Note: Descriptions are shown in the official language in which they were submitted.
SHUTTER SLAT
BACKGROUND OF THE INVENTION
[0001] The present invention relates to shutter slats and in particular to
shutter slats of the
roller type having improved resistance to stonns and break-ins. It furtheimore
relates to shutter
slats having compact refraction capability.
DESCRIPTION OF THE RELATED ART
[0002] Conventional roller shutters are designed to provide security from
break-ins or
protection from stomis. Because such protection and security may not always be
necessary or
desired, such as during the day when a retail store is open for business or
during fine weather
when a homeowner wishes to open windows or enjoy an ocean view, roller
shutters are designed
to be retractable into a casing in which they are stored. In some examples, to
facilitate compact
storage, the rigid shutter slats that are designed to resist hurricane winds
and burglars also must be
capable of confoiming to a roll.
[0003] One conventional shutter slat is made to confonn to a roll by
providing a loose
articulation between slats. Slats are slidably engaged at the upper edge of
one slat and the lower
edge of another slat. The upper edge comprises a vertical projection
tenninating in a hook-shaped
profile. The lower edge comprises a first portion and a second portion that
cooperate to define a
vertical pocket. The hook-shaped profile of the upper edge allows the upper
edge to
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engage the first portion of the lower edge, also having a hook-shaped profile.
The upper edge is
prevented from undesirably disengaging the lower edge by the second portion of
the lower edge,
which comprises a guard extending downward to slightly below the hook-shaped
profile of the
lower edge, defining a horizontal aperture between the first and second
portions of the lower
edge. The vertical pocket defined by the first and second portions of the
lower edge is similar in
depth to the height of the vertical projection of the upper edge. This shutter
configuration's
flexibility arises from the pivoting of the vertical portion of the upper edge
within the horizontal
aperture.
[0004] One result of this configuration is that the upper edge has
significant vertical
clearance within the vertical pocket. Shutters according to this configuration
are known to have
a clearance up to one-quarter inch per slat, or even more. A shutter having 48
slats and one-
quarter inch clearance per slat would then have a total clearance of twelve
inches between the
fully open and fully closed positions. To raise such a shutter having a
torsion spring as a
counterbalance, a user must lift the bottom slat either by hand or
mechanically to correct for the
full amount of clearance before the shutter will begin to retract. In such a
shutter, a user would
have to lift approximately 150 pounds by twelve inches in order to engage the
shutter's retraction
mechanism. Shutters of this configuration do not obtain full benefit of the
counterbalance, as
provided by the torsion spring or by other means.
[0005] A further result of this configuration is that the loosely
articulated slats are known
to be noisy. The slats rattle against each other during extension and
retraction. In addition, when
the roller shutter is deployed, the normal forces of the wind are sufficient
to cause the slats to
rattle audibly.
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[0006] Conventional shutter slats are generally designed to hang from a
roll or spindle,
the roll or spindle contained in a casing. When the shutter is retracted, the
slats wrap around the
spindle. Because the slats do not fit together compactly around the roll, the
resulting shutter
assembly, when retracted, creates a roll with a large diameter, and therefore
requires a large
casing for the roll. This can be unsightly, especially in shutter applications
used on residential
buildings. Thus, a shutter assembly that is capable of compact storage is
desirable.
[0006] One solution to the problem of compact storage includes integration
of a boss
concentric with the articulation between adjoining slats, as described in U.S.
Pat. No.
6,095,225 to Miller, titled "Shutter Slat with Integrated Boss." The slats in
this configuration are
also slidably engaged at the upper edge of one slat and the lower edge of
another slat. The upper
edge comprises a short vertical projection terminating in a c-shaped screw
boss, and the lower
edge comprises a c-shaped channel having a diameter sufficient to accommodate
the upper edge.
The flexibility of this shutter configuration arises from the cooperation of
the rounded internal
surface of the c-shaped channel and the rounded external surface of the c-
shaped screw boss.
The diameter of the upper edge is smaller than the diameter of the c-shaped
channel, but greater
than the width of the aperture defined by the c-shaped channel, preventing the
upper edge from
simply falling out of the c-shaped channel provided by the lower edge.
[0007] One result of this configuration is that if the exposed portion of
the c-shaped
channel of the lower edge gives way upon exertion of pressure on the
articulation, the slats may
separate undesirably. Because the retention of the upper edge by the c-shaped
channel is based
on a relatively small difference in size, damage to either edge may result in
a breach of the
rolling shutter. For example, if a putative intruder hits the shutter, the c-
shaped channel may be
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forced open. Even if the channel is bent only slightly, once a gap is formed
between an upper
edge and a lower edge, the two slats may be pried apart with undesirably
slight effort.
[0008] There is a need for shutter slats that completely minimize the space
required for a
rolling shutter made up of the slats to be wound up in a fully closed
configuration. There is also
a need for shutter slats that do not retain water, which can freeze and damage
the slats.
SUMMARY OF THE INVENTION
[0009] The invention is a rolling shutter slat for use in a rolling
shutter, said slat having a
first end, a second end and a profile comprising a body having an upper edge
and a lower edge,
an outward facing side extending between the upper edge and the lower edge,
and an inward
facing side extending between the upper edge and the lower edge. The slat has
engaging track
connected to the body at the upper edge, the engaging track having a hook that
extends upward
from the upper edge at a smoothly curved transition between the engaging track
and the upper
edge. The slat further comprises a receiving track connected to the body at
the lower edge,
comprising a lip member having an outer lip surface and an articulating lip
surface, the outer lip
surface being contiguous with the inward facing side of the body and extending
downward along
the same curve as the inward facing side of the body to a curl, the curl
extending upward to a tip.
The receiving track further comprises a guard member spaced apart from the lip
member, an
articulation space wherein a second engaging track of a second identical slat
may hook the lip
member through an aperture between the lip member and the guard member to form
a hinge, and
a receptacle located between the lip member and the guard member that is
separated from the
articulation space by a first shoulder on the articulating lip surface and a
second shoulder on the
articulating guard surface, wherein the lowest point of the curl is
horizontally displaced from the
intersection of the second engaging track and a body of the second identical
slat.
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[0010] In another embodiment, the shutter slat comprises a body having a
curvature with
a convex side and a concave side, a first end and a second end. A hooking
track is positioned at
the first end, with a bend formed between the body and the hooking track, the
hooking track
projecting above the convex side of the body. A receiving track is positioned
at the second end,
the receiving track including a guard member extending along the curvature of
the body, and a
lip member projecting below the concave side of the body. An articulation
space is defined
between the lip member and guard member, the articulation space sized and
shaped to hingedly
engage the hooking track. In a further alternative embodiment, the shutter
slat may be
incorporated in a rolling shutter where a plurality of slats form a chain
extending from a spindle,
the hooking track of each successive slat engaged in the receiving track of
the preceding slat in
the chain.
BRIEF DESCRIPTION OF THE FIGURES
100111 Embodiments of the invention will now be explained in further detail
by way of
example only with reference to the accompanying figures, in which:
[0012] FIG. 1 is a side view of a shutter slat according to the present
invention;
[0013] FIG. 2 is an elevation of a shutter slat according to the present
invention;
100141 FIG. 3 is a detailed view of a hooking track according to the
present invention;
[0015] FIG. 4 is a detailed view of a receiving track according to the
present invention;
[0016] FIG. 5 is an elevation of a window aperture including a rolling
shutter according
to the present invention;
[0017] FIG. 6 is a partial horizontal sectional view of a shutter slat
according to the
present invention engaged in a track, taken along lines A-A;
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[0018] FIG. 7 is a side view of the cooperation of two shutter slats
according to the
present invention when the shutter slats are in an open position;
[0019] FIG. 8 is a detailed view of the cooperation between the hooking
track and
receiving track of the two shutter slats of FIG. 7;
[0020] FIG. 9 is a side view of the cooperation of two shutter slats
according to the
present invention when the shutter slats are in a closed position.
[0021] FIG. 10 is a side view of the shutter slats of FIG. 9, showing the
interaction
between successive windings of shutter slats.
[0022] FIG. 11 is a side view of an alternative embodiment of a shutter
slat.
[0023] FIG. 12 is a side view of a rolling shutter comprised of shutter
slats of FIG. 11 in
a retracted position.
[0024] FIG. 13 is a detail side view of the shutter slats of FIG. 12.
[0025] FIG. 14 is a side view of a further alternative embodiment of a
shutter slat.
[0026] FIG. 15 is a side view of a hinge formed by engagement of two
shutter slats of
FIG. 14.
[0027] FIG. 16 is a photo of a rolling shutter mounted in an apparatus for
testing
resistance to water intrusion.
[0028] FIG. 17 is a photo of a rolling shutter mounted in the apparatus of
FIG. 16
exhibiting water intrusion during testing.
[0029] FIG. 18 is a photo of a rolling shutter mounted in the apparatus of
FIG. 16
exhibiting no water intrusion during testing.
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DETAILED DESCRIPTION OF THE INVENTION
[0030] FIGS. 1 and 2 show a shutter slat 1 according to the present
invention.
Illustratively, shutter slat 1 is an elongated body of extruded aluminum
having a body portion 4,
a hooking track 7, and a receiving track 8. The body portion 4 is bound by an
outward facing
side 2, an inward facing side 3, a first edge 5, a second edge 6, a first end
15 and a second end
16. In this embodiment, the slat is formed of a single ply of extruded
aluminum; however,
double-ply aluminum, as well as other metal or plastic materials is also
contemplated.
[0031] FIG. 1 is a side view of a shutter slat 1 according to the present
invention. The
body portion 4 is a curved single-wall having an outward facing side 2, an
inward facing side 3, a
first edge 5, and a second edge 6. The outward facing side 2 of body portion 4
has a convex
cross-section and the inward facing side 3 has a concave cross-section when
sectioned vertically
at any location along the length of slat 1. The distance between outward
facing side 2 and
inward facing side 3 defines the thickness 50 of body portion 4.
[0032] FIG. 2 is an elevation of a low-clearance shutter slat 1 according
to the present
invention. The distance between the upper end 52 of hooking track 7 and the
lower end 53 of
receiving track 8 defines the vertical height 54 of slat 1. However, each slat
1 in a rolling shutter
9 may not have the same vertical height 54. Those skilled in the art will
recognize that the
vertical height 54 of slat 1 is not critical so long as the slat 1 is
conformed to roll into a shutter
casing 12 (FIG. 5). It may be advantageous to vary the vertical heights 54 of
slats 1 in a rolling
shutter 9 to minimize the space required to retract the rolling shutter 9 into
a fully closed
position.
[0033] The distance between first end 15 and second end 16 of body portion
4 defines the
overall horizontal width 55 of slat 1. The overall horizontal width 55 must be
wide enough to
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cover a building aperture or other opening in which a rolling shutter 9 made
with slats 1 is
designed to protect.
[0034] Outward facing side 2 and inward facing side 3 are both formed with
a radius of
curvature 51. However, those skilled in the art will recognize that radius of
curvature 51 is not
critical so long as slat 1 is conformed to wrap around a spindle 19 (FIG. 9).
The overall vertical
height 54 and the radius of curvature 51 of body portion 4 cooperate to allow
a rolling shutter 9
formed by slats 1 to roll when retracted around a spindle 19. The radius of
curvature 51 of body
portion 4, the overall vertical height 54, and the thickness 50 are selected
to facilitate retraction
and winding of a rolling shutter 9 formed from slats 1 around the spindle 19
and to provide
strength to the rolling shutter 9.
[0035] FIG. 3 is a detailed view of hooking track 7, which is connected to
body portion 4
at first edge 5, which is a smooth concave transition. Hooking track 7
includes a hook 30 with
an outer surface 31, an inner surface 32, and a tip 33. Hooking track 7 is
formed integrally with
body portion 4. However, it is understood that hooking track 7 could be formed
separately and
fixed to body portion 4. It is also understood that hooking track 7 could, in
the alternative, be
located at second edge 6.
[0036] Hook 30 of hooking track 7 has a profile that is dimensioned to be
substantially
similar to the profile of articulation space 20 of receiving track 8. Hook 30
may have a single
radius, or the radius may change along the profile of hook 30. In the
embodiment shown, the
radius of hook 30 decreases closer to tip 33.
[0037] Outer surface 31 has a radius of curvature that in conjunction with
the radius of
curvature of inner surface 32 causes hooking track 7 to have a substantially
uniform thickness 56
from tip 33 to first end 5 of body portion 4. The thickness 56 of hooking
track 7 in this
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embodiment is substantially similar to the thickness 50 of body portion 4.
Hooking track 7 also
has a vertical height 57 that extends from first edge 5 to upper end 52.
[0038] FIG. 4 is a detailed view of receiving track 8, which is connected
to body portion
4 at second edge 6. Receiving track 8 includes a lip member 10, a guard member
11, and an
articulation space 20. Receiving track 8 may also include a receptacle 23.
Receiving track 8 is
formed integrally with body portion 4. However, it is understood that
receiving track 8 could be
formed separately and fixed to body portion 4.
[0039] Receiving track 8 has a vertical height 58 that extends from second
edge 6 to
lower end 53. However, those skilled in the art will recognize that the
vertical height 58 of
receiving track 8 is not critical so long as receiving track 8 is dimensioned
to engage hooking
track 7.
[0040] Lip member 10 has an outer lip surface 15, an articulating lip
surface 16, and a tip
25. Outer lip surface 15 further includes an outer lip wall 40 and an outer
lip curl 41. Outer lip
wall 40 of outer lip surface 15 is contiguous with the inward facing side 3 of
body portion 4 such
that the curvatures 51 of inward facing side 3 and outer lip wall 40 are the
same, and there is no
break between inward facing side 3 and outer lip wall 40. This common
curvature 51 minimizes
the space taken up by slat 1 when a rolling shutter 9 made of slats 1 is
retracted into a fully
closed position.
[0041] Guard member 11 has an outer guard surface 17 and an articulating
guard surface
18. As shown, articulating surfaces 16 and 18 may be wholly or partially
concave. Such
concave articulating surfaces allow for improved articulation between adjacent
slats without the
need to provide additional vertical clearance.
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[0042] Articulation space 20 is the space within which a hooking track 7 of
an adjacent
slat 1 is received in receiving track 8 to form a rolling shutter 9. The tip
25 of lip member 10 and
the articulating guard surface 18 of guard member 11 define an aperture 22
communicating with
articulation space 20. Hook 30 of hooking track 7 of the adjacent slat 1 is
dimensioned to enter
articulation space 20 through aperture 22. The profile of articulation space
20 is dimensioned to
substantially match the profile of hook 30 of hooking track 7. Tip 33 of hook
30 of the adjacent
slat 1 seats against articulating lip surface 16 of lip member 10, thereby
forming a hinge between
hooking member 7 of the adjacent slat 1 and receptacle member 8. Outer surface
31 of hook 30
of the adjacent slat 1 contacts articulating guard surface 18 of guard member
11, thereby
preventing hooking member 7 of the adjacent slat 1 from disengaging with
receptacle member 8.
[0043] In prior art designs, receiving tracks have thin guard members that
are
substantially vertical when the slat is in a vertical position. The lowest
point of such a prior art
guard member extends below the lowest point of the communicating lip member.
Guard
member 11 is considerably shorter than the guard members of prior art slats,
and the lowest point
of guard member 11 terminates above the lowest point of lip member 10 when
slat 1 is in a
vertical position. Because guard member 11 is shorter in relation to the lip
member, it is
thickened and reinforced at the point where it engages the hooking track 7 of
the adjacent slat 1
without appreciably increasing the amount of extruded aluminum required to
form receiving
track 8, further increasing the security of the hinge formed by two slats
without requiring
additional material expense. The increased thickness of guard member 11 also
protects slat 1
from excessive articulation that may disengage the hinge formed with the
hooking track of
another slat 1.
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[0044] Receptacle 23 is adapted to receive a retention or alignment device
29 (FIG. 6).
This retention or alignment device may be a screw, bolt, or other device
capable of being
retained by the receptacle and capable of aligning slats with one another
and/or retaining the slat
to a guide. Articulating lip surface 16 has a shoulder 27 which separates
articulation space 20
from receptacle 23, and articulating guard surface 18 has a shoulder 28 which
separates
articulation space 20 from receptacle 23. When slat 1 is in a vertical
position, as shown in FIG.
1, receptacle 23 is located above shoulders 27 and 28. As shown in FIG. 4, it
is advantageous to
locate receptacle 23 between the body portion 4 and aperture 22. It is
understood that if
receiving track 8 were located at first edge 5 of slat 1, receptacle 23 still
would be located
between body portion 4 and aperture 22.
[0045] While receptacle 23 is a space distinct from articulation space 20
and separated by
shoulders 27 and 28, as shown, receptacle 23 has a portion that is open to and
in communication
with articulation space 20. The hooking track 7 of an adjacent slat 1 cannot
enter the gap
between first shoulder 27 and second shoulder 28 and cannot be retained in
receptacle 23.
Although receptacle 23 is in open communication with articulation space 20,
receptacle 23 is
protected from the collection of dirt and grime by lip member 10 and guard
member 11, and by
the hooking track 7 of an adjacent slat 1. If desired, it is understood that
receptacle 23 may be
completely separated from articulation space 20. In such an embodiment,
articulating surfaces
16 and 18 would be connected at shoulders 27 and 28 to provide a single,
continuous articulating
surface for the hooking track 7 of a second slat 1.
[0046] FIG. 5 shows an elevation of a plurality of shutter slats 1
according to the present
invention, articulated into a rolling shutter 9 which may be installed on a
building aperture such
as a window or door. Details of the building aperture are not illustrated for
the sake of clarity.
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The building aperture is further equipped with shutter casing 12 and a pair of
guides 13 and 14,
located on opposite lateral edges of the building aperture. Rolling shutter 9
may be rolled up for
storage within shutter casing 12. The first and second ends 15 and 16 of slat
1, as shown in FIG.
2, are adjacent guides 13 and 14. Retention screw 29 provides for secure
alignment of ends 15
and 16 with guides 13 and 14.
[0047] FIG. 6 is a partial sectional view taken along lines A-A of FIG. 5.
A shutter slat 1
is shown in combination with a guide 13 and a retention screw 29. Retention
screw 29 is
preferably inserted in receptacle 23 of shutter slat 1 for use with guide 13.
The head 44 of the
retention screw 29 protrudes from receptacle 23 and slides within vertical
guide 13 provided at
the end of rolling shutter 9. In this illustrative embodiment, retention screw
29 does not restrict
the rotation or pivoting of hooking track 7 within receiving track 8. As
illustrated, for
minimization of the rolling shutter, the diameter of the head 44 of retention
screw 29 is not larger
than the external profile of receiving track 8. Because of the space between
head 44 of screw 29
and first end 15 of slat 1, the receiving track 8 of one slat 1 may slide
horizontally with respect to
the hooking track 7 of another slat 1. The amount of horizontal sliding may be
limited in part by
the space between head 44 of screw 29 and first end 15 of slat 1 or by the
configuration of guides
13 and 14. An extended screw (not shown) with an extension member may be used
in place of
screw 29. The extension member of an extended screw is longer than head 44 of
screw 29 and is
better adapted to retain rolling shutter 9 within guides 13 and 14 during
either an attempted break
in or extreme wind conditions. An example of an extended screw is disclosed in
U.S. Pat. No.
7,784,522.
[0048] FIG. 7 is a side view showing the cooperation of two slats la and lb
according to
the present invention, and FIG. 8 is a detailed view of the cooperation of
receiving track 8 of slat
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la and hooking track 7 of slat lb. Both FIG. 7 and FIG. 8 show slats la and lb
engaging when
the shutter slats are in an open position. As shown in FIG. 7, the bottom slat
lb is in a vertical
position, i.e. the position as in an open shutter, with the vertical axis 59
of slat la substantially
or completely in line with vertical axis 60 of slat lb. There is very little
clearance space
provided between slats. Still, bottom slat lb can articulate in a clockwise
direction.
[0049] As shown in FIG. 8, hooking track 7 of slat lb is slidably engaged
with receiving
track 8 of slat la to form a hinge between slats la and lb. The outer surface
31 of hook 30 of
slat lb is convex and seats against the articulating lip surface 16 of lip
member 10 and the
articulating guard surface 18 of guard member 11 of slat la. Tip 33 of hook 30
of slat lb also
seats against articulating lip surface 16 of lip member 10 of slat la. Lip
member 10 of slat la
retains hook 30 of slat lb in articulation space 20. Tip 25 of lip member 10
of slat 1 a extends
into a space defined by hook 30 of slat lb. Tip 25 of lip member 10 of slat la
also curls into
articulation space 20, providing additional security to the hinge formed by
hooking track 7 of slat
lb and receiving track 8 of slat la.
[0050] Guard member 11 shields the connection of hooking track 7 of slat lb
with lip
member 10 of slat la, preventing hooking track 7 of slat lb from disengaging
from receiving
track 8 of slat la. Guard member 11 also protects hooking track 7 of slat lb
and lip member 10
of slat la from exposure to forces applied to the outward facing sides 2 of
slats la and b. In the
open position, the weight bearing portion of receiving track 8 is lip member
10. Because
hooking track 7 of slat lb does not bear directly upon guard member 11 of slat
la, damage to the
outward facing side 2 of slat la, and to guard member 11 of slat la, is less
likely to disengage the
articulation between slats la and 2b than in prior art shutters in which an
exposed portion of the
lower track was weight bearing.
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[0051] One advantage to the design of lip member 10 and guard member 11 is
that slats
la and lb do not retain water in the hinge formed by hooking track 7 of slat
lb and receiving
track 8 of slat la. Lip member 10 of slat la, at its lowest point, is
horizontally displaced from
the intersection of body portion 4 and hooking track 7 of slat lb. The
intersection of body
portion 4 and hooking track 7 of slat lb is a smooth transition. This design
allows water to flow
cleanly from lip member 10 of slat la without draining into the hinge formed
by the intersection
of slats la and lb.
[0052] Slat 1 does not require a protrusion to prevent excessive
articulation. With slat 1,
guard member 11 is thickened in comparison to prior art slats. The thickness
of guard member
11 and the shape of lip member 10 prevent slat 1 from excessive articulation,
and there is no
need for a protrusion on hooking member 7. Without a protrusion, there is no
channel to retain
water that drips off lip member 10. If water were to be retained, it could
freeze and damage the
hinge.
[0053] FIG. 9 is a side view showing the cooperation of two slats lc and ld
engaging
when the slats are in a closed position. As shown, tip 25 of lip member 10 of
slat 1 c lies flush
against inner surface 32 of hook 30 of slat Id, and body portions 4 of slats
lc and Id form a
substantially circular arc when the slats are in a fully closed position. This
arc allows an initial
subassembly of slats 1 of a rolling shutter 9 to lie substantially flush
against spindle 19 when the
slats are in a fully closed position, and allows subsequent subassemblies of
slats.] to form similar
arcs around the initial subassembly and around other subassemblies. Those
skilled in the art will
understand that it may be advantageous to alter the arcs of the slats as the
distance between the
slats and the spindle increases to minimize the overall space needed for the
rolling shutter 9 in its
fully closed position.
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[0054] The shape of guard member 11 further minimizes the overall radius of
a rolling
shutter 9 of slats 1 when the shutter is in a closed position. As set out
above, guard member 11 is
shorter and thicker than prior art slats, and the lowest point of guard member
11 is above the
lowest point of lip member 10 when slat 1 is in a vertical position. As shown
in FIG. 9, when
slats lc and id are in a closed position, guard member 11 of slat lc, at its
furthest point from the
center 65 of spindle 19, is located approximately the same distance from the
center 65 of spindle
19 as hooking track 7 of slat id at its furthest point from the center 65 of
spindle 19. This
configuration minimizes the overall radius of a rolling shutter 9 of slats 1
when the shutter is in a
closed position by minimizing the overall radius taken up by each subassembly
of slats circling
spindle 19. The outer surface of guard 11, furthermore, is formed to be
substantially parallel to
the curvature of the body, thereby reducing the overall radius of the rolled
up shutter slat.
[0055] In a preferred embodiment, the slat is provided with a bend or
indent between the
hooking track and the body of the slat. As best shown in FIG. 3, slat 1 has a
bend between the
body 4 and hooking track 7, at the first edge 5. The bend allows the hinge
between adjacent slats
to form a smooth transition. For example, FIGs. 7 and 8 show a hinge between
the slats 1a and
lb in the vertical position. When the hooking track 7 of a slat lb is engaged
in the receiving
track 8 of a slat la, the bend permits a smooth transition to be formed
between the outer surface
31 of hook 30 and the outer guard surface 17 of the guard member 11. This
smooth transition is
believed to allow water to flow cleanly over the hinge, without collecting and
draining into the
hinge. It has further been found that the more acute the angle of the bend,
the more effective in
reducing the infiltration of water into the hinge.
[0056] In some slat configurations, the presence of a bend between the body
and hooking
track can interfere with the ability to minimize the space required to retract
the rolling shutter
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into a fully closed position. For example, FIG. 10 shows slats 1 with a
hooking track 7 and a
receiving track 8 that project above the convex curvature of the body 4 of the
slat -- i.e. projects
from the outward facing side 2. The engagement of the hooking track 7 and
receiving track 8
forms a hinge 62 that projects above the common convex curvature of the slats
1, and creates
gaps 64 between the bodies 4 of adjacent slats in successive windings. These
gaps interfere with
a compact fit when the shutter is rolled into a retracted or a fully closed
position.
[0057] It has been found that the space required for the rolling shutter in
the retracted
position can be minimized without sacrificing the bend between the body and
hooking track, by
forming the slat with a receiving track that projects below the concave
curvature of the body of
the slat -- i.e. projects from the inward facing side. Referring to FIGs. 11
and 12, an alternative
embodiment of a slat is shown having a receiving track with a lip member that
projects below the
concave curvature of the inward facing side of the body. The guard member of
the receiving
track extends along the curvature of the body.
[0058] As shown in FIG. 11, slat 100 has a body 104 with a first edge 105
and a second
edge 106 opposite the first edge. Body 104 has a curvature with a radius of
curvature 151, a
convex outward facing side 102 and a concave inward facing side 103. A hooking
track 107 is
connected to the body 104 at the first edge 105, and a receiving track 108 is
connected to the
body at the second edge 106.
[0059] Receiving track 108 includes a lip member 110, a guard member 111,
and an
articulation space 120. Lip member 110 comprises a base 168 that is adjacent
to the end 106 of
body 104, and an outer lip wall 140. Lip member 110 projects below the concave
inward facing
side 103 of body 104 by a height 166. Guard member 111 extends along the
curvature of body
104. Articulation space 120 is in communication with an aperture 122 that is
defined between
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lip member 110 and guard member 111. Articulation space 120 is sized and
shaped to hingedly
engage the hooking track 107. Receiving track 108 may also include a
receptacle 123 defined
between the lip member 110 and guard member 111, that is sized and shaped to
receive a
retention or alignment device (not shown) as previously described.
[0060] Hooking track 107 comprises a hook 130 with an outer surface 131, an
inner
surface 132, a base 170 adjacent to end 105 of body 104, and a tip 133. Hook
130 is sized and
shaped to be substantially similar to the size and shape of articulation space
120 of receiving
track 108. A bend 172 having an interior angle 174 is formed between hooking
track 107 and
body 104. Bend 172 causes hooking track 107 to project above the convex
outward facing side
102 of body 104 by a height 176.
[0061] FIGs. 12 and 13 show a rolling shutter in a retracted position, that
comprises a
plurality of slats 100 forming a chain extending from a spindle 119. The
hooking track 107 of
each successive slat 100 is hingedly engaged in the receiving track 108 of the
preceding slat 100
in the chain. In the retracted position, the chain of slats is wound about
spindle 119 in a series of
windings that are increasingly distal to the spindle.
[0062] An example of a single winding is shown by the slats 100a, 100b,
100c, 100d and
100e -- i.e. where slat 100a is the initial slat in the winding positioned
closest to the spindle, slat
100e is the last slat in the winding positioned furthest from the spindle, and
slats 100b, 100c and
100d are intermediate slats positioned between the initial and last slats 100a
and 100e. As shown
in FIG. 13, the hooking track 107a of the initial slat 100a is positioned
adjacent to the receiving
track 108e of the last slat 100e. In addition, the body 104e of the last slat
100e overlaps the
hooking track 107a of the initial slat 100a. Conversely, the body 104a of the
first slat 100a
underlaps the receiving track 108e of the last slat 100e. Similarly, the
intermediate slats 100b,
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100c and 100d have hooking tracks 107 that are positioned adjacent to the
receiving tracks 108
and are overlapped by the bodies 104 of the slats in the successive winding,
and have bodies 104
that underlap the receiving tracks 108 of the slats in the successive winding.
[0063] To minimize the space required in the retracted position, slat 100
may be
configured with a receiving track 108 having a lip member 110 that projects
below (inward) the
concave side 103 of body 104 at a height 166 that is approximately the same as
the height 176
that the hooking track 107 projects above (outward) the convex side 102 of the
body 104. The
guard member 111 of the receiving track 108 has a curvature that extends along
the curvature of
body 104, and the outer wall 140 of the lip member 110 of receiving track 108
may also have a
curvature that is the same or approximately the same as the curvature of body
104. In addition,
the base 168 of the receiving track 108 adjacent to the end 106 of body 104
may be sized and
shaped to be complementary to the size and shape of the base 170 of the
hooking track 107
adjacent to the end 105 of body 104.
[0064] As discussed above, the curvature and vertical height of the body
104 may be
varied to minimize the space required by the rolling shutter in the retracted
position. As is
apparent in FIG. 12, the radius and circumference of each successive winding
increases the
further away from the spindle. Thus the radius 151 of the curvature of slats
100 may increase the
further away from the spindle 119 -- i.e. the radius of curvature of the body
104 of a slat
proximal to the spindle may be shorter than the radius of a slat distal to the
spindle. Similarly,
height of slats 100 may increase the further away from the spindle 119 --
i.e., the height between
ends 105 and 106 of the body 104 of a slat proximal to the spindle may be
shorter than the height
of a slat distal to the spindle.
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[0065] In another embodiment, the interior angle 174 of the bend 172 may
vary between
slats in a rolling shutter. Those of skill in the art will appreciate that, as
the radius 151 of the
curvature of the body 104 increases, the interior angle 174 of the bend 172
may also increase to
accommodate the flatter curvature of the body and minimize any gap between the
bodies of
adjacent slats in successive windings. Thus, the interior angle 174 of the
bend 172 of a slat 100
proximal to the spindle 119 may be smaller than the interior angle of a slat
distal to the spindle.
[0066] In a further embodiment, each winding of the rolling shutter in the
retracted
position has the same number of slats. In the embodiment of FIG. 12, each
winding comprises 5
slats, where each of the hinges 162 is seated against a preceding hinge to
form a compact roll.
[0067] In addition to minimizing the space required in a retracted
position, these
embodiments are believed to provide further advantages. As discussed above,
the receiving
track 108 may have a guard member 111 with a curvature that is the same or
similar to the
curvature of body 104, and with a lip member that 110 that projects below the
concave inward
facing side 103 of the body. This configuration minimizes the profile of the
hinge 162 on the
convex outward facing side and smooths the transition between engaged shutter
slats 100, which
allows water to flow more cleanly off the exterior surface of the rolling
shutter, and reduces any
projecting surfaces where water may collect and drain into the hinge. The
minimal profile of the
hinge 162 also reduces the exposure of the receiving track 108 and hooking
track 107 on the
exterior outward facing side 102 of the rolling shutter, which may otherwise
provide a weak
point to force apart the engaged shutter slats. The engagement of the
receiving track 108 and
hooking track 107 is moved to the interior side 103 of the rolling shutter,
allowing the guard
member 111 to more effectively protect the hooking track from forces applied
to the outward
facing sides 102 of the shutter slats.
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[0068] In yet another embodiment, the slat may be configured to further
minimize the
profile of the hinge 262. Figures 14 and 15 show a slat 200 with a body 204, a
hooking track
207 and a receiving track 208. Body 204 has a convex outward facing surface
202 with a
curvature having a radius 251. Receiving track 208 has a guard member 211 with
an outer guard
surface 217 that generally extends along the curvature of outward facing
surface 202 of body
204. Thus, outer guard surface 217 and outward facing surface 202 form a
surface with a
generally continuous curvature, which further minimizes the profile of the
outward facing
surface of the hinge 262.
[0069] In a preferred embodiment, the hooking track 207 is also sized and
shaped to
minimize the profile of the outward facing surface of hinge 262. As best shown
in FIG. 15,
when adjacent slats are in the vertical position, the outer surface 231 of
hooking track 207 does
not generally project beyond a tangent (plane) 264 to the outer guard surface
217 of the receiving
track 208. More preferably, when hooking track 207 is engaged in receiving
track 208, the outer
surface 231 and outer guard surface 217 form a hinge surface that extends
along the curvature of
outward facing surface 202. Thus, the hinge surface and outward facing surface
202 form a
surface with a generally continuous curvature. Consequently, when adjacent
slats are in the
vertical position, the junction between the two slats is essentially the
intersection between the
curvatures 251 of the outward facing sides 202 of the two shutter slats. This
configuration is also
shown by the adjacent vertical slats in FIG. 12.
[0070] The following examples are included to demonstrate preferred
embodiments of
the invention. It should be appreciated by those of skill in the art that the
techniques disclosed in
the examples which follow represent techniques discovered by the inventors to
function well in
the practice of the invention, and thus can be considered to constitute
preferred modes for its
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practice. However, those of skill in the art should, in light of the present
disclosure, appreciate
that many changes can be made in the specific embodiments which are disclosed
and still obtain
a like or similar result without departing from the scope of the invention.
[0071] Shutter slats with different designs were tested for resistance to
water intrusion.
Shutter Slat A has a conventional slat design, with a receiving track that
projects from the
convex outward facing side of the slat. Shutter Slat B has a slat design
similar to that shown in
FIGs. 11 and 14, as discussed above.
[0072] Testing was performed by mounting a shutter in a vertical frame or
buck, as
shown in FIG. 16. The hinges between adjacent slats of the shutter were
compressed by the
weight of the shutter. A spray rack was positioned on the exterior side of the
shutter, with
multiple spray nozzles directed toward the convex outward facing side of the
slats. The spray
nozzles were centered on the hinges, with a spray angle of 0 , +45 or -45
from horizontal.
Water was sprayed against the shutter for a period of 10 minutes, at a flow
rate of either 3, 4 or 5
gpm (gallons per minute). A catch trough was positioned on the interior side
of the shutter, at
the bottom of the shutter to measure the amount of water (ml) that penetrated
through the hinge
from the exterior side.
Table 1: Water Intrusion Results
0 Spray Angle +45 Spray Angle -45 Spray Angle
gpm 4 gpm 3 gpm 5 gpm 4 gpm 3 gpm 5 gpm 4 gpm 3 gpm
Slat A 20 ml NM 0 ml NM 0 ml 0 ml 0 ml 0 ml 0 ml
Slat B 0m1 0 ml 0 ml 0m1 0 ml 0 ml 0m1 0 ml 0 ml
[0073] The results of the water intrusion testing is shown in Table 1.
Significant
amounts of water were found to penetrate the conventional shutter design Slat
A at 5 gpm with a
0 spray angle. Immediate, steady drips from multiple hinges were observed, as
shown in FIG.
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17. Slow drips from a single hinge producing non-measurable (NM) amounts of
water were also
observed at 4 gpm with a 0 spray angle, and at 5 gpm with a +450 spray angle.
In contrast, no
water was found to penetrate the shutter design Slat B under any conditions,
as shown in FIG.
18.
100741 Modifications in addition to those described above may be made to
the structures
and techniques described herein without departing from the spirit and scope of
the invention.
Accordingly, although specific embodiments have been described, these are
examples only and
are not limiting on the scope of the invention.
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