Abstract:
A hurricane protection system, specifically for protection of the window and door openings in a building using transparent plastic panels attached in a manner that accommodates new and old architectural designs. The present system uses old standards and new unique methods, a transparent panel shaped to grow in strength when wind pressure is applied, attached to buildings using standard industry methods with an unique use of a rubber washer that acts as a shock absorber and lock washer on all bolted applications. The system has new and unique extrusions that allow the panels to be mounted away from the wall, to avoid protruding decorative trim and sills, in one-sixteenth inch increments.

Description:
FIELD OF INVENTION  
       [0001]     The present invention relates to plastic panel storm shutter and, more particularly, to a system of plastic panels with mounting methods to protect glass window and door openings in homes, office buildings and other walled structures from the destructive force of storm systems, such as hurricanes.  
       BACKGROUND OF THE INVENTION  
       [0002]     Violent storms are natural phenomena that often generate winds having the potential for destruction of property and life. This potential is evidenced upon review of the storm systems known as hurricanes that struck the United States in 2004 and 2005. Those hurricanes were especially destructive taxing the entire nation in the form of rebuilding costs and increased insurance rates. In light of the escalating costs for rebuilding, home owners, business owners and insurance companies alike have a common goal in protecting property. Proper shuttering of window and door openings, typically the weakest portion of a structure, has become a necessity if the structure&#39;s contents are to be protected.  
         [0003]     The study of storms has determined that storm shutters must withstand more than just high winds. In reality the majority of the destruction is a direct result of impacts by debris carried by these high winds. In an effort to reduce the destructive effect of such windborne debris, changes to the building codes in areas frequently subjected to these type storms have been made, notably first in Florida, then throughout the coastal United States, with the introduction of the new Florida statewide code and next the International Building Code. One change made included in these codes requires that storm shutters withstand a large missile impact. Testing is performed by projecting a nine pound wood two by four at a velocity of 50 feet per second or higher, against the storm shutter being tested, this is intended to simulate the impact of windborne debris in a hurricane or similar storm. Then the shutter is wind resistance tested with 4500 cycles of wind up to one and one-half times the shutter design load to simulate the 3 second pulsating wind of a hurricane. To successfully pass, the shutter must remain intact after the testing.  
         [0004]     Along with providing protection from such storms or hurricanes, it has been found desirable for storm shutters to be constructed of translucent materials so as not to nullify the main purpose of transparent glass window and door openings, especially when the electricity has been lost in a storm. The transparent materials prevent claustrophobic tendencies of occupants secured within the structure; yet permit law enforcement officials to inspect shuttered structures.  
         [0005]     A number of U.S. patent numbers, notably U.S. Pat. Nos. 4,685,261, 4,175,357, 5,228,238 and 5,457,921, disclose various types of translucent storm shutter assemblies having a transparent panel constructed of flat plastic such as polycarbonate and mounted in a frame of aluminum or steel or a corrugated plastic such as polycarbonate and mounted in a frame of aluminum or steel. The plastic sheet used in the &#39;261 and &#39;357 patents is firmly secured to a frame with little if any allowance for expansion and contraction relative to the frame. Such restriction can cause the shutter assembly to become damaged even without exposure to storms. The plastic sheet used in the &#39;238 patent, on the other hand, is mounted to its frame so as to allow each sheet relative freedom to expand and contact. As taught by the &#39;238 patent, this problem may be avoided by mounting each plastic sheet in a frame so that it is relatively unrestricted and free to change in size in response to temperature changes. In order to accomplish this, however, the &#39;238 patent discloses a very elaborate and thus relatively expensive storm shutter assembly. The &#39;921 discloses a corrugated sheet of plastic such as polycarbonate, that was made of material 0.062 to 0.125 thick about 13 inches wide. The &#39;921 patent shows a storm shutter that had to be put up in pieces and reinforced with aluminum or steel braces. This made the shutter very consumer unfriendly, unable to pass the new building codes and worse yet, no method of overcoming the loosing of the bolts used to hold the panel in place when the material contracted in size in response to temperature changes.  
         [0006]     A common problem shared by transparent storm shutters of the prior art is that in order to successfully pass the current missile impact test, like previously described, each plastic sheet is relatively thick, typically on the order of a 0.5 inch or more, with a jigsaw puzzle of reinforcement. Since impact plastics such as polycarbonate are relatively expensive and heavy, these designs cannot compete in the market.  
         [0007]     Therefore, there is a need for a transparent storm shutter that is relatively inexpensive to manufacture, is compatible with current shutter systems, is easy to install, overcomes the new architectural opening surround décor that protrudes from the wall and prevents the use of old mounting methods, yet capable of withstanding direct impacts from windborne debris during a storm.  
       SUMMARY OF THE INVENTION  
       [0008]     The present invention is directed to a relatively inexpensive corrugated transparent impact plastic such as thin lightweight polycarbonate, this shutter is made to replace multiple narrow panels with a panel large enough to cover an opening with one piece and eliminate the need for jigsaw puzzle reinforcement, making it consumer friendly. It is shaped with radius topped corrugations making it stronger with less weigh per square foot of coverage. When the radius corrugation top is wind loaded it flattens causing the perpendicular sides to go more perpendicular to the surface, thereby adding strength without adding weigh to the panel. The one piece panel eliminates panel joints, the weakest point in all prior art.  
         [0009]     The present invention is a system of installations that are compatible with existing methods with changes that make it able to pass the needed code testing to become a viable product in today&#39;s hurricane protection market. The present invention lightweight polycarbonate panel cannot be bolted in place using the industry standard bolt and wingnut because the bolt thread will saw the hole open and the wingnut will spin off because when the plastic shrinks with temperature changes, the wingnut loosens and the hurricane force winds spin it off. The present invention system uses a rubber washer with all bolt and wingnut fastenings that acts as a shock absorber, prevents the screw from sawing the panel and is a lock washer to keep the wingnut from spinning off when the material shrinks due to changes in the temperature. This is accomplished by using a one-half inch diameter hole in the panel for a one-quarter inch diameter screw allowing room around the screw to squeeze the rubber washer between the screw and panel when the wingnut is applied. The shrinkage in the panel thickness is compensated with the rubber washer and it becomes a locking device for the wingnut thusly preventing it from spinning off.  
         [0010]     The present invention is to a system of installations that eliminate the most common problems in installation of panel over décor surrounded openings. The present invention system using a “h” header that is an adjustable distance out from the wall of the structure in one-sixteenth inch increments. The “h” header is made of aluminum angle with segregations that meshes with an “u” shaped aluminum extrusion that has mating segregations, this allows the “u” part to be moved in and out, then screwed in place when the exact distance needed from the wall is obtained. The present invention system uses a matching “F” track sill that is an adjustable distance out from the wall of the structure in one-sixteenth inch increments. The “F” track sill is made of aluminum angle with segregations that meshes with a “F” shaped aluminum extrusion that has mating segregations, this allows the “F” part to be moved in and out, then screwed in place when the exact distance needed from the wall is obtained.  
         [0011]     In one embodiment of the present plastic panel hurricane protection system it can be used with current standard mounting with the addition of the rubber washer. In other embodiments, the system can stand alone using the adjustable “h” headers and “F” tracks with rubber washers when bolted to the wall or mounting extrusions. This plastic panel hurricane protection system will give building occupants, when a storm is imminent and the shutters are mounted, light inside and the ability to see outside conditions. Still being secure by knowing the envelope of their building cannot be breached and flying debris will be deflected. Further, security after the storm, because the panels can be left up and not block the light at a time when electric is most likely to be out.  
         [0012]     It has also been found that an additional benefit of the particular system is that it take an average of 12 panels with no reinforcement for the averages home, prior systems took 100 or more panels and elaborate reinforcement systems for the average home. The present plastic panel hurricane protection system takes about hour to install when a storm is imminent, prior systems take days instead of hours to install.  
         [0013]     Another objective of the present invention is to teach a plastic panel may be secured in place and not restrict the thermal expansion and contraction of thin lightweight corrugated plastic panels with no chance of damage.  
         [0014]     Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]      FIG. 1  is a perspective view of several embodiments of the present plastic panel hurricane protection system, it shows several ways a panel could be mounted and used to cover and protect a window or door opening in a structure.  
         [0016]      FIG. 2  is a cross-section of plastic panel showing direct attachment and depicting the radii that gives the panel its strength.  
         [0017]      FIG. 3  is a cross-section of fastener using a bolt or stud, a washer wingnut or sidewalk bolt and rubber washer, it depicts how the rubber washer is squeezed into the panel to act as a shock absorber on impact and a lockwasher when tightened.  
         [0018]      FIG. 4  is a cross-section of an adjustable “h” header used in the present plastic panel hurricane protection system when a panel must mounted away from the wall to avoid décor around an opening.  
         [0019]      FIG. 5  is a cross-section of an adjustable “F” track sill used in the present plastic panel hurricane protection system when a panel must mounted away from the wall to avoid décor around an opening, also the use of a rubber washer with bolt and wingnut.  
     
    
     REFERENCE NUMBERS IN DRAWINGS  
       [0020]    
       
         
               
               
               
               
             
           
               
                   
               
               
                   
               
             
             
               
                 11 
                 Serrated large angle 
                 14 
                 Serrated “h” header 
               
               
                 17 
                 Serrated “F” track 
                 20 
                 Serrated small angle 
               
               
                 23 
                 Corrugated plastic panel 
                 26 
                 “h” header-industry standard 
               
               
                 29 
                 “F” track-industry standard 
                 32 
                 Extended “F” track-industry 
               
               
                   
                   
                   
                 standard 
               
               
                 35 
                 Studded angle-industry standard 
                 38 
                 Tapcon screw 
               
               
                 41 
                 Bolt 
                 44 
                 Rubber washer 
               
               
                 47 
                 Washer wingnut 
                 50 
                 PanelMate Plus fastener 
               
               
                 53 
                 Stud 
                 56 
                 Tek screw 
               
               
                 59 
                 Sidewalk bolt 
               
               
                   
               
             
          
         
       
     
       DETAILED DESCRIPTION OF THE INVENTION  
       [0021]     Although the invention has been described in terms of a specific embodiment, it will be readily apparent to those skilled in this art that various modifications, rearrangements and substitutions can be made without departing from the spirit of the invention. The scope of the invention is defined by the appended hereto.  
         [0022]     The present invention is directed to a system using a transparent panel  23  that is mounted over window and door openings in buildings protecting the window and door glass (not shown) from the high force winds and windborne debris typical of storm systems such as hurricanes.  
         [0023]     Referring in general to  FIG. 1 , one embodiment of the present plastic panel hurricane protection system allows mounting the panel several ways, using past industry standards, past industry standards with modifications and new methods that are part of this invention. At the top of the panel we can use the “h” header  26  an industry standard that is attached to the building with Tapcon screws  38  and the plastic panel  23  slides into the “h” header  26  or a “F” track  29  an industry standard that can be used at the head or sill (as shown) is attached to the building with Tapcon screws  38 , the Plastic panel  23  is then bolted to the “F” track  29  using Bolt  41 , Rubber washer  44  &amp; Washer wingnut  47 , the Rubber washer  44  being a key ingredient of this invention because it allows the use of thin lightweight Plastic panel  23  that expands and contracts with temperature changes, it also acts as a shock absorber in the one-half inch diameter hole in the Plastic panel  23  for a One-quarter inch diameter screw and a locking device for the Washer wingnut  47 . This use of the Rubber washer  44  also applies in its uses further described herein. At the sill it shows the option to use the Extended “F” track  32 , an industry standard which can also be used at the head (not shown), it builds the panel out from the wall a certain distance, the Extended “F” track  32  is mounted to the wall with Tapcon screws  38 , the panel is then bolted to the Extended “F” track  32  using Bolt  41 , Rubber washer  44  &amp; Washer wingnut  47 , the Rubber washer  44  being a key ingredient of this invention because it allows the use of thin lightweight Plastic panel  23  as stated above. At the sill it shows the option to use the Studded angle  35  an industry standard which can also be used at the head (not shown), Tapcon screws  38  are used to mount the Studded angle  35  to the building, the panel is then bolted to the Studded angle  35  using Stud  53 , Rubber washer  44  &amp; Washer wingnut  47 , the Rubber washer  44  being a key ingredient of this invention because it allows the use of thin lightweight Plastic panel  23  as stated above. At the head and sill an optional direct mounting method is shown using a PanelMate plus 50 fastener, Rubber washer  44  and Washer wingnut  47 , the Rubber washer  44  being a key ingredient of this invention because it allows the use of thin lightweight Plastic panel  23  as stated above.  
         [0024]     Referring to  FIG. 2 , one embodiment showing a cross-section of Plastic panel  23  that depicts direct attachment with PanelMate plus 50, Rubber washer and Washer wingnut  47 . It show the unique radii on corrugation that gives it more strength per pound making the Plastic panel  23 , such as polycarbonate, able to withstand the high winds associated with hurricanes.  
         [0025]     Referring to  FIG. 3 , one embodiment showing an exploded view of the typical fastener using Bolt  41  or Stud  53 , Washer wingnut  47  shown or Sidewalk bolt  59  and Rubber washer  44 . It depicts the importance and uniqueness of the Rubber washer  44  being squeezed into the Plastic panel  23  between the Bolt  41  or Stud  53  such as one-quarter inch and the mounting hole in the Plastic panel  23  such as one-half inch by tightening the fastener so it may act as a shock absorber when the Plastic panel  23  is impacted. The Rubber washer  44  also acts as a lockwasher when tightened, this very important since Plastic panel  23 , such as polycarbonate shrinks and expands with temperature changes, otherwise the fastener would loosen.  
         [0026]     Referring to  FIG. 1 , one embodiment shown at the top is the use of Serrated large angle  11  and Serrated “h” header  14  used together to create an adjustable “h” header is a unique and innovative part of this plastic panel hurricane protection system patent and is better shown in  FIG. 4 , it is an adjustable “h” header that can be adjusted in one-sixteenth inch increments to build-out the panel from the wall a distance exactly as needed instead of a certain dimension, that may not fit, that current industry standard extended “h” header offer. The Serrated large angle  11  is mounted to the building with Tapcon screws  38 , the Serrated “h” header  14  is meshed with the serrations in Serrated large angle  11  and set to the distance from the wall needed and locked in place with Tek screws  56 , and the Plastic panel  23  slides into the “h” header  14 .  
         [0027]     Referring to  FIG. 1 , one embodiment shown at the bottom is the use of the Serrated small angle  20  and Serrated “F” track  17  used together to create an adjustable “F” track that is a unique and innovative part of this plastic panel hurricane protection system patent and is better shown in  FIG. 5 , a cross-section of an adjustable “F” track that can be adjusted in one-sixteenth inch increments to build-out the panel from the wall a distance exactly as needed instead of a certain dimension, that may not fit, that the current industry standard extended “F” track offer. The Serrated small angle  20  is mounted to the building with Tapcon screws  38 , the Serrated “F” track  17  is meshed with the serrations in Serrated small angle  20  and set to the distance from the wall needed and locked in place with Tek screws  56 , the panel is then bolted to the “F” track  29  using Bolt  41 , Rubber washer  44  &amp; Washer wingnut  47 , the Rubber washer  44  being a key ingredient of this invention because it allows the use of thin lightweight Plastic panel  23  that expands and contracts with temperature changes.  
         [0028]     Several exemplary Plastic panel  23 , such as one-sixteenth to five-thirty second inches thick polycarbonate using this Plastic Panel Hurricane Protection System have successfully passed a large missile impact test performed according to the International Building Code (ICC), Florida Building Code (FBC) and ASTM International standards. The exemplary Plastic panel  23  teaches how to fasten lightweight to a structure that withstood the impact of a length of 2×4 lumber weighing nine pounds, traveling at a speed of 50 feet per second. Storm shutters using corrugated or flat sheet of polycarbonate with hard to install aluminum or steel reinforcements have not been able to pass this test unless the material thickness was too thick and heavy for practical applications.  
         [0029]     Because the present Plastic Panel Hurricane Protection System uses existing standards with new and unique methods Plastic panel  23  can be mounted with less elaborate and less expensive mounting mechanisms makes it much more consumer friendly the methods previously used to mount panels. The Plastic panel  23  has the added benefit of enabling thinner and lighter sheets of the plastic material to be used while still providing the same of better degree of impact resistance afforded by much thicker flat or corrugated sheets of the same plastic material.  
         [0030]     From the above disclosure of the general principles of the present invention and the preceding detailed description, those skilled in the art will readily comprehend the various modifications to which the present invention is susceptible. Therefore, only the following claims and equivalents should limit the scope of the invention thereof.