), the profile portion that is comprised between one notch of said first pair of notches  24 ′,  24 ″ and the cutting line T between two slats and which defines a second tab  25 ,  26  of said slat  1  so as to close the coupling cavity  20 , also ata second longitudinal end of said slat  1  after the insertion of the coupling appendage  30  of another slat  1  into the coupling cavity  20 .       

     The invention allows numerous advantages to be obtained, which have already been described in part. 
     The slat  1  for roller shutters according to the present invention may be assembled to form a shutter while ensuring a more stable and secure coupling between the coupling appendage and the hollow seat without at the same time requiring changes to the external face of the slat itself. This benefits the aesthetic aspect of the shutter obtainable by means of the assembly of slats according to the invention. 
     The slat  1  for roller shutters according to the invention is furthermore simple and cost-effective to produce. 
     The invention thus conceived therefore achieves its intended objectives. 
     Obviously, in practice it may also assume different forms and configurations from the one illustrated above, without thereby departing from the present scope of protection. 
     Furthermore, all details may be replaced with technically equivalent elements, and the dimensions, shapes, and materials used may be any according to the needs.