Patent Abstract:
A shutter assembly includes a first and second shutter panel, where each panel includes a missile-repelling membrane panel, a frame having an elongated hollow body with inwardly disposed wall elements forming an inwardly facing U-shaped channel adapted to retain the membrane panel on at least two sides, and a membrane-retaining element separably attachable to the frame, allowing the membrane panel to be removed from the frame or secured within the frame.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims the priority, under 35 U.S.C. § 119, of U.S. Provisional patent application Ser. No. 11/502,245, filed Aug. 10, 2006 and entitled Hurricane Pocket Shutter System, the entire disclosure of which is hereby incorporated herein by reference in its entirety. 
   FIELD OF THE INVENTION 
   This invention relates to shutters for protecting openings, and more particularly relates to a shutter assembly that protects building apertures from strong wind forces, wind-borne missiles, and other wind-related damage. 
   BACKGROUND OF THE INVENTION 
   Within hours of an announcement that a hurricane is coming to a specific geographical area, home and business owners scurry to add hurricane protection to their homes and business facilities. High winds cause flying debris to become air-borne projectiles capable of breaking glass windows and damaging property. Once a window is broken, the structural integrity of the entire building becomes problematic because of the pressure differences existing between the inside of the building and the environment. This pressure difference has the ability to cause roof loss, which is to be avoided. Thus hurricane protection is desirable. 
   Hurricane protection is currently available in many forms, which include permanent and temporary attachments to the structure that they are intended to protect. Examples of permanent construction additions include
         (a) accordion hurricane shutters, which are housed beside the windows when not in use and unfold to cover and protect during a storm. And, although they are easy for one person to make storm-ready, they are expensive to install and can detract from the aesthetics of the dwelling, need continuous maintenance, and, based on their roller mechanism, are prone to break more easily.   (b) colonial hurricane shutters, which are expensive louvered shutters that attach to the wall beside each window and fold together to protect the window. This type of shutter is easy for one person to make storm-ready, and actually can add to the beauty of the dwelling, however, depending on the construction, may require a time-consuming installation of a center bar and cannot be used to protect non-window openings such as doors.   (c) Bahama hurricane shutters, which are an expensive one-piece louvered shutter attached above the window and can be propped open to provide shade for the window. They are easily made storm-ready by one person when lowered and secured to the wall. Since the shutter is opaque, it creates a dark cave effect within the dwelling.   (d) roll-down hurricane shutters, which roll down from an enclosed box above the window and can easily be made storm-ready by one person. These shutters are the most expensive and can be relatively difficult to roll up after a storm during a power outage.   (e) hurricane glass, which, once installed, is, of course, the easiest to use since it becomes the window glass. However this specially treated glass (comprised of a synthetic layer sandwiched between glass) will break the outer layer upon impact. The center synthetic layer will prevent a hole, however, after the storm, the broken window or door and frame needs to be replaced at a significant cost.   (f) plastic screens, which are predominantly used to protect openings from high-speed wind, rain, and air-borne missiles. Although this type of shutter system theoretically can be installed initially by an installer and then by the home or business owner before each storm, installation is difficult and dependent on securely anchoring plastic screen holders and, furthermore, storm readiness depends on ability of home or business owner to secure studs into grommets, often taking more than one person to do so.       

   Examples of temporary additions include:
         (a) corrugated storm panels, which are overlapped and mechanically fastened to a track of studs. Each panel is heavy and awkward to install (often requiring more than one person), takes a lot of time to install, and is opaque, making an enclosed dwelling dark and creates a cave-effect inside. Furthermore overlapping storm panels create a hazard if and when an emergency escape is required. These panels are virtually impossible to open from the inside.   (b) plywood storm panels, which are formed by one or more pieces of plywood and attached to the window or dwelling outside wall by means of anchors. Each panel is heavy and awkward and usually takes more than one person to install, takes a lot of time to install, does not allow light to pass through, and is not able to be opened from the inside.   (c) corrugated plastic panels, which are lightweight, translucent and relatively easy to install, however, the supporting structure is the weakest component of this type of hurricane shutter. Overlapping storm panels create a hazard if and when an emergency escape is required. These panels are virtually impossible to open from the inside.       

   Unfortunately, permanent construction additions typically require installation by a certified building contractor, which brings with it an associated skilled-labor cost. Temporary additions, on the other hand, are typically installed by homeowners and are therefore, less expensive. However, temporary additions require a large amount of time and labor on the part of the home or business owner to install the protection prior to a storm and to remove the protection after the storm. 
   Therefore, a need exists to overcome the problems with the prior art as discussed above. 
   SUMMARY OF THE INVENTION 
   A device is disclosed for protecting building apertures from damage during storms or other natural occurrences, such as hurricanes. In one embodiment, the invention comprises a shutter with a missile-repelling membrane panel surrounded by a frame with an elongated hollow body with inwardly disposed wall elements forming an inwardly facing U-shaped channel adapted to retain the membrane panel on at least two sides, and a membrane-retaining element separably attachable to the frame, allowing the membrane panel to be removed from the frame or secured within the frame. 
   In accordance with an embodiment of the present invention, the shutter includes a hinge attached to one side of the frame and providing a pivot for moving the shutter relative to a building structure. 
   In accordance with a further feature, an embodiment of the present invention includes a locking mechanism accessible from an interior of a building structure and preventing the shutter from significant movement relative to the building structure. 
   In accordance with a yet a further feature, an embodiment of the present invention includes a first, a second, and a third frame element, each element capable of receiving and retaining a separate side of the membrane panel. 
   In accordance with another feature, the membrane-retaining element includes an elongated hollow body with inwardly disposed wall elements forming an inwardly facing U-shaped channel adapted to retain the membrane panel on one side. 
   In accordance with the present invention, a shutter assembly includes a first and second shutter panel, each assembly having a missile-repelling membrane panel, a frame having an elongated hollow body with inwardly disposed wall elements forming an inwardly facing U-shaped channel adapted to retain the membrane panel on at least two sides, and a membrane-retaining element separably attachable to the frame, allowing the membrane panel to be removed from the frame or secured within the frame. 
   In accordance with a further feature, the present invention includes a first hinge with a first side attached to the frame of the first shutter panel and a second side attached to a building structure, and a second hinge with a first side attached to the frame of the second shutter panel and a second side attached to the building structure. 
   In accordance with a yet a further feature, the present invention includes a first stop attached to a lower portion of the frame of the first shutter panel, and a second stop attached to an upper portion of the frame of the second shutter panel, wherein the first stop and the second stop, when the lower portion of the frame of the first shutter is placed directly above the upper portion of the frame of the second shutter and a pivot of the first hinge is aligned with a pivot of the second hinge, allow the first and second shutters to be moved relative to each other in a first pivot direction and prevent the first and second shutters from moving relative to each other in a second pivot direction. 
   In accordance with an additional feature, the present invention includes an alignment track with a first portion that couples to the membrane-retaining element of the first shutter panel and a second portion that couples to the membrane-retaining element of the second shutter panel, the first and second portions of the alignment track making contact and preventing the first and second shutter panels from moving relative to each other in at least one direction. 
   In accordance with yet another feature, the first alignment track includes an F-shaped channel and the second alignment track includes an inverse-F-shaped channel. 
   In accordance with yet one more feature, the present invention includes a locking mechanism accessible from an interior of a building structure and preventing the shutter assembly from significant movement relative to the building structure. 
   In accordance with an additional feature, each membrane-retaining element includes an elongated hollow body with inwardly disposed wall elements forming an inwardly facing U-shaped channel adapted to retain the membrane panel on one side. 
   In accordance with a further feature, the present invention includes a set of ribs disposed within the hollow body of the frame and a set of ribs disposed inside the hollow body of the membrane-retaining element. 
   In accordance with an additional feature, the present invention includes an L-shaped bracket adapted to fit between the ribs in the frame and the ribs in the membrane retaining element and physically couple the frame and the membrane-retaining element. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, and which together with the detailed description below are incorporated in and form part of the specification, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention. 
       FIG. 1  is an elevational view of a shutter assembly, according to an embodiment of the present invention. 
       FIG. 2  is an elevational view of a shutter panel from the shutter assembly shown in  FIG. 1 . 
       FIG. 3  is a perspective view of a back side of the shutter panel of  FIG. 2 . 
       FIG. 4  is an edge view of one exemplary embodiment of a shutter panel frame element of the shutter panel of  FIG. 2 . 
       FIG. 5  is a cross-sectional view of one exemplary embodiment of a shutter panel frame element of the assembly of  FIG. 1  aligned with another shutter panel frame element of the assembly of  FIG. 1 . 
       FIG. 6  is a perspective view of two vertically-adjacent shutter panels mounted upon a hinge assembly, according to an embodiment of the present invention. 
       FIG. 7  is a perspective view of the shutter panels of  FIG. 6  aligned in a co-planar configuration. 
       FIG. 8  is an enlarged perspective and partially exploded view of a membrane panel removed from the shutter panel frame of  FIG. 2 . 
       FIG. 9  is a fragmentary cross-sectional view of a membrane panel and frame, according to an embodiment of the present invention, with a first exemplary embodiment of a surface-resistance reducing ridge. 
       FIG. 10  is a fragmentary cross-sectional view of a membrane panel and frame, according to an embodiment of the present invention, with a second exemplary embodiment of surface-resistance reducing legs. 
       FIG. 11  is a fragmentary enlarged perspective and partially exploded view of a shutter panel frame alignment pin, according to an embodiment of the present invention. 
       FIG. 12  is a fragmentary, enlarged plan view of an F-channel alignment track, according to an embodiment of the present invention. 
       FIG. 13  is an elevational view of the F-channel alignment track of  FIG. 13  with locking mechanisms, according to an embodiment of the present invention. 
       FIG. 14  is an isometric view of a plastic insert with outer flange, according to an embodiment of the present invention. 
       FIG. 15  is an isometric view of the pocket shutter module as it relates to the framed plastic insert and installation components for a single pocket shutter module, according to an embodiment of the present invention. 
       FIG. 16  is an isometric view of the pocket shutter module as it relates to framed plastic insert and mid section support channel in a closed position, according to an embodiment of the present invention. 
       FIG. 17  an isometric view of two pocket shutter modules as it relates to module adjacent inside supports between upper and lower pocket shutter modules, according to an embodiment of the present invention. 
       FIG. 18  is a plan view of a set of two pocket shutter modules as it relates to module adjacent inside and outside supports between upper and lower pocket shutter modules, according to an embodiment of the present invention. 
       FIG. 19  is an isometric view of two pocket shutter modules as it relates to mid section support channels used for four or more pocket shutter module installations where pocket shutter modules open in an arc-like manner for insertion as preparation for a hurricane or storm, according to an embodiment of the present invention. 
       FIG. 20  is an isometric view of four pocket shutter modules such that two modules rotate about building hinge and two modules rotate about first two modules in a fold-like manner for insertion as preparation for a hurricane or storm, according to an embodiment of the present invention. 
       FIG. 21  is a fragmentary, enlarged plan view of a shutter assembly that includes an F-channel alignment track with a hinge, according to an embodiment of the present invention. 
       FIG. 22  is an elevational view of the shutter assembly shown in  FIG. 21  folded into a stowed position, according to an embodiment of the present invention. 
       FIG. 23  is a plan view of the folded shutter assembly of  FIG. 22 , according to an embodiment of the present invention. 
       FIG. 24  is a cross-sectional view of one exemplary embodiment of a shutter panel hinge attachment using angle material. 
       FIG. 25  is a cross-sectional view of one exemplary embodiment of a shutter panel hinge attachment using a “T” adapter. 
   

   DETAILED DESCRIPTION 
   As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. 
   The terms “a” or “an,” as used herein, are defined as one or more than one. The term “plurality,” as used herein, is defined as two or more than two. The term “another,” as used herein, is defined as at least a second or more. The terms “including” and/or “having,” as used herein, are defined as comprising (i.e., open language). The term “coupled,” as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. 
   The present invention provides a novel and efficient shutter assembly that protects an aperture of a building during severe weather conditions, such as hurricanes, tornadoes, tsunamis, typhoons, and others. The assembly includes a hinged pocket system where one or more pockets have a rigid material to form a strong durable outer layer protecting a building&#39;s aperture, such as a windows or door, from wind and debris. A hinge system allows for easy installation and removal before or after storms and also allows one to open and re-close portions of the assembly for emergency escape. 
     FIG. 1  shows an embodiment of a shutter assembly  100  in accordance with the present invention. The shutter assembly  100 , as will be explained in detail below, interlocks with its associated parts to provide a solid protective surface that prevents projectiles from penetrating the assembly  100  and reaching the opening that the assembly  100  is protecting. The assembly  100  also prevents wind forces from exerting damaging pressure that often distorts and breaks unprotected windows or doors within the openings. As tested, the assembly  100  can withstand a 2×4 hitting the panel at 200 mph. 
   The assembly  100  shown in  FIG. 1  includes four individual panels  102   a - d  that interlock with each other as will be shown in the subsequent figures and described below. An alignment channel  104 , shown separated from the assembly  100  in this view, fits in the gap  106  between two panel sets, with one panel set being  102   b  and  102   c  and one panel set being  102   a  and  102   d . The shape of the channel  104  and the interlocking relationship between the channel  104  and panels  102   a - d  will be explained in detail below and shown in  FIG. 12 . 
   Each panel  102   a - d , in this embodiment, includes a protective missile-repelling membrane that is surrounded by and supported within a frame. Referring to  FIG. 2 , a front view of a single panel  102   a  is shown in an elevational view. The shutter panel  102   a  has a frame  200  that includes four main sections  202   a - d . The four sections  202   a - d  fit together to form a rectangular shape that surrounds and supports a membrane panel  204 . The frame  200  can be made of any sufficiently rigid material, such as aluminum or other metals, composites, wood, and others. 
   The membrane panel  204  includes a material that is able to withstand direct impacts from objects or wind pressure associated with severe weather conditions for which the panel  100  is intended to protect against. The membrane panel  204 , in one embodiment, includes missile-repelling membrane material made of LEXAN. LEXAN is a registered trademark for General Electric&#39;s brand of highly durable polycarbonate resin thermoplastic intended to replace glass where the need for strength justifies its higher cost. LEXAN is similar to polymethyl methacrylate (Plexiglas/Lucite/Perspex)—commonly described as acrylic—in appearance, but is far more durable, often to the point of being described as “bulletproof” (depending on the thickness of the sample and the type of weapon used). LEXAN is advantageous because it is transparent and has great strength with a low weight. 
   Other suitable materials include KEVLAR Fiber, Carbon Fiber, Aluminum, Steel, Carbon Steel, Stainless Steel, Cooper, Brass, Reinforced Safety glass, Wood, Lumber, Plywood, Ceramic, Polycarbonate Sheet, Polycarbonate multi walls, Polycarbonate Corrugated Sheet, MAKROLON, MAKROLON multi walls, MAKROLON Corrugated Sheet, TUFFAK, TUFFAK multi walls, TUFFAK Corrugated Sheet, Plexiglas Sheet, multi walls and/or Corrugated, Polyethylene LDPE and HDPE, ABS, Acrylic sheets, Acrylic multi walls, Nano Tech materials, MICARTA, Fiberglass, Acetal, Polyvinyl Chloride, ceramic, and other materials. The selected membrane material is referred to herein as “missile-repellant” because it is able to withstand at least the required impact forces in accordance with the Hurricane Test Laboratory requirements and the Miami and Texas Building Codes. 
   Referring now to  FIG. 3 , a perspective view of a backside of the panel  102   a  is shown. From this back view, additional features of the present invention can be seen. First, the panel  102   a  includes a set of hinge portions  300   a  and  300   b , which, in this embodiment is two, but can be more than two. The hinges portions  300   a  and  300   b  are male portions that mate with counterpart female hinge portions permanently attached to a wall. Although other attachment measures are acceptable, the hinges  300   a  and  300   b  are advantageous as they allow the panel  102   a  to be easily attached to a wall or other surface by sliding into their female hinge counterparts (see  FIG. 6 ). In one embodiment, a pin portion  302   a  of one of the hinge portions  300   a  is longer than a pin portion  302   b  of the other hinge portion  300   b . Having one pin portion  302   a  longer than the other pin portion  302   b  is advantageous as it simplifies installation. This is particularly true if there are more than two hinge portions on a single panel. Specifically, if all of the pin portions are the same length, an installer would have to align all male pin portions with all female receptacles simultaneously. This is often difficult if the panels are large and heavy or if they are being installed in hard-to-reach locations. With one pin being longer, the installer merely needs to focus on aligning the longest pin with its female counterpart. Once the longest pin mates with the female receptacle, the other pins will automatically become aligned and drop into position. In one embodiment, the uppermost pin is the longest pin. 
   Also shown in  FIG. 3  is a support bar  306 . Referring briefly back to  FIG. 1 , it can be seen that each of the panels  102   a - d  has a support bar near a center of the overall assembly  100 . The support bars  306  add stability and strength to each panel  102   a - d  and to the overall assembly  100 . During high winds, as occur during a hurricane, the weakest and most likely area of a window to break is its center. This is because the edges of the opening in the building provide adequate support to the corresponding edges of the window or other opening cover that are attached to the building. The center of the opening cover, however, has little or no support from the building. The support bars  306  of each panel  102   a - d  can be coupled to each other by any suitable measure to provide superior strength to the shutter assembly  100 . 
   Returning again to  FIG. 3 , a stop  304  can be seen along a bottom edge  310  of the panel  102   a . The stop  304  is attached to, or integral with the frame portion  202   c , and extends below a bottom edge of the frame portion  202   c . The stop  304  can run the entire length of the panel  102   a  or just a portion of the length.  FIG. 4  shows an edge view of the lower frame portion  202   c , where the stop  304  can be seen in more detail. The lower frame portion  202   c , and each of the other frame portions  202   a ,  202   b , and  202   d  are elongated hollow bodies having inwardly disposed wall elements  402 ,  406 , and  404 . The direction “inwardly” refers to a direction towards a central region of the membrane  204  and is shown as the mid-point  308  of the membrane in  FIG. 3 . Inwardly disposed wall elements  402 ,  406 , and  404  form an inwardly facing U-shaped or C-shaped channel  408 . The U-shaped channel  408  is useful for accepting and holding an edge portion of the membrane  204 . 
   Element portion  202   c , and each of the other frame portions  202   a ,  202   b , and  202   d , also include a first lower side wall element  410 , a second lower side wall element  412  opposing the first lower side wall element  410 , and a lower edge element  414  opposing the wall element  406 . The element portion  202   c  is generally hollow as shown by cavity  416 . Within this cavity  416  are a set of upstanding ribs  418   a - d . Ribs  418   a  and  418   b  extend perpendicularly from wall element  410  and ribs  418   c  and  418   d  extend perpendicularly from wall element  412 . The ribs  418   a - d  add rigidity and restrict the movement of the wall elements  410  and  412  to prevent bending or warping. 
   Extending from the second lower side wall element  412  on a side opposite the upper wall portion  404  is the stop  304 . As will be shown in  FIG. 5 , the stop  304  ensures the proper alignment of the first panel  102   a  with the lower adjacent panel  102   d . Additionally, attached to the lower edge element  414  is a spacer  420 . The spacer  420 , as will be shown in  FIG. 5 , reduces friction and self aligns the panel  102   a  when it mates with the panel  102   d.    
   Referring now to  FIG. 5 , the first panel  102   a  is aligned with and directly on top of the lower panel  102   d . This view reflects the configuration of  FIG. 1 . In this view, the lower frame portion  202   c  of the first panel  102   a  is shown mated with an upper frame portion  500  of the lower adjacent panel  102   d . Each of the panels  102   a  and  102   d  has a stop  304  and  502 , respectively, that automatically align the panels  102   a  and  102   d  with each other. The upper frame element  500  of the lower adjacent panel  102   d  has an upper stopper  502  that makes contact with the first upper wall element  402  and the first lower side wall element  410 . Similarly, the stop  304  of the frame element  202   c  makes contact with a first lower wall element  504  and first upper side wall element  506  of the upper frame element  500  of the panel  102   d . Once aligned in the position shown in  FIG. 5 , the stops  304  and  502  allow the upper panel  102   a  to separate from and move relative to panel  102   d  in a first direction  506 , but prevent it from moving in a second direction  508 . 
   The round spacer  420  provides a gentle ramp that allows the two panels  102   a  and  102   d  to close adjacent to each other. Without the spacer  420 , a misalignment of the panels  102   a  and  102   d  could cause the corners  510  and  512 , respectively, to hit each other and prevent the panels from closing. A similar spacer is located on the bottom of each of the lower panels  102   c  and  102   d  to provide easy closing within the opening of the building structure. 
   This relationship is shown in  FIG. 6 , where the upper panel  102   b  is not aligned with the lower panel  102   c . By “not aligned,” it is meant that the surfaces  610  and  612  of the membrane panels are not co-planar. The panels  102   b  and  102   c  are free to pivot along the hinges  602 ,  604 ,  606 , and  608 . This allows a user to install one panel at a time and then swing the panels toward each other to align them. This also allows a user to open the shutters to let air into the building or to escape from the building. A stop  611  attached to the lower panel  102   c  prevents the upper panel  102   b  from moving past a position, shown in  FIG. 7 , where the membranes  610  and  612  of the panels  102   b  and  102   c , respectively, are co-planar with each other. Likewise, a stop  614 , shown only in  FIG. 6 , on the upper panel  102   b  also prevents the upper panel  102   b  from moving past a position where the membranes  610  and  612  of the panels  102   b  and  102   c , respectively, are, as shown in  FIG. 7 , co-planar with each other. 
   Referring now to  FIG. 8 , another inventive aspect of the present invention is shown. As can be seen in this view, one of the frame elements  802  is separable from the other three shutter panel frame elements  804 ,  806 , and  808  ( 808  is not shown in this view.) By separating the first frame element  802  from the other three frame elements  804 ,  806 , and  808 , advantageously, the membrane panel  810  can be removed from the U-channel  812  created by the frame elements  804 ,  806 , and  808 . The membrane panel  810  can also be easily separated from the separable element  802 . Removal of the membrane panel  810  from the shutter panel  102   a  provides several advantages. First, the shutter panels  102   a - d  are made considerably lighter by not having the weight of the membrane panel  810  in them. The reduced weight makes the shutter panels  102   a - d  easier to install, hang, take down, and transport. In addition, removing the membrane panel  810  and storing it in a controlled environment during the majority of the year, when storms are not a threat, extends the life and aesthetics of the protective membrane material. Also, the frames, without the membrane panel  810 , can be left on the building structure without having a negative aesthetic effect on the building. Furthermore, if one of the membranes  814  should happen to crack, break, or otherwise need replacing, instead of having to replace the entire structure, as is done in prior-art storm protection systems, the single damaged membrane panel  810  can be removed and quickly replaced. This results in a drastic reduction in relevant cost to the user. 
     FIG. 8  shows that the membrane panel  810  includes a membrane material  814  surrounded by a frame  816 . The frame  816  provides support and protection to the membrane material  814 . Specifically, the frame  816  protects the edges of the membrane material  814  and provides durable surfaces that make contact with and couple to the U-channel  812  of the panel frame elements  802 ,  804 ,  806 , and  808 . 
     FIG. 9  shows a fragmentary cross-sectional view of the membrane material  814 , upper element  902 , and lower element  904  of the frame  816  affixed to the membrane material  814 . In a first embodiment of the membrane frame  816 , the lower membrane frame element  904  has an extension  906  protruding from a bottom surface  910  of the lower membrane frame element  904 . The extension  906  is advantageous as it reduces the amount of surface area that makes contact with the lower element of the U-shaped channel  812  as the membrane frame  810  is slid into and out from the channel  812 . Instead of the entire bottom surface  910  making contact, which could have a large friction, only the extension  906  touches the channel  812 . By reducing the amount of surface area, the sliding resistance of the membrane frame  810  is reduced as it slides into the U-shaped channel  812 . Because the membrane panels  810  are not limited in size, the panels  810  can be substantial in weight. This reduction in surface area can result in considerable reduction in installation effort. 
     FIG. 10  shows another embodiment of the membrane frame  810 . In this embodiment, the membrane material  814  has flat bars  1002 ,  1004 ,  1006 , and  1008  attached at the top and bottom of the membrane material  814 . The flat bars  1006  and  1008 , attached at the bottom of the membrane material  814 , extend beyond the bottom surface  1010  of the membrane material  814 . When this embodiment of the membrane panel is slid into or out of the U-channel  812 , only the bottom edges  1012  and  1014  of the flat bars  1006  and  1008  make contact with the lower element of the U-shaped channel  812 . By reducing the amount of surface area, the sliding resistance of the membrane frame  810  is reduced as it slides into the U-shaped channel  812 . In one embodiment, the flat bars  1002 ,  1004 ,  1006 , and  1008  are attached to the membrane material  814  with adhesive, such as glue or double-sided tape. The bars  1002 ,  1004 ,  1006 , and  1008  can be metal, plastic, or any other substantially rigid material. 
   Referring now back to  FIG. 8 , an alignment and coupling bracket  818  is shown at the top of the separable frame element  802 . The bracket  818  is of a size to, when the frame is assembled, fit within the cavity  416  and, more particularly, between the set of internal ribs  418   a - d  of the upper frame element  804 . 
     FIG. 11  shows another view of the shutter panel  102   a , where the bracket  818  is completely removed from both frame elements  802  and  804 . Separable frame element  802  has the same internal rib structure as does frame element  804 , which was shown in greater detail in  FIG. 8 . One half  1102  of the L-shaped bracket  818  slides into the cavity  416  in frame element  802  and the other half  1104 , as shown in  FIG. 8 , slides into frame element  804 . The L-shaped bracket  818  keeps the frame elements  802  and  804  at a consistent angle (approximately 90 degrees) and approximately co-planar with each other on both sides of the frame  200 . Although not shown, a second L-shaped bracket fits in the opposing end of the frame element  802  and aligns the frame element  802  with a bottom element of the shutter frame  102   a.    
     FIG. 12  is an edge view of two adjacent panels  102   a  and  102   b . Between the panels  102   a  and  102   b  is a pair of F-channel alignment tracks  1202  and  1204 . The alignment tracks  1202  and  1204  are called “F” channel tracks because of their shape when looking along the edge, as shown in  FIG. 12 . One track,  1204 , has the shape of an “F,” and the other,  1202 , has the shape of an reversed “F.” The alignment tracks  1202  and  1204  attach to inside edges  1206  and  1208 , respectively, of the shutter panels  102   b  and  102   a , respectively. The alignment tracks  1202  and  1204  have at least two functions. First each track aligns vertically-adjacent panels. For instance, referring briefly back to  FIG. 1 , alignment track  1202  will attach to the inside edge  1206  of panels  102   b  and  102   c  and align them in a substantially co-planar configuration. Similarly, track  1204  will attach to an inside edge  1208  of panels  102   a  and  102   d  and align them in a substantially co-planar configuration. 
   Referring back now to  FIG. 12 , it can be seen that alignment track  1204  has a stop  1210  on one side. The stop  1210  makes contact with an outer surface  1212  of the other alignment track  1202  and, if panel  102   a  is held steady in the position shown in  FIG. 12 , prevents panel  102   b  from moving past a point where the two panels are co-planar. Additionally, the two alignment tracks  1202  and  1204  have opposing faces  1214  and  1216 , respectively. The two opposing faces  1214  and  1216  butt against one another when force, such as strong wind  1218 , is applied to the panels  102   a  and  102   b  and prevents the panels from moving relative to one another. 
     FIG. 13  shows an elevational view of one embodiment of the F-channel tracks  1202  and  1204 , where locking mechanisms  1302   a - e  are coupled to the tracks  1202  and  1204 . The particular locks shown in  FIG. 13  are deadbolt locks, which are known in the art. However, other locking mechanisms can also be used. The locking mechanisms  1302   a  and  1302   b  physically couple the tracks  1202  and  1204 , respectively, to an upper portion of a building structure. Similarly, the locking mechanisms  1302   c  and  1302   d  physically couple the tracks  1202  and  1204 , respectively, to a lower portion of a building structure. The F-channel tracks  1202  and  1204 , by coupling to a building structure, provide solid structural support to the overall shutter assembly  100 . In addition, a locking mechanism  1302   e  physically couples the two tracks  1202  and  1204  to each other, thereby adding further strength to the overall shutter assembly  100  by preventing the first track  1202  from moving relative to the second track  1204 . An advantage to the placement of the locking mechanisms  1302   a - e  is that they are reachable by one standing on the interior of the building. This allows one to unlock and open the shutter panels, for instance, to exit the building or to begin removal of the shutter assembly  100  from the building. 
   Embodiments or versions of shutters configured with the present invention may be divided into two major categories. A shutter within the first category is for a single pocket module used to protect a window or door opening sized less than or equal to 48-inches by 48-inches. A shutter within the second category is for multiple pocket modules used to protect a window or door opening sized larger than 48-inches by 48-inches. 
   Various versions or embodiments of the present invention will now be discussed in the general order described above. That is, a discussion of examples from the first category will be followed by a discussion of examples from the second category. 
   The hurricane pocket shutter system is comprised of one or more modules, where each module includes a pocket like frame and a window insert with flange for easy insertion and removal of the window insert. Referring to  FIG. 14 , the window insert  10  is enclosed within a frame  11 . To the framed insert, flange  12  closes the frame opening and provides a means to handle the flanged window insert. 
   Referring to  FIG. 15 , window insert  10 , frame  11  and flange  12  are assembled to form flanged insert  15 . Installing the hurricane pocket shutter system first entails installing wall studs  2  into adjacent wall or box frame structure S surrounding the window or door opening. 
   Pocket shutter module  20  is a 6-sided skeletal housing with one open end. There are two wall studs  2  mounted to structure S to facilitate means of supporting pocket shutter module  20  about structure S. 
   Support means is accomplished by lifting, aligning and setting pocket shutter module  20  hinge rings  1  over wall studs  2 . Not only is the pocket shutter module  20  supported, the pocket shutter module  20  is also hinged such that the pocket shutter module  20  can swing open in order to insert flanged insert  15  into the pocket shutter module  20 . 
   After the pocket shutter module  20  is secured about structure S, with flanged insert  15  inserted within the pocket shutter module  20 , section support channel  50  is used to close or secure flanged insert  15  within the pocket shutter module  20 . To further secure pocket shutter module about structure S, deadbolt  3  mechanically attached to section support channel  50  is slid up and down, respectively, to secure pocket shutter module  20  against the top and bottom, respectively, of structure S.  FIG. 16  shows a completely assembled single pocket shutter module  20  including pocket shutter module  20 , flanged insert  15  and section support channel  50 . 
   For varying window and door configurations and sizes, multiple pocket shutter modules are used.  FIG. 17  refers to outer mid section support  30  and inner mid section support  31 .  FIG. 18  refers to an assembled view of two pocket shutter modules  20 . Both outer and inner mid section supports  30  and  31 , respectively, are recessed from the edges of pocket shutter module  20  to permit closure by section support channel  50 .  FIG. 19  shows an assembled view of two pocket shutter modules hinged on the left  61 , and two pocket shutter modules hinged on the right  63  of structure S. Also shown is an extended section support channel  55  closing left pair of pocket shutter modules  61  and right pair of pocket shutter modules  63 , respectively. 
     FIG. 19  illustrates two pairs of pocket shutter modules as they are hinged in an arc-like fashion to open for insertion or removal of flanged inserts.  FIG. 20  illustrates outer view of two pairs of pocket shutter modules where the first pair of pocket shutter modules  61  is hinged about the structure S, and the second pair of pocket shutter modules  65  is hinged about the first pair of pocket shutter modules  61 . In this figure, pocket shutter modules  65  includes rotational stud  6  that is inserted into expansion ring  62 . In order to insert flanged inserts  15  into each pocket shutter  20 , the first pair of pocket shutter modules  61  is swung outward, and as pocket shutter modules  61  move outward, pocket shutter modules  65  rotates about pocket shutter modules  61  such that both openings face the same outward direction permitting flanged inserts  15  to easily be inserted into respective pocket shutter modules  20 . 
   With larger window and door openings, multiple pairs of pocket shutter modules can be added as shown in  FIG. 19  as arc-type or  FIG. 20  as folded or any combination thereof. Additionally a pair of pocket shutter modules may be replaced by more than a pair as the application warrants. 
   With the preferred embodiment, a home or business owner can either install the pocket shutter module wall stud  2  or pocket shutter module  20  with or without flanged insert  15  prior to the beginning of the hurricane season, and either add pocket shutter module  20  if only the studs were installed; or add flanged inserts  15  if both studs and pocket shutter module were installed just prior to the arrival of a hurricane. Another feature of the preferred embodiment is that once flanged inserts are installed, then deadbolts  3  are engaged from the inside of the home or business dwelling. The advantage is that in an emergency, the hurricane pocket shutter system can easily be opened from the inside providing the dweller an opportunity to escape. And since the system locks from the inside, the hurricane pocket shutter system also provides security. 
   For storm readiness, the home or business owner simply removes the latch stud  3  from top and bottom latching holes, and swivels pocket shutter module  20  about the hinge mechanism in an outward direction or away from the window or door frame to the open position. When in the open position, the home or business owner slides flanged insert  15  along the grooved insert of pocket shutter module  20  until flanged insert  15  is completely inserted into pocket shutter module  20 . 
   In the preferred embodiment, window insert  10  can be any material such as a polycarbonate transparent material like LEXAN. Flanged insert  15  with LEXAN or similar material can be left inserted inside of pocket shutter module  20  throughout the hurricane season or easily removed between hurricanes. LEXAN is transparent and provides light passivity during or between hurricanes. 
   A further embodiment of the present invention is shown in  FIG. 21 . In this embodiment, the first shutter panel  102   a  and the second shutter panel  102   b  are coupled to the each other by the F-channel  104 , which has a first track  1204  and a second track  1202  that are pivotally attached to each other by a hinge  2102 . The hinge  2102  allows the first shutter panel  102   a  to move relative to the second shutter panel  102   b  in a first direction  2104 . Hinge  2102  can be a single hinge or multiple hinges. The legs  2106  and  2108  of the F-channel  104  prevent movement of first shutter panel  102   a  relative to the second shutter panel  102   b  in a second direction  2110  opposite the first direction  2104 . The hinge  2102  allows the panels to be folded on top of each other. This folding ability has several advantages, which includes the ability to aesthetically store the shutters assembly  2100 , which includes at least two panels  102  in a configuration that appears from a distance to be only one panel on the outside of the building. 
     FIG. 22  shows an elevational view of the assembly  2100  in its stowed position  2200  attached to a building structure  2202 . In the stowed position  2202 , only panel  102   a  is visible to one viewing the building  2202  from this elevational perspective. The hinge  2102  of the F-channel  104  allows the first shutter panel  102   a  to remain in the same configuration (i.e., exterior face  2204  facing away from the building  2202 ) as when the shutter assembly  2100  was deployed and protecting the building&#39;s opening  2206 . Accordingly, the F-channel  104  can still be seen on the left side of the shutter panel  102   a . Behind shutter panel  102   a  is shutter panel  102   b , which cannot be seen in this view, with its exterior side facing the building  2202 . The assembly  2100  can be stored with or without membrane panels in place. 
   In this embodiment, one or more securing mechanisms  2208  are attached to, or couple to, an edge  2210  of the first shutter panel  102   a . The securing mechanism  2208  shown in  FIG. 22  are sliding pins, however, the invention is not so limited and can include other securing mechanisms, such as screws, bolts, hooks, and many others. A coupling half  2212  of the securing mechanism is attached to or near an edge  2214  of the aperture  2206  of the building structure  2202 . The securing mechanism  2208  can slide into and couple with the coupling half  2212  of the mechanism once the shutter assembly  2100  is deployed and covering the opening  2206 . Although two panels  102   a  and  102   b  are all that are shown and described in connection with this folding embodiment, more than two panels can be included in the assembly  2100 . 
   Moving now to  FIG. 23 , a top view of the panel assembly  2100  and partially hidden view of the building  2202  is shown. In this view, both shutter panels  102   a  and  102   b  can be seen folded and placed next to the building  2202 . Leg  2106  of F-track  1202  makes contact with the building  2202  and spaces the shutter  102   b  away from the building. In order to maintain a consistent distance from the building  2202  all along the length of the shutter  102   b , in one embodiment, the position of the hinge assembly  602  is spaced away from the building  2202  by a distance approximately equal to the length of the leg  2106  of the F-channel track  2102 . 
     FIG. 23  shows a first position  2302  where the pivot point of the hinge  602  could have been located for a non-folding shutter assembly, such as that shown in  FIG. 6 , inter alia. This pivot point  2302  could be moved to the extended position  2304  by a “T” shaped adapter, or any other extending device. 
     FIG. 24  shows an angle  2402  that is used for attaching female hinge portions  2404  to a recess  2406  of a door or window  2408 . For the foldable embodiment  2100  of the present invention, a “T” adapter  2502 , as shown in  FIG. 25  may be used. The “T” shape provides sufficient coupling space to the recess  2406  and to the new hinge location  2504 . An alternative to the T-adapter is a length of tubing that extends past the recess  2406 . 
   The folding directions, hinge locations, hinge types, and stowing and deployment configurations shown in  FIGS. 21-25  are merely exemplary and are not meant to limit the invention in any way. The present invention can have many other options for folding one or more shutter panels relative to one or more other shutter panels. 
   CONCLUSION 
   As should now be clear, embodiments of the present invention provide a shutter assembly that protects apertures, such as glass covered openings and doors, of a building during a hurricane or other violent natural elements. The assembly includes a hinged pocket system where pockets are filled with opaque, transparent, or translucent rigid materials that form an missile-repellant outer sheath protecting the building apertures. The hinge system makes it easy to open and re-close the individual shutter panels between subsequent hurricanes without compromising building security or ability of emergency escape. The shutters, whether individually, or as an assembly are lightweight and fast and easy to install. 
   NON-LIMITING EXAMPLES 
   Although specific embodiments of the invention have been disclosed, those having ordinary skill in the art will understand that changes can be made to the specific embodiments without departing from the spirit and scope of the invention. The scope of the invention is not to be restricted, therefore, to the specific embodiments, and it is intended that the appended claims cover any and all such applications, modifications, and embodiments within the scope of the present invention.

Technology Classification (CPC): 4