Note: Descriptions are shown in the official language in which they were submitted.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
APPARATUS AND METHOD FOR WINDLOCI~ING
A BUILDING OPENING
Field of the Invention
This application is a continuation-in-part of co-pending application
serial number 091520,845, filed March 8, 2000. The invention is in the field
of windlocl~ing a building opening to prevent the intrusion of unwanted air,
fluid (typically water or sea,water) and debris. During hurricanes and other
high wind velocity storms, the breach of a building opening can cause great
damage to the structure. If the building structure is not breached, then
substantial damage can be prevented.
Background of the Invention
Many building codes are now requiring or will soon require hurricane
shutters on all new homes built in coastal areas. Similar requirements for
buildings other than homes are anticipated as well. The South Florida
Building Code, 1994 Edition, requires that storm shutters shall be designed
and constructed to insure a minimum of a one inch separation at maximum
deflection with components and frames of components they are to protect
unless the components and frame are designed to receive the load of storm
shutters.
The determination of actual wind loading on building surfaces is
complex and varies with wind direction, time, height above ground, building
shape, terrain, surrounding structures, and other factors. The American
Society For Testing And Materials (ASTM) has promulgated a Standard Test
Method For Structural Performance of Exterior Windows, Curtain Walls, And
Doors By Uniform Static Air Pressure Difference and its designation is E33'0-
97 and was published April 1998. The test method requires that the person
specifying the test translate anticipated wind velocities and durations into
uniform static air pressure differences and durations. Durations are
considered because most materials have strength or deflection characteristics
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
2
which are time dependent. Testing under this method is performed in a test
chamber which measures the pressure difference across the test specimen.
Similarly, ASTM has declared a Standard Test Method For Water
Penetration Of Exterior Windows, Curtain Walls, And Doors By Uniform
Static Air Pressure Difference which includes a water spraying apparatus
within the test chamber. See, ASTM designation E331-96. Leakage rate
testing can be done under the ASTM Standard Test Method For Determining
The Rate Of Air Leakage Through Exterior Windows, Curtain Walls And
Doors Under Specified Pressure Differences Across The Specimen. See,
ASTM designation E283-91.
When a building envelope is breached devastating pressure differentials
cause large amounts of damage. Kinetic energy due to the velocity of the
fluid is proportional to the square of the velocity. Energy from the wind,
therefore, pressurizes the interior of a home or other structure which in
combination with the profile of the roof makes the roof, in effect, act like
an
airplane wing causing it to blow off the remaining structure. Windload and
impact resistance requirements depend on the particular community
promulgating the requirements.
The American Society of Civil Engineers' Standard 7 is being
increasingly used by public regulators in formulating requirements. In some
areas of high probability for high wind occurrences, such as hurricanes,
existing homes are required to upgrade windows and doors or add shutters and
other protective devices to building openings to protect them.
Conventional storm window protection as shown in U.S. Patent No.
4,065,900 to Eggert, U.S. Patent No. 4,069,641 to De Zutter and U.S. Patent
No. 4,478,268 to Palmer are methods of attaching outer coverings to window
or door openings. U.S. Patent No. 4,065,900 to Eggert discloses an apparatus
for framing and fastening a secondary glazing pane which utilizes a hinge.
U.S. Patent No. 4,069,641 to De Zutter discloses a storm window frame which
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
3
utilizes double-faced tape to mount the storm window frame and, hence, the
storm window. U.S. Patent No. 4,478,268 to Palmer discloses a hard flexible
curtain door, a tensioned storage or wind-up drum, and channels in which the
door resides. The door moves out of the channels under impact and is wound
up to open for vehicle passage.
U.S. Patent No. 4,126,174 to Moriarty, et al. discloses a tensioned
flexible sheet storage roller, a guide roller and side seal guides. These
coverings are normally clear flexible materials that must be installed and
removed as needed or can be rolled and stored in a storage area above the
window. These materials can be tinted to provide a reduction in sunlight
transmission, but tinting would also reduce vision at night. These storm
window coverings offer good thermal insulation, but offer minimal protection
from high wind velocity pressures and wind borne debris. Further, these
coverings are usually made of flexible polyvinyl chloride and will
functionally
deteriorate with time and must be replaced. The coverings that are of rolling
constr~.iction must have adequate clearance between the guide rails and the
sheet to prevent jamming of the sheet in the guide rails during opening and
closing.
U.S. Patent No. 4,294,302 to Ricke, Sr. discloses a security shutter and
avnling device for covering windows and doors. The device includes slats
made from aluminum or other exti-udable material of sufficient strength to
protect against storms and/or vandalism. The shutter of Ricl~e, Sr. may be
slidably mounted and pivoted so as to act as an awning.
U.S. Patent No. 4,601,320 to Taylor discloses a pressure differential
compensating flexible curtain with side edge sections which are sealingly
engaged with channels. The first upper end of the curtain is attached to a
curtain winding mechanism which includes a spring barrel. Taylor discloses
an elastomeric curtain having plastic supports with rubber covers banded
thereto. Alternatively the plastic supports may be high molecular weight
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
4
plastic strips. The purpose behind the design of the supports is to minimize
the friction of these supports enabling operation of the door/curtain with a
high differential pressure across it.
U.5. Patent No. 4,723,588 to Ruppel discloses a roller shutter slat
which interlocl~s with the adjacent roller sheet slat. U.5. Patent No.
5,657,805
to Magro discloses a wind-resistant overhead closure with windlocl~s on the
lateral edge portions of the intermediate and bottommost slats of the closure.
First means to limit the lateral movement of the lateral edge of the
intermediate potions and second means to limit the lateral movement of the
endmost door portion are disclosed. Intermediate slats and endmost slats are
provided. The '805 patent indicates in col. 2, lines 12 et seq. that it
conforms
with the South Florida Building Code, 1994 Edition, previously referred to
hereinabove. Further, the '805 patent states that its teachings are applicable
to
both doors and windows.
Windlocl~s can be added at the end of slats which will improve the
resistance of multileaf shutters or doors to wind velocity pressures by
transmitting the stresses on the continuous hinge area to the ends of the
slat, to
the guide system and finally to the jambs or building structure. In order for
the windlocl~s to engage the guide tracl~ the slat must deflect a considerable
amount. Normally clearance is allowed between the guide tracl~ and the
windlock to beep the door from jamming during operation and the more
clearance allowed the more deflection of the slats before the windlocks
contact the guide traclc. Typically, these windlocl~s are larger in cross
section
than the slat profile and when the shutter or door deflects from high wind
velocity pressures, the windlocl~s are designed to engage the same space in
which the slats are guided. When storing a rolling multileaf shutter or door
equipped with windloclcs, additional room is needed because the depth of the
windlocl~ is larger than the slat profile, the diameter of the storage area
increases dramatically. In these designs, clearance between the windlocl~ and
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
S
the traclc must be allowed to prevent the windlocl~s from jamming and care
must be tal~en when operating shutters or doors in a wind because the
windlocl~s will sometimes jam as the product deflects.
U.S. Patent No. 5,445,902 to Lichy discloses a damage minimizing
closure door somewhat similar to U.S. Patent No.4,478,268 to Palmer. The
Lichy '209 patent discloses a flexible curtain and a guide for receiving and
guiding the side edges of the flexible door during vertical movement. A
counterbalancing power spring is associated with the door to assist in raising
and lowering the curtain. Side edges of the curtain separate from the guide
assembly upon being impacted by an externally applied force such as a
vehicle.
U.S. Patent No. 5,482,104 to Lichy discloses in Fig. 17 thereof, a
flexible curtain and double windlocl~s which breal~away from the channel
upon the application of excessive force to the curtain. See, col. 7, lines 33
et
seq. U.S. Patent No. 5,131,450 to Lichy discloses in Fig. 6 thereof a double
edged guide and a curtain edge with two loose portions sewn to the transverse
curtain. See, col. 6, lines 21, et seq. U.S. Patent No. 5,232,408 to Brown
discloses a flexible tape drive system wherein the tape is relatively rigid
and it
is driven by a toothed cog to provide both push and pull capabilities. U.S.
Patent No. 5,048,739 to Unoma, et al. illustrates a conical toothed drive
paper
feeder .
Conventional storm curtains without windlocl~s to engage into guides
will pull out of the guides. This is especially true of wider curtains where
they
might be partially lowered for shading purposes without attaching storm bars
required for storm protection. If, while lowering, or subsequent to lowering,
wind forces exist that are significant but in no way threatening, the storm
curtains typically escape from the guides due to excessive deflection of the
slats. When this occurs, the slats become damaged as well as the facade
surrounding the guide area becomes damaged as the ends of the slats typically
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
6
rape the surrounding area in the process of escaping. The majority of
applications for conventional storm curtains do not use windlocl~s. Rather
than using windloclcs, the problem of excessive curtain deflection which
causes the curtain to escape from the guides is addressed with the use of
storm
bars. Storm bars, however, have disadvantages.
Storm bars create a passive system i.e. in the event of a severe storm
they need to be taken out of storage and attached in predetermined locations
across the span of the curtain. A wide curtain may require as many as three
sets of storm bars. Sets consist of two bars in close proximity to each other
in
such a way as the curtain passes between the two bars. This addresses
deflection that occurs in both positive and negative directions. Positive
deflection is in the direction of the building and negative deflection is away
from the building. At each storm bar location, brackets must first be attached
to the floor, ~soffit and sills. Depending on the surrounding construction
materials, secure locations are often difficult to find. After the brackets
are
attached to the building, the next step is to attach the storm bars to the
brackets. Care must be taken to number and code the brackets to the matching
storm bar, otherwise the pre-drilled holes for the bolts will not line up with
the
holes in the storm bars. Also, care must be taken to match and code the storm
bars to their various locations since even a slight variation in the bar
length
causes the holes in the storm bar to misalign with the pre-drilled holes in
the
building facade. Also, these pre-drilled holes in the facade are permanent and
cause problems aesthetically when the storm bar brackets are removed. Given
the problems associated with escaping storm curtains, the building owner
faces a dilemma when moderate storms are predicted such as severe
summertime thunder storms. The daunting task of attaching the storm bars
cannot be justified for every storm. Because the risk of damaging the storm
curtains without attaching the stone bars is so great, the curtains are not
utilized in moderate storms. Therefore, the building owner has a protection
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
7
system that is either "on or off," "on" meaning storm bars and curtains and
"off ' meaning nothing at all.
Conventional storm curtains do not have windlocks to prevent the slats
from escaping the guides because windlocks have a larger cross section than
that of the slat and using windlocks increases storage coil diameter which is
a
major limiting factor. With windlocks of the related art, storm curtains have
a
tendency to bind in the guides/tracks when being lowered because of the
deflection of the curtain in moderate wind conditions. Enough friction is
created, windlock to the inside edge of the guide, to cause the curtain to
I O become obstructed and create unwanted accumulation of slats in the coil
storage area. Additionally, adding windlocks to the ends of slats is very
labor
intensive and creates many more parts to drill and attach.
The instant invention addresses these three issues. The first issue with
conventional storm curtains, that being an increase in coil storage
requirement,
is addressed by utilizing an interrupt formed on the ends of the tension rods
of
the instant invention which does not increase the requirement for coil storage
when the curtain is stored.
The second issue regarding binding of the curtain is addressed by the
instant invention since the tracks are mounted at a divergent angle with
respect
to each other and contact with the interrupts in the rod and the "J-shaped"
channel does not occur until the guide is in a fully closed position
minimizing
friction. Further, in the instant invention, unwanted accumulation in the coil
storage area does not occur and the drive system is able to generate downward
closing forces that overcome minimal friction that may occur between the
interrupt and the "J-shaped" channel.
Finally, regarding the issue of windlocks being labor intensive, the
interrupts formed near the ends of the rods in the instant invention are made
with a single stroke of a press after the rods are inserted into the curtain
and,
as such, do not make the windloclc system labor intensive.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
g
Summary of the Invention
The instant invention uses light weight materials that have stiffiiess in
the direction of the opening and closing but will bend around a radius as
small
as 0.5 inches. This strengthens the curtain by uniformly spreading the
stresses
developed by wind velocity pressure or impact over the width of the curtain
and transfernng the stresses to the track and to the structure of the
building.
The invention adds tension to the elements of the curtain in the
direction along its width or perpendicular to the force that is created by
wind
velocity pressure or impact from debris. The tension is directly proportional
to the wind velocity pressure or impact from debris. Angled guide tracks may
be used that tension the curtain when the curtain is closed without jamming
the curtain in the guide traclcs. Metallic, non-metallic materials (or a
combination of both) may be used and they may be and can be opaque or
transparent.
The windloclc feature of the instant invention is incorporated into the
curtain without affecting the thickness of the curtain and therefore does not
affect the size of the storage area. The mass of the curtain is~low allowing
precise control of raising and lowering the curtain with a small power source
and can be battery powered. Materials such as aramid fibers may be used thus
malting the curtain bullet proof.
An apparatus and method for windlocking a curtain covering
and protecting an opening in a building is disclosed and claimed. The
windlocking curtain resides to the exterior of the window, door or other
opening and protects it from the intrusion of air, water or debris. In its
upper
position the windlocking curtain permits normal use of the opening and in its
lower position it secures the opening. A flexible corrugated curtain has
tension rods therethrough and the tension rods run in tracks on each side of
the
curtain and necessarily on each side of the opening. Interengagement of the
tension rods with the tracks is accomplished by deformations in the rods that
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
9
are referred to as interrupts. In one embodiment the rods are successively
longer from top to bottom of the curtain and their interrupts matingly wedge
with angled tracks to secure the curtain. In another embodiment the interrupts
matingly engage parallel traclts upon the application of force due to wind,
fluid (usually water or sea water) or debris. In another embodiment tension
rods and interrupts are not used or necessary and a flap on the edges of a
three-ply flexible curtain engage the interior of the side tracks absorbing
shocl~ing and sealing the opening. A method for securing the opening
utilizing the apparatus is also claimed which provides top, bottom and side
securement.
The flexible curtain comprises part of a curtain system for covering an
opening in a building. A frame is affixed to an opening in a building. A
flexible, con-ugated curtain has a plurality of rods extending through some of
the corrugations of the curtain. Preferably the rods, sometimes referred to as
the tension rods, are rectangular in cross-section so as to provide maximum
strength of the rod. Other cross-sectional sizes may be used. Angled tracks
are provided in one embodiment which mate and wedge with angled interrupts
when the curtain is in its second, closed position. When the curtain is open,
it
is in its first position and resides primarily on a counterbalanced windup
reel.
Each successive tension rod is longer than the prior rod so as to engagingly
wedge with the angled traclts. The tracks are angled away from each other
when the top point of the tracks are taken as the reference points. In other
words, the tracks are at a divergent angle and get farther apart at the
bottom.
The tension rods include a deformed portion sometimes referred to as
an interrupt. The purpose of the interrupt is to matingly engage the tracks.
In
the embodiment which employs tracks which diverge from the top to bottom,
the preferred divergent angle is one-half of one degree. Specifically, each
track is diverging with respect to an imaginary vertical line at an angle of
one-
half degree malting the total divergence for two tracks equal to one degree.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
One-half to one degree divergence from vertical per track (one to two degree
divergence for both tracks) has been found to work well. Larger divergence
angles require necessarily deeper tracks and larger interrupts particularly if
a
long building opening is to be protected. Those skilled in the art will
readily
5 realize from reading this disclosure that other angles may be used depending
on the size of the opening to be covered.
Corrugated flexible curtain is used in one embodiment as stated above
and slits therein may be employed in the face of the curtain to improve the
flexibility for storing on the counterbalanced wind-up reel. In regard to
10 storage of the curtain and tensioning rods, the deformations of the
tensioning
rods (interrupts) do not increase the space required for storage because the
thickness of the tension rod is not increased in the direction of the radii of
the
wind-up reel.
Operation of the flexible curtain is enhanced by using divergently
separating track as the occurrence of jamming is minimized. AlI of the
tension rods are designed to engage the angled tracks at approximately the
same time creating a wedge effect since the interrupts are defoi-~ned at a
mating angle which matches the angle of the track.
Another embodiment of the invention employs parallel tracks and the
tension rods do not engage the tracks except during times when they are
loaded. In this embodiment the tension rods are all the same length and when
the curtain is closed in its second position the lips of the interrupt do not
engage the track. When the wind velocity becomes sufficiently high, the
curtain deflects and pulls the mating surfaces of the interrupts into
engagement with the traclc.
Another embodiment of the invention employs tension rods having a
ninety degree radius at the ends thereof and eliminates the need for
interrupts.
It is the ninety degree radius which engages the angled/parallel tracks.
Rectangular apertures exist in the flexible corrugated curtain for
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
11
engagement with teeth of a driving gear or gears. The gears, under resistance
of a counterbalance spring affixed to the wind-up rod, drive the curtain from
a
first, open position to a second, closed position. All embodiments disclose
rectangular curtains. Standard window dimensions are 30 to 36 inches wide
and 30, 38 or 54 inches long. However, longer and wider openings can be
secured with the embodiments of the invention disclosed herein.
Corrugated curtains can be driven with a single gear or with dual gears.
Openings in buildings of all sizes may be protected using the principles of
the
invention.
Alternatively, a driven adapter rack and/or an adapter rack and a gear
may be simultaneously used to drive the tension rods.
Another embodiment employs a flexible curtain comprising three-plies
laminated together. The plies may be laminated together under the influence
of heat and pressure. Additionally adhesive may be used to secure the plies
together. Two outer plies or sheets are polymeric and the inner ply is woven.
A living seal is formed on the edges of the curtain by folding the edges of
the
curtain bacle on the curtain itself. The folded portion is secured by
stitching
with thread, or by adhesive, or by heat fusing, or by ultrasonic welding. Only
a portion of the folded flap is secured. Preferably two-thirds (2/3) of the
folded flap is secured to itself and one-third (1/3) remains free. When the
three-ply curtain is tensioned under the influence of wind or debris loading,
for instance, the folded portion engages the interior of the track which
houses
the folded portion preventing its escape therefrom. Further, the folded flap
provides a total seal which is sometimes referred to herein as a living seal.
The free portion of the flap provides a shock absorber which cushions the
frame against time variant forces which may be applied due to fluctuating
wind and/or debris. The three ply curtain may also be used with angled track
by slitting the outer face of the three ply curtain. The slitting provides a
loose
flap which engages the traclc.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
12
Cylindrical apertures reside in the folded portion of said three-ply
curtain and the drive cog interengages the apertures for raising and lowering
the curtain against the force of the counterbalance spring. Preferably, there
is
a folded portion on each side of the curtain residing in its respective track
and
being driven by its respective drive cog. Conically shaped cogs fit the
apeutures well and, additionally, the apertures may be fitted with eyelets. A
bowed bottom bar is secured within a folded portion of the curtain and guides
the curtain into a slot. In other words, the curtain is slightly longer at its
edges
than in the middle such that as the curtain is coming down for securement in
the second, closed position the sides enter the retaining slot first. If the
curtain
is being closed during a strong wind event, the middle of the curtain may be
deflected slightly inwardly but the side portions axe not because they are
within the tracks which are directly aligned with (above) the retaining slot.
This enables the bottom bar to begin seating in the retaining slot at the side
edges and guide the bottom bar into place. Additionally, the weight of the bar
assists in positioning it in place in the retaining slot. Additionally, a
living
seal formed by a flap extending from the stitched or heat sealed bottom bar
may be employed in a modified retaining slot sometimes referred to herein as
a storage slot.
Another embodiment of the bottom bar interengages a sill or bottom
member having a seal therein. The bottom bar may be affixed to the bottom
of the curtain by any one of several l~nown fastening devices such as rivets,
bolts and threads, and the like. The curtain system covers a window, door or
other opening a building. The curtain system may reside to the exterior of the
window, door or other opening or it may reside to the interior of the window,
door or other opening.
Accordingly, it is an object of the present invention to provide a low
cost and light weight flexible curtain which develops transverse (side to side
when viewed from the front) tension each time the curtain closes.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
13
It is a further object of the present invention to provide a curtain system
which uses a light weight counterbalance because of the lightweight
construction of the curtain.
It is a further object to provide a curtain having windload and impact
resistance which is always active when the curtain is closed and requires no
other action by the user in the event of a high velocity wind occurrence.
It is a further obj ect to provide a curtain which will not j am and cause
. damage to the curtain during operation even if operated during high wind
occurrences.
It is further object to provide a storm curtain which stores within
standard wall thicl~ness found in the United States. It can be incorporated
into
the window frame in such a way that the storm curtain does not require
additional frameworl~ or cover for protuberances created by the larger storage
coil diameters typical of conventional storm curtains.
It is a further object of the present invention to provide a curtain system
which resides to the exterior or the interior of the window, door or other
opening in a building.
It is a further obj ect to provide a low maintenance storm curtain.
Conventional storm curtains require periodic high pressure washing especially
along coastal areas where they are exposed to salt spray and blowing sand.
Conventional storm curtains are designed so that the longitudinal edges of the
slats telescope into each other approximately three-eighths inch (3/~") to one-
half inch (%2") as shown in U.S. Patent No. 4,173,247 to Prana and U.S. Patent
No. 5,322,10 to Hoffman. The telescoping portion of the slat is exposed
when the storm curtain is partially closed, typically for sun control, and
because of the weight of the slat suspended below, the slats will be extended
from each other. When salt spray and sand accumulate on this portion of the
surface of the slat, abrasion and friction will interfere with slat to slat
telescoping. If the slats are not cleaned and pressure washed periodically,
the
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
14
lower slats usually start to malfunction first since they have the least
gravitational force to cause separation. If this separation or telescoping
does
not occur and the slats enter the coil storage area they will be put into a
severe
bind and as a consequence, become damaged. Telescoping slats develop more
beam strength when the longitudinal edges of the slats are telescoped into
each
other when fully closed. However, the maximum allowable radius
requirement for the curtain to coil within the allocated storage area cannot
be
met unless the slat edges are fully extended from each other as they begin to
articulate into the coil storage position. In the instant invention, the
outside
surface consists of a smooth polymeric material with no requirement to
telescope. As such, there is no opportunity for salt spray and sand to
accumulate in irregular surfaces. It is a further object of this invention to
provide a smaller storage area.
Another advantage of the instant invention, unlike conventional storm
curtains, is that the instant invention becomes taut from top to bottom when
in
a closed position. For this reason there is no chatter, banging or rattling
that
exists with conventional storm curtains in buffeting winds. Further, when the
embodiment of the living seal is employed, the loose or free portion of the
folded flap or strip absorbs shock and therefore does not transmit it to the
surrounding frame. This will make a quieter system with low or no
maintenance.
Still another advantage of the instant invention is that the storm curtain
is directly linked to drive gears and a drive shaft which are engaged into
perforations pierced into the curtain and essentially (but not actually) place
the
gear teeth in contact with the metal tension rods lodged in the corrugated
curtain which, when activated, cause the curtain to be raised and lowered. The
tension rods are completely sealed with respect to contamination by the
corrugated material. In the embodiment of the three ply curtain, it completely
seals against the intrusion of wind borne salt and debris.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
Another advantage of the instant invention is that the storm curtain can
be pre-installed into the window frame at the factory as a single unit. The
sub-contractor nonnally involved in the installation of storm curtains is no
longer required. Another problem frequently encountered and avoided with
5 the instant invention is related to the typically varied conditions
prevalent on
job sites. With a wide range of window conf gurations depending on the
manufacturer and varied contractor preferred framing methods and sill details,
these variations often complicate the installation of stone curtains. This can
greatly increase the cost of installation where additional re-framing may be
10 required or where other modifications need to be made so the storm curtain
can be installed correctly. In the instant invention, the storm curtain is pre-
installed into the window frameworl~ and these problems do not exist.
Another advantage of the instant invention is that since the interrupts
pressed (deformed) into the metal rods embedded in the curtain are engaged
15 into the "J-shaped" track, the curtain cannot escape or "blow out".
Brief Description of the Drawings
Fig. 1 is a front plan view of a seventy-two inch flexible curtain having
a track at one degree (1 °) from vertical.
Fig. 2 is an exploded view of a portion of Fig. 1.
Fig. 3 is an exploded view of a portion of Fig. 2.
Fig. 4 is a composite view illustrating a reduced scale view of Fig, 1
together with reduced scale views of Figs. 4A and 4B.
Fig. 4A is a cross-sectional view of the flexible curtain illustrated in
Fig. 1 taken along the lines 4A-4A.
Fig. 4B is a cross-sectional view of the flexible curtain and window
illustrated in Fig. 1 taken along the lines 4B-4B.
Fig. 4C is an enlarged cross-sectional view of Fig. 4A illustrating the
application of the invention to protect a window opening.
Fig. 4D is a cross-sectional view similar to that of Fig. 4A illustrating
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
16
the wind-up reel in greater detail for use in connection with the three-ply
flexible curtain and the cog drive.
Fig. 5 is a schematic view of the seventy-two (72") inch curtain
illustrating a one degree (1 °) i-unout of the tracks and tension rods.
Fig. 6 is a front view of a seventy-two inch (72") curtain similar to that
illustrated in Fig. 1 except that the left side and right side tracks are
parallel to
each other and, additionally, illustrates that the tension rods do not have
any
runout.
Fig. 7 is an enlarged portion of Fig. 6.
Fig. 8 is a schematic representation of the flexible curtain, track and
tension rods of the embodiment of Fig. 6.
Fig. 9 is a front view of a thirty-eight inch (3 8 ") curtain illustrating a
one-half degree (1/Z°) runout of the tension rods.
Fig. 9A is a view similar to that of Fig. 1 illustrating a one-half degree
(1/2°) runout of the tracks, interrupts and tension rods.
Fig. 9B is an enlarged portion of Fig. 9 illustrating the tension rods,
flexible curtain and the drive apertures in the curtain.
Fig. 9C is a perspective view of a portion of the curtain having a one-
half degree runout further illustrating the corrugated flexible curtain and
the
interrupts mating with the track restraining movement of the flexible curtain
toward the window.
Fig. 10 is a schematic of the thirty-eight inch (38") curtain illustrating a
one-half degree (1/2°) runout of the track, interrupts, and tension
rods.
Fig. 11 is a top view of a left side track like that of Fig. 1 illustrating
the top rod in its fully down position engaging the traclc. Fig. 11
illustrates a
cross-sectional view of the top of the track which has a one degree (I
°)
runout. The runout, however, is not illustrated in this drawing.
Fig. I 1A is a front view of the left side track and the top rod illustrated
in Fig. 11.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
17
Fig. 11B is a top view of a left side track life that of Fig. 9A illustrating
the top rod in its fully down position engaging the track. Fig. 9A illustrates
a
cross-sectional view of the top of the traclc which has a one-half degree
(1/2°)
runout. The runout, however, is not illustrated in this drawing.
Fig. 11C is a front view of the left side track and the top rod illustrated
in Fig. 11B.
Fig. 12 is a top view of a left side track like that of Fig. 1 illustrating
the bottom rod in its fully up position entering the track. Fig. 12
illustrates a
cross-sectional view of the top of the track which has a one degree (1
°)
runout. The runout, however, is not illustrated in this drawing.
Fig. 12A is a front view of the left side track and the top rod illustrated
in Fig: 12.
Fig. 12B is a top view of a left side track like that of Fig. 9A illustrating
the bottom rod in its fully up position entering the track. Fig. 12B
illustrates a
cross-sectional view of the top of the track which has a one-half degree
(1/2°)
runout. The runout, however, is not illustrated in this drawing.
Fig. 12C is a front view of the left side track and the top rod illustrated
in Fig. 12B.
Fig. 13 is a cross-sectional view of the bottom bar sealingly engaging
the bottom sill which is affixed to the frame of the structure.
Fig. 13A is a cross-sectional view of a three-ply flexible curtain affixed
to a bottom bar.
Fig. 13B is a cross-sectional view of a three-ply curtain with a bottom
bar secured therein by adhesive or lamination.
Fig. 13C is the same as Fig. 13B except stitching is used to secure the
bottom bar.
Fig. 13D is a front view of the vertically bowed bottom bar alone.
Fig. 14 is a perspective view of a tension rod.
Fig. 15 is an enlarged portion of the tension rod illustrated in Fig. 14.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
18
Fig. 16 is another enlarged view of a portion of a tension rod.
Fig. 17 is a view of the end portion of a tension rod illustrating a
circular in cross-section tension rod.
Fig. 18 is a plan view of a tension rod.
Fig. 19 is a side view of a tension rod illustrating the interrupts therein.
Fig. 20 is a perspective view of the track.
Fig. 21 illustrates a plan view of one of the tracks.
Fig. 22 is a cross-sectional view of a three-ply curtain and track taken
along the lines 22-22 of Fig. 28.
Fig. 22A is a cross-sectional view similar to the view of Fig. 22 further
illustrating eyelets in the apertures.
Fig. 22B is a cross-sectional view identical to Fig. 22 except the cross
hatching of the polymeric plies is not illustrated so as to better depict the
curtain.
Fig. 22C is a cross-sectional view identical to Fig. 22A except the cross
hatching of the polymeric plies is not illustrated so as to better depict the
curtain.
Fig. 23 is a cross-sectional view of a three-ply curtain and track with
the curtain taken along the lines 23-23 of Fig. 7.
Fig. 23A is a cross-sectional view similar to the view of Fig. 23 except
the cross hatching of the polymeric plies is not illustrated so as to better
depict
the curtain.
Fig. 23B is similar to the view shown in Fig. 23 except the curtain is
shown under the influence of pressure "P."
Fig. 23C is similar to the view shown in Fig. 23A except the curtain is
shown under the influence of pressure "P."
Fig. 24 is a cross-sectional view of a three-ply curtain together with a
semi-rigid strip affixed to one edge thereof.
Fig. 25 is a cross-sectional view of a three-ply curtain similar to the
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
19
view of Fig. 23 with the curtain under the influence of a force, for example,
a
high velocity wind.
Fig. 26 is a cross-sectional view of a three-ply curtain having a folded
edge and illustrating two polymer sheets and a woven sheet secured together
with adhesive.
Fig. 26A is a cross-sectional view of a three-ply curtain having a semi-
rigid strip affixed to one edge thereof by means of adhesive.
Fig. 26B is a cross-sectional view of an embodiment employing two
plies of polymeric material secured together with a fiber reinforcement. One
ply of the polymeric material has been slit to engage the track when the
curtain is under tension.
Fig. 27 is a rear view of the three-ply flexible curtain illustrating a
semi-rigid strip applied to both edges of the curtain.
Fig. 28 is a front view of a three-ply curtain being driven by a gear
having conical teeth or cogs.
Fig. 28A is a cross-sectional view taken along the lines 28A-28A of
Fig. 28 illustrating the drive roller.
Fig. 28B is a cross-sectional view taken along the lines 28B-28B of
Fig. 28 illustrating counterbalanced springs which tension the curtain between
the drive cogs and the storage reel. Further, securement of the springs to a
fixed structure is shown in this view but is not shown in Fig. 28.
Fig. 28C is a view similar to Fig. 28 further illustrating a bowed bottom
bar.
Fig. 28D is a perspective view illustrating the bottom bar being guided
by the tracks into the storage slot.
Fig. 28E is a front view of a flexible curtain and window in a building
illustrating the curtain in its first, open position.
Fig. 28F is a front view of a flexible curtain and window in a building
illustrating the curtain in its second, closed position.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
Fig. 29 is a side view of Fig. 28.
Fig. 30 is a perspective view of the chain (drive adapter rack) and gear
drive.
Fig. 31 is a perspective view of an adapter rack illustrating tensioning
5 rods having a ninety degree.(90°) bend at the edges thereof.
Fig. 32 is a perspective view of an adapter drive.
Fig. 33 is a perspective view of the gear drive.
Fig. 34 is another embodiment of the invention illustrating pressure
from the wind applied to the glass window which resides exteriorly to the
10 flexible curtain.
A better understanding of the drawings will be had when taken together
with the description of the invention and the claims which follow hereinbelow.
Description of the Invention
The first embodiment is the combination of a curtain composed of
15 con-ugated nonmetallic material with metallic rods embedded in the
coxTUgations. Inward from the ends of the metallic rods, also known as the
tension rods, interrupts are formed which maintain the cross-sectional area of
the rod. This provides for uniform tensile strength of the rod. The rod
lengths
uniformly increase from rod to rod from the top of the curtain toward the
20 bottom of the curtain. The ends of the rods form an angle with respect to
the
con-ugated nonmetallic material of the curtain. The interrupts in the rods
have
a matching or corresponding angle to the angle of the tracks. This angle
allows the curtain assembly to wedge when the curtain is closed. The tracks
have a "J-shaped" portion with one leg angled back from the mouth of the "J"
to form a mating interrupt with the interrupt on the rod such that as tension
is
developed in the rod due to wind velocity pressure or windbome debris, the
"J" will close on the rod with a clamping action transferring the stress Ioad
to
the tracks and then to the opening frame and onto the building structure. The
curtain is additionally supported by a counterbalance drive tube that will
assist
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
21
in returning the curtain to a rolled up stored position.
The nonmetallic portion of the curtain can also be made from sheets of
material laminated together capturing and positioning the metallic rod. These
sheets can be fused, glued, stitched, or attached by other fastening means to
prevent the rotation of the rod in relationship to the curtain. The metallic
rods
preferred in this curtain can be round or polygonal in shape. The more
polygonal, the more retention needed to hold the rod in position. Conversely,
the less polygonal or the fewer number of sides in the polygon, then less
retention is required.
A version of this embodiment can be used on conventional rolling door
systems where the slats are cut in uniformly, progressively longer lengths
from the top of the door to the bottom of the door with standard windlocks
alternately attached to the slat ends and the guide track deepened to the
longest slat and set at a matching angle where the slats are uniformly placed
in
tension when the door is closed.
The second embodiment ("parallel" embodiment) is a combination of a
curtain composed of corrugated nonmetallic material with metallic rods
embedded in the corrugations. Inward from the ends of the metallic rods,
interrupts are formed in the tension rods which maintain the cross-sectional
area for uniform tensile strength of the rod. Rod length is uniform from rod
to
rod, from the top of the curtain toward the bottom of the curtain, so that the
ends of the rods are aligned parallel to the corrugated nonmetallic material
of
the curtain. A guide track system is employed that has vertical guide tracks
that are parallel to the edge of the curtain. The guide tracks have a "J-
shaped"
end portion with one leg angled back from the mouth of the "J" to form a
mating interuupt with the tension rods such that as tension is developed in
the
rod, the "J" will close on the rod with a clamping action. The curtain is
supported by a counterbalanced drive tube that will assist in returning the
curtain to a rolled up position. Further, the curtain is taut between the
drive
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
22
tube and the wind-up reel. The profile of the corrugated noiunetallic material
is such that the front and back faces are in continuous contact allowing the
curtain to be driven down without jamming or binding. The stored portion of
the curtain has a tensioning device (i.e., a counterbalanced spring) to
prevent
the curtain from resisting movement as the diameter of the stored curtain
reduces.
A third embodiment employs a flexible curtain comprising three plies
laminated together. These plies can be fused, glued, stitched or attached by
other fastening methods. Two outer plies or sheets are polymeric. The inner
ply is woven. A living seal is formed on the edges of the curtain by folding
the edges of the curtain back on the curtain itself. The folded portion is
secured by stitching with thread, by adhesive, or by heat fusing or by
ultrasonic welding. Only a portion of the folded flap is secured, preferably
two-thirds (2/3) of the folded flap is secured to itself and one-third (1/3)
remains free. Under tension, this free portion of the folded flap seals and
cushions the shock caused by the wind or airborne debris. Under the tension
the free portion of the flap engages the guide track. The three ply flexible
curtain is driven by a cog wheel having conically shaped cogs which drive
apertures located along the edges of the flexible curtain of this embodiment.
Another version of this invention is a curtain employing a flat sheet of
flexible material. It has grooves cut into one face that serve as an interrupt
to
a mating edge of the "J-shaped" track or of a track having another shape.
Inward from the edges of the sheet, grooves at the same angle as track are cut
into the curtain such that the grooves at the top of the curtain are closer
together than they are at the bottom of the curtain. The guide tracks are then
placed at the same angle to place the curtain in tension when the curtain is
in
the closed position. The grooves create a loose flap which engages the track
when the curtain is all the way down in its second position.
Fig. 1 is a front plan view of a 72" flexible curtain having tracks which
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
23
are 1 ° from vertical. The entire curtain is not depicted in Fig. 1
because
resolution would decrease. Put another way, the traclcs are at a 1 °
angle from
the edges of the corrugated curtain. Reference numeral 100 indicates
generally the 72" flexible curtain. The curtain may be driven by motor 101 or
by a pulley 102 as determined by a coupling 103 which may engage either the
motor or the pulley as a source of energy for raising and lowering curtain
115.
Curtain 11 S is a rectangular con-ugated nonmetallic curtain. Apertures 116
reside in the left-hand portion of the corrugated curtain and apertures 117
reside in the right-side portion of the corrugated curtain 11 S.
Left-side tracl~ 111 is affixed to the frame or building structure as is
right-side track 112. Reference numeral 113 is spaced leftwardly of track 111
and reference numeral 113 denotes the bottom portion of the left-side traclc
111. Reference numeral 114 illustrates the bottom portion of the right-side
track 112 and it too indicates a runout rightwardly with respect to the right
side track 112.
It will be noticed that Fig. 1 depicts the first several tension rods and
interrupts and the last several tension rods and interrupts. Interrupt 121 is
near
the top of the curtain. Interrupts 122 and 127 are near the bottom left side
of
the curtain. Tension rods 123 and 124 are shown entering the left side of the
curtain traversing through the curtain in corrugated sections thereof and
extending rightwardly through the curtain. It will be observed that tension
rod
123 has a left side interrupt 122 and a right side interrupt 125. A plurality
of
slits 126 are indicated in Fig. 1 to enhance the flexibility of the curtain.
Gears
119 and 120 are viewed in Fig. 1 for driving apertures 116 and 117 in the
flexible curtain 115. A front view of bottom bar 118 which engages a
sill/receptacle not shown in Fig. 1 is illustrated therein.
Referring still to Fig. 1, shaft 104 is supported by bearings 105 and
106. Curtain 115 extends onto windup reel 107 which is a counterbalanced
windup reel. Supports 108 and 109 support the windup reel 107. Platform
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
24
110 which is interconnected to the opening in the building supports the
structure generally.
Fig. 2 is an exploded view of a portion of Fig. 1. Referring to Fig. 2,
reference numeral 200 generally represents the enlarged portion of Fig. 1.
Track 111 is shown in a cross-sectional view. The outer edge 201 and the
intermediate support 202 of track 111 are shown. Mating surface 203 of the
"J-shaped" portion 204 of track 111 are also shown. Mating surface 203 on
the "J-shaped" portion 204 of track 111 are shown in better detail in Fig. 3:
Fig. 3 is an exploded view of a portion of Fig. 2.
First interrupt 205 is illustrated in Figs. 2 and'3 and mating point 206 is
also illustrated in both figures. Referring to Fig. 3, inter~.-upt 205
includes a
surface which engages the mating surface 203 of track 111. It must be kept in
mind that track 111 is angling downwardly and leftward when viewing Figs. 2
and 3 such that the track and the interrupts are angled at a 1 ° angle
with
respect to the left side portion of the left side 220 of the curtain 115. The
second interrupt 207 is illustrated with mating surface 208 which engages
mating surface 203 on the "J-shaped" portion 204 of track 111. Similarly
mating surface 209 of interrupt 210 engages mating surface 203 of track 111.
Reference numeral 211 indicates the end of interrupt 205. Referring to Fig. 3,
reference numeral 212 indicates the beginning of the interrupt of the first
tension rod near curtain 115. Similarly the runout of the rods and inten-upts
can be viewed when reference is made to reference numeral 213 which is the
beginning of the interrupt of the third tension rod of the curtain. Reference
numeral 213 "points" to a place further leftwardly. The 1 ° runout of
the track,
interrupts and the ends of the rods are illustrated in Fig. 5.
Fig. 4 is a composite view illustrating a reduced scale view of Fig. 1
together with reduced scale views of Figures 4A and 4B. Fig. 4A is a cross-
sectional view of the flexible curtain illustrated in Fig. 1 taken along the
lines
4A-4A. Fig. 4B is a cross-sectional view of the flexible curtain illustrated
in
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
Fig. 1 tal~en along the lines 4B-4B. Support frame 407 is interconnected to
the
frame of the building opening. Fig. 4 illustrates the environment of the
invention. Fig. 4A illustrates window 401 along with interior wall 402 and an
exterior sheathing 403 such as plywood. A space 404 between the window
5 401 and curtain 115 is illustrated. Fig. 4C is a full cross-sectional view
of Fig.
4A illustrating the application of the invention to protect a window opening.
Referring to Fig. 4C, reference numeral 405 represents a full sized 38"
window tal~en along the lines 4A-4A without tracl~ 112 shown. Reference
numeral 406 generally indicates wood framing. Still referring to Fig. 4C,
10 windup reel 107 is indicated and the curtain is shown in both a minimum
position indicated by reference numeral 408 (i.e., the curtain in its down,
second position) and a maximum position as represented by reference numeral
409 (i.e., the curtain in its up, first position). Reference numeral 404
indicates the space between the curtain 115 and the window to be protected
15 401. The curtain may be a flexible three ply curtain or it may be
corrugated.
Some regulatory authorities have promulgated a standard such that the curtain
may not deflect within 1" of the glass 401 under hurricane strength winds.
In Fig. 4C, the wind pressure and/or debris is coming from the
rightward side of the drawing figure and is headed leftwardly. In Fig. 4C, the
20 curtain resides exteriorly of the window, door or other building opening.
In
Fig. 34, the wind, debris and pressure "P" is illustrated as coming from the
leftward side of the drawing figure and is headed rightwardly. In Fig. 34, a
flexible three ply curtain 2805 is depicted. A single ply or double ply
curtain
may also be used. In Fig. 34, the curtain 2805 resides interiorly to the
25 window, door or other building opening. In the embodiment of Fig. 34, the
window 401 would be smashed by debris in a hurricane, but the building
would still be protected. Reference numeral 3402 represents the exterior wall
and reference numeral 3403 represents the interior wall in Fig. 34. Slot 2820
restrains the curtain 2805 at the bottom.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
26
Fig. 4D is a cross-sectional view similar to that of Fig. 4A illustrating
the wind-up reel 107 (sometimes referred to herein as the storage reel) in
greater detail adapted for use in connection with the three-ply flexible
curtain
and the cog drive.
Fig. 5 is a schematic view of the 72" curtain illustrating a 1 °
runout of
the leftside traclc, tension rods, and inter -opts. Reference numeral 500
generally indicates a schematic representation of a 1 ° runout for a
72" long
window. The interrupts are actually at a 1 ° angle which matches the
angle of
mating surface 203 on the "J-shaped" portion of the track. Fig. 11 illustr
ates
the top of a 72", 1 ° track in cross section. The "J-shaped" portion of
the track
in Fig. 11 is indicated by reference numeral 1101. Referring again to Fig. 5,
the dashed unnumbered lines are at 1 ° angle with respect to the side
220 of
curtain 115. The outer edge 201B of the track at the bottom is approximately
1.25" leftwardly of the point marked by reference numeral 201 in the preferred
embodiment of the 72", 1 ° curtain. The intermediate support 202 at the
bottom has a runout of the same magnitude as indicated by reference numeral
202B. All of the runouts, of the rods, the interrupts, and the tracks are the
same. When all of the rods progress to their closed, second position as
illustrated in Figures 1 and 5, the interrupts engage the mating surface 203
of
the track and, wedge into place. This secures the curtain in its closed
position.
Reference numeral 203B illustrates the runout of the mating surface at the
bottom of the 1 °, 72" long building opening. Reference numeral 501
illustrates the runout of the outside of the track. Reference numeral 502
illustrates nunout of the tension rods. It will be noted that the tension rod
124
illustrates a runout of approximately 1.25" from the side of the curtain 220.
Reference numeral 503 illustrates a runout of the interrupt engaging surfaces
with the mating surface 203 of track 111. Reference numeral 504 illushates
the runout of the inside portion of track 111. Curtain 115 has no runout as
illustrated by reference numeral 505.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
27
Track 111, at a 1 ° angle, must have a relatively wide mouth, or
opening, for use in protecting a 72" long building opening. Given that
reference numeral 502 defines the runout of the rods and, indeed, the end of
tension rod 124, it must fit within the track as it enters from its stored,
open,
first position. Fig. 5 illustrates that point 502 will fit within the mouth of
track
111 as defined by its outer edge 201.
Fig. 6 is a front view of the 72 inch curtain similar to that illustrated in
Fig. 1 except that the left side and right side tracks are parallel to each
other
and additionally the tension rods do not have any runout. Fig. 6 is one of the
illustrations of the second (parallel) embodiment. Reference numeral 600
generally refers to the parallel embodiment. Left side track 602 and right
side
traclc 603 are illustrated as being parallel to each other. Drive apertures
616
and 617 are driven by gears as was indicated in connection with the gears 119
and 120 of Fig. 1. The left side 620 of the curtain is parallel to the right
side
630 of the curtain and the interrupt of the first rod 705 (Fig. 7) is in the
same
position relative to the track 602 as is the last rod 627 (Fig. 6). Fig. 7 is
an
enlarged portion of Fig. 6. Fig. 7 illustrates first tension rod 701, second
tension rod 702, and third tension rod 704. Interrupts 705, 707 and 710
include respective mating surfaces 706, 708, 709. Those mating surfaces are
spaced apart from the conjugate mating surface 703 on the "J-shaped" portion
718 of the track 602. Fig. 6 illustrates the curtain in its second, fully down
position. In this second embodiment the interrupts do not wedge and engage
with the mating surface 703 on the guide 602 unless pressure due to wind or
debris is applied to the curtain. Rather, at rest, there is a distance of
approximately 1/8" in the preferred embodiment between the mating surface
703 and the mating surfaces 706, 708, 709, etc. on the interrupts of the
tension
rods. Therefore, for engagement to occur between the mating surfaces on the
interrupts and the mating surface on the J-shaped channel, the flexible
corrugated curtain must be deflected and the rods must bow inwardly to move
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
28
the mating surfaces (703, 706, 708, 709) into contact with each other. The
interrupts for the parallel arrangement are approximately 0.50 inches in
length
and the end portions are spaced an additional .150 inches away from the
mating interrupt surfaces. Reference numeral 711 indicates an end of a
tension rod. Reference numerals 712 and 713 indicate the beginnings of the
interrupts 705 and 707 in tension rods 701 and 702. The tension rods extend
about .250 inches leftwardly and rightwardly of the con-ugated curtain before
the interrupts begin. The parallel arrangement is driven similarly to the
wedging arrangement illustrated in the previous drawing figures and Fig. 7
illustrates teeth 719 on the gear driving the con-ugated curtain.
The preferred material of the corrugated curtain is polycarbonate and
the preferred material of the tension rod is aluminum. As the cross-sectional
areas of the tension rods increase, so does the shear strength of the rods.
The
"J-shaped" portion of the track is at an angle of approximately thirty degrees
and the gap between the mating edge 703 of the J-shaped portion 718 and the
support 702 is approximately 0.07 inches.
Fig. 8 is a schematic representation of the flexible curtain, track and
tension rods of the embodiment of Fig. 6. Reference numeral 800 generally
indicates the parallel arrangement. Referring to Fig. 8, reference numeral 801
illustrates no runout of the track 602, reference numeral 802 indicates no
runout of the ends of the tension rods, reference numeral 803 indicates no
runout of the mating surface of track 602, and reference numeral 804 indicates
no runout of the curtain. All embodiments employ a curtain having a zero
runout. It should be noted in connection with the parallel embodiment that the
interrupts are pressed (formed) such that they are parallel to the curtain
and/or
perpendicular to the longitudinal axes of the tension rods.
Fig. 9 is a front view of a 38" curtain illustrating a 1/2 ° runout
of the
tension rods. Reference numeral 900 indicates the curtain generally, slits 926
add flexibility to the curtain and drive apertures 916 and 917 are indicated
as
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
29
well.
Fig. 9A is similar to that of Fig. 1 illustrating a 1/2 ° runout of the
traclcs,
interrupts, and tension rods. Reference numeral 900A illustrates the 38" long
curtain having a %2 ° runout in its fully extended down or second
position.
Left side track 911 runs out as indicated by reference numeral 913 which is
the lower portion of the left side track. Similarly, reference numeral 914
indicates a small, 1/z ° runout of the right side track 912. The last
tension rod
924 illustrates a relatively small space between the curtain 915 and the
interrupts on that last tension rod 924. A counterbalanced wind-up reel 907 is
employed as illustrated in Fig. 9A. Bottom bar 918 is illustrated in Fig. 9A.
Fig. 9B illustrates an enlarged portion of Fig. 9. A relatively small
nunout between the near side interrupts 931 and 932 (first and fifth rods of
the
curtain) is indicated. In other words, interrupt 932 of the fifth rod down is
not
much leftwardly relative to the interrupt 931 of the first rod.
Fig. 9C is a perspective view of a portion of a curtain having a 1/a
°
runout further illustrating the corrugated flexible curtain 915 and interrupts
906, 908 and 909 mating with the corresponding mating surface 903 at points
903A, 903B and 903C on the "J-shaped" portion 904 of track 911 when the
curtain is in its fully down or second position. In this position movement of
the flexible curtain toward the window is restrained and the curtain has been
wedged into place. Fig. 9C illustrates the "J-shaped" portion 904 angled back
(with respect to the side of the curtain). Mating surface 903 is at the same
angle as the mating surfaces on interrupts 906, 908 and 909. Reference
numerals 903A, 903B and 903C signify a flush contact between the "J-
shaped" portion 904 of the track 911 and the respective interrupts. Fig. 9C
also illustrates the outside edge 901 of the track and this figure does a
particularly good job in representing the corrugated curtain 915. Corrugations
936 can be viewed in apertures 916 are indicated as are face slits 926.
Reference numeral 935 illustrates the rectangular in cross-section rod
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
extending through the curtain 915. It will be noticed that where the rods
extend through the curtain that there is no slit at a corresponding point in
the
face. The rods are sealed within the curtain so that contaminants such as sea
salt cannot reach them enabling a low maintenance curtain.
5 Fig. 10 is a schematic representation similar to that of Fig. 5 only it will
be noticed that the angle is 1/2° illustrated over a 38" length as
compared to 1 °
angle illustrated over a 72" length in Fig. 1. It will be apparent when
viewing
Fig. 10 that a smaller mouth or area is needed to receive the bottom rod of a
1/2°, 38" curtain system because the runout is much less. Reference
numeral
10 1000 generally indicates this schematic representation. The side of curtain
1013 does not have any runout. Curtain 1015 includes apertures 1016 and the
bottom bar is denoted by reference numeral 1018. Track 1 O 11 has an outer
edge 1012 whose runout is indicated with reference numeral 1001. Similarly
the first tension rod has an end 1020 whose runout is indicated with reference
15 numeral 1002. The first mating interrupt of the first rod is indicated by
reference numeral 1007 and its runout is indicated by reference numeral 1003.
Finally, the inner portion of the guide also has a runout as indicated by
reference numeral 1004. Reference numeral 1009 illustrates the surface of the
"J-shaped" portion of the track 1011 which mates with the inten-upts. In this
20 1/2°, 38" embodiment, the interrupts are also at a 1/2° angle
mating
arrangement. The track support 1008 performs the same function that the
track support performs in the first embodiment in that it supports and
restrains
the rods during tensioning. During tensioning, the rods will pivot slightly on
mating surface 1009 and the end portions thereof, for example end portion
25 1020, will engage support 1008.
The track supports (i.e., 1008) are necessarily close to the mating
surface (i.e., 1009) of the "J-shaped" portion of the track in the embodiments
employing an angled track as well. Bending moments are thus minimized
because the gap is preferably small, on the order of .007 inches.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
31
The distance between the mating surface 1009 and the track support
1008 is important. If this distance is too large then the rods tend to shear
as
the bending moment caused by the structure of the curtain with the rods
therethrough is too large. It has been found that a preferred distance between
the track support 1008 and the mating surface 1009 of the track is
approximately 0.07 inches. This distance can, however, be changed as those
skilled in the art will appreciate.
Fig. 11 is a top view of the leftside track like that of Fig. 1 illustrating
the top rod in its fully down position engaging the track. Fig. 11 illustrates
a
cross-sectional view of the top of the track which has 1 ° runout. The
ninout,
however, is not illustrated in this drawing. Reference numeral 1100 generally
illustrates the rod and the relative spacing arrangements for a 72" long
opening having a 1 ° runout. Rod 1104 includes a relatively long
interrupt
1105. "J-shaped" portion 1101 of track 1103 is shown engaging the mating
surface 1106 of the interrupt 1005 of the rod 1104. In viewing Fig. 1 it is
obvious that there are many rods employed in the curtain and each of those
rods will seat against the "J-shaped" portion 1101 of the track 1103.
Fig: 11A is a front view of the leftside track 1103 and the top rod 1104
illustrated in Fig. 11. Reference 1100A generally illustrates this front view.
Gap 1108 is the space between the J-shaped portion 1101 and the track
support 1109 and is preferably small (.007 inches).
Fig. 11B is a top view of a leftside track like that of Fig. 9A illustrating
the top rod in its fully down position engaging the track. Fig. 11B
illustrates a
cross-sectional view of the top of the track which has a %2 ° runout.
The
runout, however, is not illustrated in this drawing. Reference numeral 1100B
generally denotes the view. It will be noticed that the track 1103B is
somewhat smaller when compared to the traclc necessary for a 72" opening
having a 1 ° runout. Further, it will be noticed that the rod 1104B
includes a
smaller interrupt 1105B as compared to the 72", 1 ° runout. "J-shaped"
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
32
portion 1 lOlB engages the mating surface 1106B of interrupt 1105B. End
portion 1107B of the track is supported by support 1109B during tensioning as
was discussed previously. Gap 1102B is illustrated between "J-shaped"
portion 1101B and track support 1109B. Fig. 11C is a front view of the
leftside track and top rod illustrated in Fig. 11B. Reference numeral 1100C
generally denotes this view. Reference numeral 1200 generally denotes this
view.
Fig. 12 is a top view of a leftside track like that of Fig. 1 illustrating the
bottom rod in its fully up position entering the track. Fig. 12 illustrates a
10, cross-sectional view of the top of the track which has a 1 ° i-
unout. The runout,
however, is not illustrated in this drawing. It will be noticed that the
interrupt
1205 is relatively and necessarily large. Because this interrupt is relatively
large a relatively large mouthed track 1203 is necessary to in effect swallow
or
accept the tension rod 1204. The interrupt must straddle the gap 1202
between the "J-shaped" portion 1201 of the track and the track support 1209.
This is caused by a long or large 72" opening having tracks at 1 °
divergence
from vertical. Put another way, the tracks have a 2° divergence from
track to
track. The end 1206 of rod 1204 must have sufficient clearance inwardly from
tracl~ 1203 to enter it. Fig. 12A is a front view of the leftside track and
the
bottom rod illustrated in Fig. 12 and reference numeral 1200A generally
denotes this view.
Fig. 12B is a top view of a leftside track like that of Fig. 9A illustrating
the bottom rod 1204B in its fully up position entering the track. Fig. 12B
illustrates a cross-sectional view of the top of the traclc which has a 1/2
° runout.
The runout, however, is not indicated in this drawing. Reference numeral
IZOOB generally denotes this view. A smaller track 1203B is acceptable
because the runout over a 38" long opening having tracl~s that diverge
1/z°
from vertical or 1 ° from each other does not require a lengthy
interrupt
1205B. Additionally, it will be noticed too that there is a small clearance
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
33
between the "J-shaped" portion 1201B of the track 1203B and the interrupt
1205B. This is necessary so that the rods may progress downwardly without
much friction. Clearance is indicated in all of Figs. 11 and 12. Sufficient
clearance between end portion 1206B of the rod 1204B and the track 1203B is
indicated. Gap 1202B is indicated between J-shaped position 1201B and the
support 1209B.
Fig. 12C is a front view of the leftside track and the top rod as
illustrated in Fig. 12B and reference numeral 1200C generally denotes this
view.
In all of Figs. 11 and 12, the J-shaped portion is at an angle of
30° and
the gap between the mating surface of the J-shaped portion and the support is
0.07 inches. This geometry provides good securement of the curtain under
load.
Returning to Fig. 5 the problem associated with a long opening such as
the 72" opening employing a track at 1 ° to vertical (2 ° angle
divergent fr om
hack to traclc) is that the width of the interrupt must increase so that it
may
straddle the "J-shaped" mating surface and still be within (short of) the
outer
edge of the track. Therefore, although this invention is useful over any
practical angle of divergence from track to track, it is usually more
economical to employ a 1/2 ° runout and wedge than a 1 ° runout
and wedge for
long openings. The wedge principle works over any practical angle, but it
may be more economical for some combinations of angle and length than
others.
Fig. 13 is a cross-sectional view of the bottom bar 1300 sealingly
engaging the bottom sill 1304 which is affixed to the frame 1306, 1307 of the
structure. Fig. 13 illustrates a curtain 1309 which is corrugated. Corrugated
curtain 1309 is affixed to the bottom bar 1300 by means of a fastener 1310.
Magnet 1302 is a part of bottom bar 1301 and is attracted to the sill or other
structure. Sill 1304 includes seal 1308 which is restrained in sill 1304 by
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
34
means of adhesive or epoxy. The wood frame traps sill portion 1305 to assist
in holding the sill in place. Catch 1303 engages sill 1304 when curtain 1309
is
sufficiently flexed by wind or debris.
Fig. 13A is a cross-sectional view of a three-ply flexible curtain 1300A.
Two polymeric sheets or plies 1320, 1321 are pressed and fused into
engagement with a woven ply 1322 which is affixed by fastener 1310 to
bottom bar 1301.
Fig. 13B is a cross-sectional view of a three-ply flexible curtain 1300A
together with a vertically bowed bottom bar 1330 entrapped by
adhesive/lamination of the flexible curtain. Fig. 13C illustrates entrapment
of
bottom bar 1330 by stitching the plies together. The bowed bar 1330 is
illustrated in Fig. 13D and functions to guide the curtain into a retaining
slot
2820 as illustrated in Figs. 28C and 28D. When wind pressure or pressure
from debris is applied, the middle portion 2841 of the curtain may bow toward
the window. The side portions, however, are guided by the tracks (2801,
2204) and the bottom portion 1340 of the curtain is vertically bowed and is
guided into retaining slot 2820 first below the tracks and then in the middle.
The bottom portion is restrained by the tracks against the pressure of the
wind.
This gets the curtain started at the sides of the retaining slot and the
middle of
the curtain follows.
Fig. 14 is a perspective view of a tension rod 1401 having an interrupt
1402 in an end portion 1404 and having an interrupt 1403 in an end portion
1405. The rod is generally represented by the reference numeral 1400. The
tension rod is rectangular in cross-section and the cross-sectional shape has
been found to be the strongest shape. Other shapes, however, may be, used.
Fig. 15 is an enlarged portion of the tension rod 1401 illustrated in Fig.
14. Interrupt 1402 is shown having curved radii 1501, 1502 and 1503.
Reference numeral 1500 generally denotes the end portion of the rod. Flat
portion 1504 shown inwardly from radius 1502 engages the mating surface of
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
the "J-shaped" portion of the tracl~.
Fig. 16 is another enlarged view of a portion of a tension rod.
Reference numeral 1600 generally indicates the end portion of the tension rod
with end 1602 and radius 1601. Mating surface 1601 is a good representation
5 of an angled surface with respect to the longitudinal axis of the tension
rod. It
is this mating surface 1601 which engages a similarly angled mating surface
on the "J-shaped" portion of the tracks. In other words, surface 1601 is at an
angle with respect to the longitudinal axis of the rod.
Similarly Fig. 17 is a view of the end portion of a tension rod
10 illustrating a circular in cross-section tension rod. Reference numeral
1700
generally represents this embodiment with end portion 1702 having an
interrupt formed therein with mating surface 1701 being angled to match the
"J-shaped" portion of the tracks. When the embodiment of Fig. 6, to wit, a
parallel arrangement is illustrated, the mating surfaces 1601 and 1701 will
15 necessarily be perpendicular to the longitudinal axes of the tension rods.
The
tension rods are preferred to be rectangular in cross-section so as to
maximize
the area filled in the corrugated material which is rectangular in cross-
section.
The rectangular in cross-section rod has been found to be the strongest
because it occupies the largest cross-sectional area.
20 Fig. 18 is a plan view of a tension rod illustrating the interrupts 1402
and 1403. Reference numeral 1800 is a general designation for this rod.
Dashed lines 1801, 1802, 1803 and 1804 correspond to angled track. Fig. 19
is a side view of a tension rod of Fig. 18 illustrating the interrupts
therein.
Reference numeral 1900 is a general designation for this view of the rod.
25 Fig. 20 is a perspective view of the track which has been referred to in
this figure by reference numeral 2000. J-shaped portion 2001 is well shown in
this illustration. Fig. 21 illustrates a plan view of one of the tracks 2000
with
bolt holes or apertures 2101 for fixing to a casing or frame. Reference
numeral 2100 generally denotes this drawing figure.
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
36
Fig. 22 is a cross-sectional view of a three-ply flexible curtain 2200
talcen along the lines 22-22 of Fig. 28. Figs. 22-29 illustrates the third
embodiment of the invention. A first polymeric sheet 2201, a second
polymeric sheet 2202, and a third woven sheet 2203 are heated and pressed
together forming the construction of a flexible curtain. Track 2204,
preferably
metal, is illustrated in Fig. 22. The edges of the flexible curtain 2200 are
folded upon themselves and are maintained in the folded position by stitching
2205. Alternatively, the folds may be glued to the curtain. The stitching is
preferably placed such that 1/3 of the folded flap will be loose and 2/3 of
the
folded flap will be secured to the curtain. Drive apertures 2206 are shown and
reference numeral 2207 indicates the loose flap. Reference numeral 2208
indicates the folded portion of the curtain. Fig. 22A is identical to Fig. 22
only eyelet 2209 in aperture 2206 is illustrated. Eyelets 2209 add strength
for
driving the curtain between its first, open and second, closed positions. It
may
be noticed that the cross-hatching used for the plies 2201 and 2202 appear to
cause an optical illusion such that the plies do not appear parallel but, in
fact,
they are parallel. Figs. 22B and 22C are identical to Figs. 22 and 22A,
respectively, but Figs. 22B and 22C do not include the cross-hatching. Figs.
22B and 22C do not portray any optical illusions.
Fig. 23 is a cross-sectional view taken along the lines 23-23 of Fig. 28.
Fig. 23A is identical to Fig. 23 without cross-hatching of the polymeric plies
illustrated. Figs. 23 and 23A illustrate the curtain without any pressure
applied. Figs. 23B and 23C correspond to Figs. 23 and 23A, respectively,
only they are illustrated with pressure applied.
Figs. 23B and 23C are cross-sectional views of the three-ply curtain
and tracks with the curtain under the influence of a force, for example, a
high
velocity wind indicated by the letter "P." The force of the wind causes the
curtain to attempt to extract itself from the tracks 2204 and 2801. The folded
edge which have loose flaps are deformed and seal the interior of the tracks
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
37
2204 and 2801. There are at least four sealed points 2302, 2303 on the right
side and 2304, 2305 on the left side when viewing Figs. 23B and 23C. Gaps
2306 and 2307 are created between the flaps 2207 and 2209 the three-ply
flexible curtain when the curtain is under pressure "P." Gap 2308 between
S track 2204 and the folded edge is created as the curtain attempts to exit
the
track. Similarly, gap 2309 between track 2801 and the other folded edge is
created as the curtain attempts to exit the track. As force is applied, flaps
2207 and 2209 are no longer loose and act as shock absorbers which take up
energy imparted to the curtain by the wind. The elastic properties of the
flexible curtain absorb the energy of the wind. Hook portions 2210 and 2811
of tracks 2204 and 2801 are spaced from the curtain at rest such that the
aforementioned seals will be made when the curtain is subjected to pressure.
Fig. 24 is a cross-sectional view of a three-ply curtain together with a
semi-rigid polymeric strip 2401 affixed to one edge thereof. The polymeric
1 S rigid strip 2401 includes a flap 2402 which is not securely fastened to
the
three-ply curtain 2400. Stitching 2405 or other means may be used to affix
the strip to the curtain 2500.
Fig. 2S is a cross-sectional view of a three-ply curtain similar to the
view of Fig. 23 with the curtain under the influence of a force, "P," for
example a high velocity wind. A seal is made at points referred to by
reference numerals 2503 and 2507. Gap 2504 exists between the rigid strip
2402 and the main three-ply curtain.
Fig. 26 is a cross-sectional view of a three-ply curtain having a folded
edge and illustrating two polymeric plies 2201 and 2202 and a woven sheet
ZS 2203 secured together with adhesive 2601. Reference numeral 2602 indicates
a 1/3 flap length as the preferred free distance of the flap. Similarly,
reference
numeral 2603 illustrates that 2/3 of the flap is secured by stitching 2205.
Those skilled in the art will readily recognize that different lengths may be
chosen for securement with attendant different results. In the preferred
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
38
embodiment the tracl~ has an approximate inner length of one inch meaning
that 1/3 of an inch would be the free distance for the flap and 2/3 of an inch
would be the secured distance for the flap. These distances represent the
preferred embodiment and in no way limit the invention.
Fig. 26A illustrates adhesive 2609 affixing a portion of the semirigid
strips 2401 to the main three-ply curtain. Alternatively, a ship of the three-
ply
curtain may be used in place of the semirigid strip.
Fig. 26B is a cross-sectional view of an embodiment employing two
plies of polymeric material 2615, 2616 secured together with a fiber
reinforcement 2617. This material is high-tear vinyl polyester and is
commercially available from BONDCOAT MANUFACTURING
COMPANY. A loose flap 2620 has been slit such that it engages truclc 2204
at lip 2210 when the curtain is under the influence of pressure. The slit may
be used in either the horizontal or the divergent angle embodiments.
Fig. 27 is a rear view of the three-ply flexible curtain 2700 illustrating a
semi-rigid strip applied to both edges of the curtain. Semi-rigid strip 2702
is
applied to the left side of the curtain and semi-rigid strip 2701 is applied
to the
right side of the right edge of the curtain. Apertures 2703 are placed in a
repeating fashion along the left and right side edges of the curtain for
interengagement with conical cogs to raise and lower the curtain.
Fig. 28 is a front view of a three-ply curtain 2805 driven by a cog/pin
drive 2802 (sometimes referred to herein as the drive roller 2802) having
cogs/pins 2803. Leftside traclc 2801 is illustrated in Fig. 28 as is rightside
tracl~ 2204. These tracl~s are secured to the building structure as indicated
in
Fig. 4. Wind-up reel 2804 sometimes referred to herein as a storage reel is
illustrated and it is also counterbalanced. See, Fig. 28B. Fig. 28 illustrates
the
curtain in its second, down position.
Fig. 28A is a cross-sectional view tal~en along the lines 28A-28A of
Fig. 28 illustrating the drive roller 2802. The drive roller 2802 is driven by
a
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
39
motor or by a hand operated pulley. See, Fig. 1 illustrating an arrangement
for
accomplishing operation of the drive roller 2802. The drive roller 2802 and
the storage reel are supported as illustrated in Fig. 1. The drive roller 2802
supports the curtain which is under constant tension between the cogs/pins
2803 and the storage reel 2804. In practice, the three-ply curtain is less
than
1/16 of an inch thick and, where folded, less than 1/8 of an inch thick. It is
important to keep the flexible curtain taut between the storage reel 2804 and
the drive roller 2802 so as to ensure an even accumulation of the curtain on
the storage roller. By even, it is meant a smooth continuous winding without
folds or creases.
Fig. 28B is a cross-sectional view tal~en along the lines 28B-28B of
Fig. 28 illustrating counterbalanced springs 2820', 2821 which tension the
curtain between the drive cogs 2803 and the storage reel 2804. The springs
are grounded by pegs 2850 which are coupled to the building 2840. Spring
holders 2822, 2833 secure the spring to the storage reel 2804. Fig. 28C is a
view similar to Fig. 28 further illustrating a bowed bottom bar 1340
approaching a retaining slot 2820 as illustrated in Fig. 28D as previously
described above. Tracks 2801 and 2204 keep the edges of the curtain aligned
with the retaining slot. The edges 1341, 1342 of the bottom portion 1340 of
the cux-tain enter the retaining slot 2820 first followed by the middle
portion.
Fig. 28E is a front view of flexible curtain 2805 and window 2870 in a
building illustrating the curtain in a first, open position. Bottom bar 1340
is
shown in phantom behind siding 2860. Reference numeral 2880 indicates
travel of the curtain upwardly and downwardly. Fig. 28 F is a front view of a
flexible curtain 2805 illustrated in the second, closed position. Window 2870,
side tracks 2801 and 2204, and retaining slots 2820 are illustrated in Fig.
28F
in phantom. The side tracks and retaining slots are affixed to the frame of
the
building in a manner understood by those spilled in the art. Alternatively,
the
window 2870 and curtain may be preinstalled as illustrated in Figs. 4B and
CA 02419639 2003-02-19
WO 02/15755 PCT/US00/23357
4D, for example. Frame 407 in Fig. 4B represents an embodiment which may
be used to preinstall the window and curtain.
Fig. 29 is a side view of Fig. 28 and reference numeral 2900 generally
indicates the assembly. Track 2204 is also shown in Fig. 29.
5 Fig. 30 is a perspective view of the chain drive (drive adaptor rack) and
gear drive. In this embodiment the tension rods 3006 pass through the flexible
curtain 3007 and are tensioned and rolled up upon counterbalanced wind-up
reel 3009. Adaptor racy 3001 includes notched holes 3002 that are vertically
spaced between slots 3003 with rods 3006 at a spacing equal to the circular
10 pitch of the drive gear 3005 as the curtain is moved from the opened, first
position to the closed, second position. The drive system of Fig. 30 is
preferably used with the parallel embodiment but with certain modifications it
may be used with the divergent track.
Fig. 31 is a perspective view of an adaptor rack 3104 illustrating
15 tensioning rods 3101 having a 90 ° bend 3102 at the edges thereof.
This
embodiment of the drive system may be used with the divergently angled
tracks or it may be used with the parallel tracks. Rods 3101 pass through
corrugated curtain 3106. Track 3105 is the same track described previously.
Fig. 32 is a perspective view of an adaptor drive illustrating
20 engagement of tensioning rods 3203 with the adaptor drive 3201 .
Fig. 33 is a perspective view of a gear chive such as the one illustrated
in Fig. 1 and is generally represented by reference numeral 3300. Gear 3303
includes teeth 3301 which drive the flexible curtain 3302. Fig. 33 illustrates
the curtain in the down, second position.
25 It will be understood by those skilled in the art that several changes
may be made to the instant invention without departing from the spirit and
scope of the claims which follow hereinbelow.
