Abstract:
A protective shutter assembly is provided for a door and/or a window. The shutter assembly includes a plurality of interfitted shutter slats, where each slat has an intermediate portion and a first and second end. The first and second ends take a curvilinear shape, where the first end of a first shutter slat is rotatably coupled to the second end of a second shutter slat. The first end of the first shutter slat is secured to the second end of the second shutter slat and an angle between the first and second shutter slat is adjustable between a minimum angle at an open position and a maximum angle at a closed position.

Description:
RELATED APPLICATIONS 
       [0001]    This patent application claims benefit of the Provisional Patent Application No. 61/139,727 filed on Dec. 22, 2008. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates in general to protective shutters for windows, doors and the like, and is particularly directed to an accordion type shutter that is comprised of a plurality of interfitting, generally rectilinear slats having curvilinear end portions. 
       BACKGROUND OF THE INVENTION 
       [0003]      FIG. 1  is a diagrammatic plan or end view of a conventional accordion type window and door track-supported shutter, which has generally box or square type joints between respective shutter slats. As shown therein, in their fully deployed or closed configuration, the individual shutter slats, which are customarily made of extruded aluminum, engage one another at ninety degree angles so as to form a series of interlocking ‘V’s 10. Although such shutters are effective in covering a door or window, the fact that the respective shutter slats interlock with one another at ninety degree angles means that the effective (projected) coverage area of an individual shutter slat is substantially less than (e.g., on the order of only seventy percent of) the actual width dimension W of the shutter slat. Thus, the cost of the materials necessary to cover a window is relatively expensive, as compared to an arrangement in which each shutter slat covers a greater respective length of the window or door. 
         [0004]    Accordingly, it would be advantageous to provide a window and/or door shutter, that addresses the shortcomings of the conventional shutter discussed above, and is capable of covering a window and/or door opening with less material, thereby minimizing the cost of the shutter. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0005]    In one embodiment of the present invention, a protective shutter assembly is provided for a door and/or a window. The shutter assembly includes a plurality of interfitted shutter slats, where each slat has an intermediate portion and a first and second end. The first and second ends have a curvilinear shape, where the first end of a first shutter slat is rotatably coupled to the second end of a second shutter slat. The first end of the first shutter slat is secured to the second end of the second shutter slat and an angle between the first and second shutter slat is adjustable between a minimum angle at an open position and a maximum angle at a closed position. 
         [0006]    In another embodiment of the present invention, a protective shutter assembly is provided for a door and/or a window. The shutter assembly includes a first plurality of interfitted shutter slats and a second plurality of interfitted shutter slats. Each plurality of slats includes a respective mate slat, where a first end of the mate slat of the first slats takes a cross-sectional shape, and a second end of the mate slat of the second slats has an opening to receive the cross-sectional shape, to secure the first and second plurality of slats. 
         [0007]    Each shutter slat has an intermediate portion and a first and second end, where the first and second end take a C-shaped curvilinear shape. An inner diameter of the C-shaped curvilinear shape of the second end is greater than an outer diameter of the curvilinear shape of the first end, such that the curvilinear shape of the first end of a first slat is rotatable within the curvilinear shape of the second end of a second slat and the first and second slat are secured within a respective plurality of interfitted shutter slats. An angle between the first and second slats among the respective plurality of shutter slats is adjustable between a minimum angle at an open position to a maximum angle at a closed position. 
         [0008]    In another embodiment of the present invention, a method is provided for forming a protective shutter assembly for a door and/or a window. The method includes providing a plurality of interfitted shutter slats, followed by shaping each shutter slat with a curvilinear first and second end. The method further includes rotatably coupling the first end of a first slat with the second end of a second slat, such that the first end of the first slat is secured to the second end of the second slat. The method further includes adjusting an angle between the first and second shutter slat between an open position and a closed position. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is an end view of a typical prior art accordion type window and door track-supported shutter, which has generally square type joints between respective shutter slats; 
           [0010]      FIG. 2  shows an end view of an individual shutter slat in accordance with the present invention; 
           [0011]      FIG. 3  shows an end view of a pair of shutter slats of  FIG. 2  in their open or nested position; 
           [0012]      FIG. 4  shows an end view of a pair of shutter slats of  FIG. 2  in their closed position; 
           [0013]      FIG. 5  is an end view of a center-mate slat used to join respective sections of shutter slats as configured in  FIGS. 2-4 ; 
           [0014]      FIG. 6  is an end view of a terminal fastener strip used to terminate a respective section of the shutter assembly in accordance with  FIGS. 2-5 ; 
           [0015]      FIG. 7  shows the overall assembly of the shutter components of  FIGS. 2-6  for the open configuration of the shutter; and 
           [0016]      FIG. 8  shows the overall assembly of the shutter components of  FIGS. 2-6  for the closed configuration of the shutter. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Before describing in detail the particular methods and apparatuses related to window and door shutters, it should be observed that the present invention resides primarily in a novel and non-obvious combination of elements and process steps. So as not to obscure the disclosure with details that will be readily apparent to those skilled in the art, certain conventional elements and steps have been presented with lesser detail, while the drawings and the specification describe in greater detail other elements and steps pertinent to understanding the invention. The following embodiments are not intended to define limits as to the structure or method of the invention, but only to provide exemplary constructions. The embodiments are permissive rather than mandatory and illustrative rather than exhaustive. 
         [0018]    As previously discussed, conventional shutters feature slats that are not capable of forming a respective angle beyond about 90 degrees with respect to one another when the shutter is in the closed position. Thus, it would be advantageous to provide a shutter that features segments or slats that have an adjustable angle with respect to one another, including an angle greater than about 90 degrees, thereby allowing a greater coverage area for each shutter slat, and thereby reducing the material and/or cost required for such a shutter. For efficient coverage it is desired that as much shutter material as possible serve the purpose for which the shutter is intended—namely, to cover and protect the area behind it. Generally, the present invention requires two shutters to cover the door or window. Each shutter comprises a plurality of interfitting slats, each slat having a length slightly shorter than a height of the window or door (for a shutter assembly that is deployed horizontally to cover the window or door) or each having slat a length slightly shorter than a width of the window or door (for a shutter assembly that is deployed vertically to cover the window or door). 
         [0019]    In accordance with the present invention, this objective is successfully addressed by a new and improved track-supported, accordion type shutter comprised of interfitting slats having interfitting curvilinear end portions that form interlocking curvilinear channels. As will be described herein, these curvilinear channels allow the slats to be compactly stacked or nested against one another in the open configuration of the shutter, and expandable from their stowed configuration such that two successive slats are disposed in a linear or nearly linear orientation in the closed or deployed configuration of the shutter. In such a deployed configuration, the angle between two successive slats is greater than 90 degrees as is known in the prior art. 
         [0020]    The embodiments of the present invention discuss an “open” and “closed” position of the window/door shutter. The “open” position is defined as a position of the shutter in which successive shutter slats have a minimal spacing therebetween, while the “closed” position is defined as a position in which successive shutter slats have a maximum spacing therebetween. In an exemplary embodiment, the “open” position may be employed when a door and/or window is open, such that the shutter is moved away from a center region of the door and/or window to a respective side of the door and/or window so not to obstruct the opening. As a result of moving the shutter to a respective side of the door and/or window, the shutter slats are placed in a more closely spaced orientation. In an exemplary embodiment, the “closed” position may be employed when a door and/or window is closed, such that the shutter is moved toward the center portion of the door and/or window and away from a respective side of the door and/or window. The shutter may be placed in this orientation to protect the door or window from wind-blown debris, for example. As a result of moving the shutter away from the sides of the door and/or window, the shutter slats assume a spaced-apart orientation, when compared with the open orientation, and the angle between adjacent slats increases. 
         [0021]    More particularly,  FIG. 2  shows an end view of an individual shutter slat or slat  20  in accordance with the invention having a generally rectilinear portion  21 , which is terminated at a first end  22  thereof by a first generally curvilinear or ‘C’-shaped portion  23 , and at a second end  24  thereof by a second ‘C’-shaped portion  25  that is terminated by a generally circular land portion  26 . The generally circular land portion  26  is shown as having a generally curvilinear finger-like portion  31  that is spaced apart from and generally parallel to the ‘C’-shaped portion  25  so as to form a generally curvilinear channel  32  therebetween. 
         [0022]    As shown in  FIG. 3  wherein two adjacent slats are mated, the width of the channel  32  is sized to accommodate the end  33  of the ‘C’-shaped portion  23  of an adjacent shutter slat. Adjacent to the generally curvilinear finger-like portion  31  is a generally circular aperture or bore  35 , which is sized to receive a fitting, such as a self-tapping screw, that is used to attach a track wheel assembly (not shown), for enabling the shutter slat to be supported by and travel along a shutter track of conventional configuration. 
         [0023]    Although  FIG. 2  illustrates that the first and second ends  22 , 24  of the shutter slats  20  feature a ‘C’-shaped curvilinear portion, the ends may take any curvilinear form, and need not take a strictly ‘C’-shaped form. Additionally, the channel  32  need not be formed between the finger-like portion  31  and the ‘C’-shaped portion  25 , and instead may be formed anywhere within the second end  24 , so to receive the end  33  of the ‘C’-shaped portion  23 . 
         [0024]    As further shown in  FIG. 4 , which is an end view of a pair of mutually engaged shutter slats  20 - 1  and  20 - 2 , in their extended or closed configuration, the inner diameter of the generally curvilinear or ‘C’-shaped portion  23 - 1  of slat  20 - 1  is proximate, but slightly larger than, the outer diameter of the generally circular land portion  26 - 2  of slat  20 - 2  to allow the ‘C’-shaped portion  23 - 1  of slat  20 - 1  to rotate around the generally circular land portion  26 - 2  of slat  20 - 2 . In a complementary fashion, the inner diameter of the ‘C’-shaped portion  25 - 2  of shutter slat  20 - 2  is proximate, but slightly larger than, the outer diameter of the ‘C’-shaped portion  23 - 1  of slat  20 - 1 , so as to allow the ‘C’-shaped portion  23 - 1  to rotate relative to the ‘C’-shaped portion  25 - 2 . 
         [0025]    As previously discussed, the ends of the slats  20 - 1 ,  20 - 2  need not be C-shaped nor curvilinear, and thus the slat  20 - 1  need not be configured to “rotate” around the slat  20 - 2 . The ends of the slats  20 - 1 , 20 - 2  may take the form of any polygon shape, the angle between the slats  20 - 1 , 20 - 2  may be varied, as the slats  20 - 1 , 20 - 2  move relative to one another, based on the particular form of the ends of the slats  20 - 1 , 20 - 2 . 
         [0026]      FIG. 5  is an end view of a center-mate slat assembly used to join respective sections of shutter slats as configured in  FIGS. 2-4 . As shown therein, a male center-mate slat  50  has a first end  51  configured in the manner of the end  22  of an individual shutter slat  20  shown in  FIG. 2 , so that it may engage the second end  24  of an adjacent shutter slat  20 . The center-mate slat  50  also has a second end  52  of a generally rectangular shape and sized to fit within and engage an associated second, generally rectangular end  62  of a female center-mate slat  60 . 
         [0027]    The female center-mate slat  60  has a first end  61  also configured in the manner of the end  22  of an individual shutter slat  20  shown in  FIG. 2 , so that it may engage the second end  24  of an adjacent shutter slat  20 , as shown. The generally rectangularly shaped center-mates  50  and  60  also include respective ‘C’ shaped regions  53  and  63 , having inner diameters that are sized to receive fittings, such as self-tapping screws, that are used to attach the center-mate slats to a track wheel assembly for the shutter, as described above. 
         [0028]    Although the embodiment of  FIG. 5  illustrates a rectangular end  52  of the center-mate slat  50  and a rectangular end  62  of the center-mate slat  60  with a rectangular opening to receive the rectangular end  52 , the embodiments of the ends  52 , 62  of the center-mate slats  50 , 60  are not limited to a rectangular configuration, but may take the form of any polygon. Additionally, the embodiment of  FIG. 5  need not include the ‘C’-shaped regions  53 , 63 , or may include a region having a varied form other than ‘C’-shaped to attach a track wheel assembly for the shutter. 
         [0029]      FIG. 6  is an end view of a terminal fastener strip  70  used to terminate a respective section of the shutter assembly in accordance with  FIGS. 2-5 . As shown therein terminal fastener strip  70  has a first generally L-shaped end  71  that is sized to receive fittings for attaching the terminal fastener strip to a shutter mounting frame and the like. Extending from the first end  71  is a generally ‘C’-shaped portion  72  the shape of which corresponds to the generally circular land portion  26  of a respective shutter slat as described above with reference  FIG. 2 . 
         [0030]    The end  71  need not be L-shaped, nor does the end  71  need to receive a fitting to attach to a shutter mounting frame. Instead, the end  71  may be attached to the shutter mounting frame using any attachment means, such as an adhesive, for example. Additionally, the portion  72  of the fastener strip  70  need not be ‘C’-shaped, and may take a similar form as the slats  20 , as discussed above. 
         [0031]      FIG. 7  shows the overall assembly of the shutter components described above for the open configuration of the shutter, while  FIG. 8  shows the overall assembly of the shutter components described above for the closed configuration of the shutter. As can be seen from these Figures, a shutter assembly formed of the shutter slat components of the present invention is stowable to a highly nested open configuration ( FIG. 7 ), and is deployable to a closed configuration that allows the shutter slats to be nearly parallel (or linear) with one another, thereby substantially increasing the coverage area per shutter slat. In the embodiment of  FIG. 8  (closed position), the respective slats  20  form a respective angle with one another that exceeds 90 degrees and is nearly 180 degrees. 
         [0032]    Among the many advantages of the shutter assembly of the present invention are: 
         [0033]    1. The slats are configured to be extrudable. 
         [0034]    2. A center to center distance between two consecutive slats is greater than prior art shutter systems. 
         [0035]    3. As a result of 2. an installation requires fewer slats than prior art systems 
         [0036]    4. Fewer fasteners and hardware (screws, wheels, bushings, etc.) are required for the shutter of the present invention than for prior art shutter systems. 
         [0037]    5. Average shorter assembly time than for prior art systems. 
         [0038]    6. The shutter can be locked from either the inside or the outside. 
         [0039]    7. The shutter may be pre-assembled for quicker installation. 
         [0040]    8. Due to the simpler dimensioning of the shutter of the present invention, estimating sizes and fabrication is easier. 
         [0041]    9. In one embodiment clear Lexan shutter slats are used. 
         [0042]    The shutter of the present invention can be configured and mounted to open/close in a horizontal or a vertical direction. That is, the two shutter segments can be deployed vertically downwardly and upwardly toward a center region where the two portions are joined, or deployed from the sides toward a center region where the two portions are joined. 
         [0043]    This written description uses examples to disclose embodiments of the invention, including the best mode, and also to enable any person skilled in the art to make and use the embodiments of the invention. The patentable scope of the embodiments of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.