Abstract:
Building window and door shutters to protect against wind and wind borne foreign objects comprising a non-rigid sheet of coated waterproof polyester and a second sheet of non-rigid material made of high tensile strength polyester fiber mesh that are mounted side by side as a layer of materials in rigid tracks affixed to the building structure adjacent the window and doors. When the shutters are not in use, they can be rolled up or folded up and stored.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates generally to removable shutters for windows and doors for protection against wind and wind borne debris from storm or hurricane winds and, specifically, to shutters made from sheets of non-rigid coated polyester material and mesh material.  
       DESCRIPTION OF RELATED ART  
       [0002]     Extreme weather conditions, such as hurricanes, have become more frequent and more destructive. Such weather produces high velocity winds and a significant volume of precipitation. The windy conditions often pick up loose objects and turn them into airborn missiles. Windows are broken and damaged through impact by these objects when the windows are not protected. Several methods of protection have been produced, however, they are often ineffective in stopping airborne missiles, cumbersome, difficult to store, difficult to install, and not water repellant.  
         [0003]     For example, U.S. Pat. No. 5,579,794 issued to Sporta on Dec. 3, 1996, is entitled “Apparatus and Method for Securing an Object Against Gale-force Winds”, and teaches of a protective cover that covers an entire mobile home. The Sporta patent is completely wind permeable and tied down through ground anchors. Thus, the Sporta patent is difficult to install and ineffective due to its allowance for wind penetration.  
         [0004]     U.S. Pat. No. 5,740,639 issued to Covington on Apr. 21, 1998 is entitled “Double Panel Storm Shutter Installation with Brace” and teaches a device that has two parallel supports that receive two rigid panels above and below the rigid panels and secure them in place with screws and clams on either side of the rigid panels.  
         [0005]     U.S. Pat. No. 6,170,050 issued to Gower on Jan. 23, 2001 is entitled “Flexible Protective Wind Abatement System” and teaches a device that attaches to the overhanging eaves of a house roof and extends to the ground below. It is then secured into the ground through stakes. It uses wind permeable mesh as the protective screen, thus allows the entry of precipitation.  
         [0006]     U.S. Pat. No. 6,325,085 issued to Gower on Dec. 4, 2001 is entitled “Flexible Protective System to Prevent Penetration of Wind Borne Missiles” and teaches the use of flexible material that has no rigid panels for structure or stability, and is not water repellant. It simply attaches to a wall of a structure and then is secured at another end to a different surface.  
         [0007]     U.S. Pat. No. 6,341,455 issued to Gunn on Jan. 29, 2002 is entitled “Protective Cover Assembly” and teaches a high strength fabric supported by fixed brackets, a rod and a bar. The fabric is stretched over a window through the use of a ratchet system. The fabric remains on the wall of a building when not in use.  
         [0008]     U.S. Pat. No. 6,408,922 issued to Desrochers on Jun. 25, 2002 is entitled “Self-supporting Construction Frame and Methods of Use Thereof for the Installation of Doors and Windows” and teaches a self supporting construction frame with two vertical portions and two horizontal portions that is used in the construction of windows and door frames.  
         [0009]     U.S. Pat. No. 6,851,464 issued to Hudoba et al. on Feb. 8, 2005 is entitled “Storm Curtain Apparatus” and teaches a storm curtain contained within a housing above a window. The curtain is rolled downward along tracks which parallel the window&#39;s sides. The curtain is secured along the bottom of the window through a bar. The curtain has strips affixed along its sides which secure it to the tracks. The strips and the curtain are two separate pieces, but various methods are used to affix them together.  
         [0010]     U.S. Pat. No. 6,886,300 issued to Hudoba et al. on May 3, 2005 is entitled “Tensioned Fabric Storm Protection Panel” and teaches a panel that includes a frame made up of four channel members interconnected by corner members. The panel is placed in its entirety over an opening such as a window and is then removed in its entirety when not in use.  
         [0011]     The prior art, therefore, fails to provide an impact protection device which is water repellant, highly effective, easily storable, and easily assembled and taken down.  
       SUMMARY OF THE INVENTION  
       [0012]     A window and door shutter to protect against wind and wind borne foreign objects comprising a first flexible sheet of material made of coated waterproof polyester and a second sheet of flexible material made of high tensile strength polyester fiber in a mesh formed in side by side layer of materials. When in use, the mesh sheet faces away from a window and the coated waterproof polyester sheet is closest to the window.  
         [0013]     The shape and configuration of each layered cover depends on the size of each window and door to be covered. Typically, most windows are rectangular. Therefore, the flexible window cover will be rectangular and slightly larger in length and width to overlap the window to be covered.  
         [0014]     Each shutter for each window and door shall have a pair of rigid elongated fasteners that are firmly attached in parallel to the building on each side of the window to be covered.  
         [0015]     Each shutter shall have rigid fastener bars mounted to the building on opposite parallel sides of the window to be covered for fastening the layered window cover to the building.  
         [0016]     The side edges of the flexible layered window cover should include a bead that is enlarged and sized to fit into a passage in order to be mounted to the window tracks on each side of the window to be covered.  
         [0017]     Each shutter is mounted over the window and attached to the building by sliding the flexible cover side beads into the window tracks on each side from bottom to top or vice versa covering the window completely. Each track is protected by a track cover. The track cover is mounted to the building through a nut and screw mechanism. When the nut and screw mechanism is tightened, the track cover places pressure on the sheets which have been inserted into the tracks, thus preventing them from exiting. When the screw and nut mechanism is loosened, the pressure is released and the used may slide the sheets out of the tracks. The track cover has a stopper structure that prevents the first and second sheets from exiting the fasteners when in use.  
         [0018]     Each shutter may be folded or rolled up when not in use.  
         [0019]     It is an object of this invention to provide a hurricane shutter that is rigid and can protect windows and doors of buildings during a hurricane of high winds and rain while the shutters can be rolled up for storage when not in use.  
         [0020]     It is another object of this invention to provide window and door covers that can function as storm shutters to prevent wind and flying debris damage from breaking windows, such that the window covers are made of fabric-like materials and are lightweight and can be easily stored.  
         [0021]     It is a further object of this invention to provide window and door covers that are lightweight and easy to install and remove by the user.  
         [0022]     It is a further object of this invention to provide a window and door cover with two separate sheets of material that allows the user to use either one individually or both simultaneously.  
         [0023]     In accordance with these and other objects which will become apparent hereinafter, the instant invention will now be described with particular reference to the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0024]      FIG. 1  is a top side view of the cover with the non-rigid sheets inserted into the fasteners.  
         [0025]      FIG. 2  is a perspective view of the cover showing one side with the track cover and one side without and showing the non-rigid sheet of coated waterproof polyester pulled out slightly from underneath the non-rigid sheet of mesh.  
         [0026]      FIG. 3  is an enlarged sectional prospective view of a fastener with the non-rigid sheets inserted into them.  
         [0027]      FIG. 4  is an enlarged front elevation view of the fastener and track cover.  
         [0028]      FIG. 5  is an enlarged perspective view of the fastener and track cover and non-rigid sheets inserted into them.  
         [0029]      FIG. 6  is an isolated enlarged view of the screw and nut assembly used to secure the track cover.  
         [0030]      FIG. 7  is an enlarged front elevation view of the track cover detached from the fastener. 
     
    
     DETAILED DESCRIPTION  
       [0031]     In reference to  FIG. 1 , a top side view of the cover  10  is shown. The cover is a device which protects openings, such as doors and windows, from wind, debris, and rain. The cover  10  is shown as it would be seen in use over an opening. A pair of fasteners  14  are permanently mounted to the outer surfaces of a building, house, or other structure. These fasteners  14  are to be mounted in pairs and on opposite parallel sides of the opening which they will cover. The fasteners  14  may be mounted in a vertical fashion or in a horizontal fashion. The cover  10  will also include a non-rigid sheet of high tensile strength polyester mesh  12 . An ideal fabric used as this mesh sheet  12  is Dacron which is commonly found as trampoline tarps on catamarans.  
         [0032]     In the preferred embodiment, the material used for the mesh sheet  12  will be constructed of 100% polypropylene and has a ¾ basketweave construction. The material has been tested to have a tensile strength that will warp at 4632 lbs and a Mullen burst strength of 3786 psi. The typical material used to provide adequate storm protection has a tensile strength of 540 lbs and a burst strength of 825 psi. The material was tested to have a tear strength of 4533 lbs and a puncture strength of 4833 lbs. The typical material used to provide adequate storm protection has a tear strength of 200 lbs and a puncture strength of 190 lbs. The porous nature of the mesh allows air to flow through at around 230 cubic feet per minute. In addition, the material will maintain UV radiation resistance for 5000 hours. Thus, in comparing what is adequate in storm protection, to the level at which the present invention has been tested, it is clear that the present invention exceeds the necessary strength. For further comparison of necessary safety codes in storm protection, the GOWER U.S. Pat. No. 6,176,050 provides a good discussion of Mullen burst and Miami-Dade County regulations, which are the most stringent in the United States.  
         [0033]     The mesh sheet  12  can be inserted into the fasteners  14  when used and may be taken out of the fasteners  14  when not used.  FIG. 1  further shows the track covers  16  which are permanently mounted to the outer surface of the building so as to cover the fasteners  14  and protect the fasteners  14  from damage during storms. While  FIG. 1  only shows one side of the cover  10  as having a track cover  16 , in use, there will be a track cover  16  over both fasteners  14 .  
         [0034]     In reference to  FIG. 2 , a perspective view of the cover  10  is shown. The cover  10  in  FIG. 2  is shown as it would be in use with the mesh sheet  12  installed in the fasteners  14  and the track guards  16  installed over the fasteners  14 .  FIG. 2  further shows a second non rigid sheet  20  consisting of high strength coated waterproof polyester. When in use, the cover  10  must be installed such that the sheet of coated polyester  20  is closest to the opening or window and the mesh sheet  12  faces outwardly from the window or opening. The material most likely used for the second sheet  20  must have a weight of at least 18 oz/yd 2  and has been tested using a weight of 20 oz/yd 2  and 22 oz/yd 2 . The second sheet  20  is coated for waterproofing and has a flame resistance quality that prevents the material from being consumed within 2 minutes. It is additionally contemplated that a user may combine more than one ply of the material to create the second sheet  20  for added strength. Further, for safety purposes, the second sheet  20  may be punctured with a sharp object such that in an emergency, an occupant of a building may quickly cut an opening in the cover  10  to escape. As shown in  FIG. 2 , the cover  10  may be installed with both the mesh sheet  12  and the polyester sheet  20 , or alternatively, the cover  10  may be installed with just one of the sheets. This is designed so that following a storm of high winds and rain, the polyester sheet  20  may be removed to allow fresh air and light to penetrate through. Both the mesh sheet  12  and the polyester sheet  20  may be completely removed from the fasteners  14  and rolled up for storage.  
         [0035]     In reference to  FIG. 3 , an enlarged perspective view of one of the fasteners  14  is shown. The fastener  14  is shown as having a first tubular receiver  30  and a second parallel tubular receiver  32 . Each tubular receiver  30 ,  32  has open ends, hollow cores, and an elongated narrow open channel cut out and angled towards the center of the window or opening the fasteners  14  surround. Many rigid materials may be used to construct the fasteners  14 , however it is anticipated that a strong and lightweight material such as aluminum will be most common. It is shown that the tubular receivers  30 ,  32  do not extend completely to the edge of the fastener  14 .  FIG. 3  further shows both the mesh sheet  12  and the second polyester sheet  20  installed within the tubular receivers  30 ,  32  of the fasteners  14 . As shown, the mesh sheet  12  is installed on the outer pair of tubular receivers  30  so that the mesh sheet  12  rests above the polyester sheet  20 .  FIG. 3  further represents the construction of the sheets  12 ,  20 . Along the sides of the mesh sheet  12  that are inserted into the tubular receivers  30 , there is a piece of high strength material  34 , such as polyester. This material  34  is stitched to the mesh sheet  12  to provide strength under situations of high stress and wind. As shown, the tested and ideal method of stitching is to use one strip of category 5 zig-zag stitching and one strip of category 2 zig-zag stitching. However, it is contemplated that alternative methods of attachment are comparable. The edges of the mesh sheet  12  that are not inserted into the tubular receivers  30  also have a similar material attached to them for durability and to prevent unnecessary tears. It has been tested to use category 2 zig-zag  39  patern on these edges.  FIG. 3  also shows an enlarged view of the second polyester sheet  20 . The second polyester sheet  20  is constructed of sturdy material and can be folded onto itself for secure stitching. The parallel sides of the second sheet  20  that are inserted into the tubular receivers  32  have been tested to use a zig-zag pattern of category 5 shown at  50  and category 2. Further the opposite parallel sides  25  have been tested to use a category 2 zig-zag pattern. However it is contemplated that alternative methods of attachment may be utilized.  
         [0036]     In reference to  FIG. 4 , a front end elevation view of one of the fasteners  14  is shown in the in use mode. The fasteners  14  are permanently mounted to the outer surface of a building or house through the use of bolts.  FIG. 4  shows a pair of tubular receivers  30 ,  32  that are in each fastener  14 . The tubular receivers  30 ,  32  and fasteners  14  are protected by a track cover  16 . The track cover is made of a rigid material. The track cover is permanently mounted to the outer surface of a building or house through the use of a nut and screw assembly  60 . This assembly  60  is such that a tubular housing  64  extends into a building and the screw  66  is able to move in and out through the rotation of a nut  70  at the top of the track cover  16 . Each nut  70  is protected from the track cover through the use of a washer  48 . For further ease of use, a spring device  62  is inserted underneath the track cover  16  such that when the nut  70  is loosened, the track cover automatically pops up. This is an important feature. The mesh sheet  12  and the second polyester sheet  20  are connected to the fastener  14  through the use of elongated leader devices  40 ,  42 . These leader devices  40 ,  42  may be ropes, wires, or plastic. The leader devices  40 ,  42  must maintain their diameter and must have a diameter large enough to not fit through the narrow elongated open channel found in each tubular receiver  30 ,  32 . The leader device  40  which is attached to the mesh sheet  12  is contained within the stitched piece of fabric  34 . The leader device  42  which is attached to the second polyester sheet  20  is contained within the polyester fabric and is simply rapped around the leader device  42 . When in use, the user simply inserts the leader devices  40 ,  42  into their respective tubular receiver  30 ,  32  and arranges it such that the sheets  12 ,  20  exit through the narrow open channels so as to extend to the opposite fastener  14  on the opposite side of the window or opening. Once the sheets  12 ,  20  are installed in the fasteners  14 , the nut  70  is tightened on the screw assembly  60 . This creates downward pressure on the track cover  16 . The downward pressure acts as a stabilizing force on the sheets  12 ,  20  so they do not exit the tubular receivers  30 ,  32 . When the user wishes to remove the sheets  12 ,  20  the nut  70  is simply loosened to the point at which the spring  62  pushes the track cover  16  away from them and allow for easy removal.  
         [0037]     In reference to  FIG. 5 , an enlarged perspective view of one of the fasteners  14  is shown with the mesh sheet  12  inserted into the tubular receiver  30  and the elongated leader device  42  on the second polyester sheet  20  being pulled out of the tubular receiver  32 . As shown, the track cover  16  extends all the way to the edge of the fastener  14 . A stopper mechanism  72 , located at the far ends of each track cover  16 , extends through the track cover and downward toward the surface of the fastener. This stopper mechanism  72  prevents the sheets  12 ,  20  from exiting the tubular receivers  30 ,  32  unnecessarily.  
         [0038]     In reference to  FIG. 6 , an enlarged view of the screw and nut mechanism  60  is shown.  
         [0039]     In reference to  FIG. 7 , an enlarged front elevation view of the track cover  16  is shown removed from the fastener  14 . The track cover  16  is mounted to the fastener  14  through the use of the screw and nut assembly  60 . At the far end of the overhanging portion of the track cover  16  is a stopper mechanism  72  that consists of a bottom extending screw  74 . This stopper mechanism  72  does not screw into the fastener  14 . The stopper mechanism  72  extends downward from the track cover  16  far enough to act as a barrier against the unwanted exit of the sheets  12 ,  20 .  
         [0040]     The cover  10  is mounted to a building or house to maximize structural rigidity. The fasteners  14  are not mounted to the eaves of a home or a window. Further, for aesthetic purposes, the fasteners  14  may be painted to match the color of the structure on which they are mounted.  
         [0041]     The effectiveness of the cover  10  stems from its combination of the two layers of sheets  12 ,  20 . When high winds accompany a storm, the wind is slowed by, but penetrates through the mesh sheet  12 . However, the second polyester sheet  20  is impermeable to water or wind. When the wind reaches the second polyester sheet  20 , it is caused to reverse outwardly toward the mesh sheet  12 . This effect creates a pocket of air or a wind barrier between the mesh sheet  12  and the second polyester sheet  20 . This pocket of air acts as a further protection device against flying debris. Thus, when the debris hits the mesh sheet  12 , it is first stopped by the strength of the mesh fabric, but is secondarily stopped by the air pocket. Additionally, the non-rigid characteristic of the sheets  12 ,  20  allow the force absorbed to be spread outwardly and evenly. Thus, no one location on the cover  10  will be more affected by wind than another. This effect increases durability and the life of the cover  10 . In addition, when the cover  10  is to be mounted onto a building in a side-by-side fashion, the displaced wind disperses in a perpetual manner to increase protection throughout.  
         [0042]     The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art.