Adjustable shutter frame rail

Abstract

An Adjustable Shutter Frame Rail An adjustable shutter frame rail including a frame body and a cover member; wherein the frame body defines a length and includes a pair of opposed spaced apart side walls which define a channel along the length of the body that is open at one end; the cover member selectively closes the open end of the channel; each of the side walls includes or defines a plurality of first engagement elements; the cover member includes or defines one or more second engagement elements; and the cover member is coupled to the frame body via interengagement of the or each second engagement element with one or more respective first engagement elements.

Description

[0001] Adjustable Shutter Frame Rail

[0002] The present invention relates to shutter frames which include one or more height-adjustable rails.

[0003] Shutter assemblies for windows are typically bespoke for each window to which they are secured. This is because the louvres and frame components tend to have a fixed size so variations in the height of the window must be accommodated by varying the pitch (distance) between adjacent louvres. Thus, the pitch of the louvres must be determined and then the relevant holes to accommodate the louvres must be drilled precisely in the side members (stiles) of the louvre shutter frame. This is a complex and time-consuming process which makes the shutters relatively expensive to produce.

[0004] CA2269433 discloses an adjustable decorative shutter frame.

[0005] It is therefore desirable to produce louvre shutters that are easier and cheaper to manufacture.

[0006] One method of achieving this goal is to make at least one of the rails of the shutter frame height- adjustable. In other words, at least one of the rails of the shutter frame may be cut to the desired size without impacting its ability to function as a shutter frame rail.

[0007] According to a first aspect of the invention, there is provided an adjustable shutter frame rail including a frame body and a cover member; wherein the frame body defines a length and includes a pair of opposed spaced apart side walls which define a channel along the length of the body that is open at one end (i.e., its top end or its bottom end); the cover member selectively closes the open end of the channel; each of the side walls includes or defines a plurality of first engagement elements; the cover member includes or defines one or more second engagement elements; and the cover member is coupled to the frame body via interengagement of the or each second engagement element with one or more respective first engagement elements.

[0008] The invention provides a two-part shutter frame rail where one of the parts is coupled to the other of the parts. In this way, the frame body may be cut to the desired size and the cover member may then be attached to the remaining frame body. Thus, a dimension of the frame body (e.g., a height dimension) may be adjusted without impacting the ability of the frame rail to function as a frame rail. Accordingly, the invention allows for the pitch of the louvres to be fixed, which in turn allows for the side stiles to have standardised pre-drilled holes to receive therein the louvres and / or for the use of a standard jig to cut the desired holes.

[0009] In an embodiment of the invention, the channel is open along its entire length. Thus, the top of the channel or the bottom of the channel may be open along the entire length of the frame body.

[0010] In an embodiment of the invention, each of the side walls defines an open end and an opposed closed end. The cover member is detachably coupled to the open ends of the side walls to selectively close the open end of the channel. For example, each of the side walls may include a first end (open end) and a second end (closed end); and wherein the frame body includes a base wall which joins the second (closed) end of a first side wall to the corresponding second (closed) end of a second side wall. Thus, the frame body may be substantially U-shaped. In such embodiments, the frame body is open at its first end. The opening is selectively closed by the cover member. Accordingly, the cover member may connect the first end of the first wall to the first end of the second wall.

[0011] It will be appreciated that each of the side walls may be cut down to the desired size. In other words, the height of each side wall (i.e., the distance by which each side wall extends from its first end to its second) may be adjusted as desired.

[0012] In a further embodiment of the invention, the frame body defines a longitudinal axis, which is parallel to the length dimension, and each of the first engagement elements extends parallel to the longitudinal axis. By having the first engagement elements extend parallel to the longitudinal axis, the side walls may be cut parallel to the longitudinal axis without impacting the remaining first engagement elements.

[0013] Suitably, each of the first engagement elements are spaced from adjacent engagement elements in a height direction (i.e., from the first end of the respective side wall to the second end of the respective side wall or vice versa). In this way, the height of each side wall may be reduced whilst still leaving one or more first engagement elements on the side wall. It will be appreciated that the number of first engagement elements provided on each side wall will determine a maximum reduction that can be made to the height of the side wall, as at least one first engagement element must remain on each of the side walls to enable the coupling of the cover member to the frame body.

[0014] In a further embodiment of the invention, a pair of adjacent first engagement elements defines therebetween a channel. The channel may receive therein a respective second engagement element. For example, the or each second engagement element may be an elongate element, such as a rib, which is sized to be received within the channel defined by the adjacent first engagement elements. The first engagement elements may be elongate rails that define between them respective channels. The rails may have a rectangular cross-section, a triangular cross-section or an arcuate cross-section. As the second engagement element may form a snap-fit coupling within a respective channel, the rails suitably have a triangular or arcuate cross-section such that the side walls may be urged apart to permit the second engagement element to be received within the channel. Thus, the engagement of the second engagement element(s) with the respective first engagement elements may cause the side walls to be deflected outwards.

[0015] In a further embodiment of the invention, each side wall defines an outwardly facing surface and an inwardly facing surface (i.e., a surface which faces the opposing side wall). Suitably, the first engagement elements as defined anywhere herein are provided on the inwardly facing surface of each side wall.

[0016] Suitably, the cover member defines a pair of opposed elongate longitudinal channels, wherein each channel is defined by an outer wall and an inner wall. The inner wall may carry the or each second engagement element. The outer wall may engage the outwardly facing surface of the respective side wall. Thus, a portion of each side wall may be disposed within a respective one of the cover member channels when the cover member is engaged with the frame body.

[0017] According to a second aspect of the invention, there is provided a method of adjusting the height of a shutter frame rail, the method comprising: providing an adjustable shutter frame rail according to the first aspect of the invention as defined anywhere herein; cutting each side wall of the frame body along its longitudinal axis to provide side walls having the desired height; and coupling the cover member to the frame body. Thus, the longitudinal cut may be made between the first end of the side wall and the second end of the side wall. In this way, the height of the channel is reduced, but the channel retains an open end. According to the third aspect of the invention, there is provided a shutter frame comprising a pair of opposed stiles; a first rail which connects a first end of one of the stiles to a first end of the other stile; and a second rail which connects a second end of one of the stiles to a second end of the other stile; wherein at least one of the first and second rail is an adjustable shutter frame rail according to the first aspect of the invention as defined anywhere herein.

[0018] In an embodiment of the third aspect of the invention, both the first and second rails are an adjustable shutter frame rail according to the first aspect of the invention as defined anywhere herein.

[0019] According to a fourth aspect of the invention, there is provided a shutter assembly including a shutter frame according to the third aspect of the invention; and a plurality of louvres disposed within the frame. The louvres are suitably disposed between the opposed stiles of the frame. For example, each louvre may define a longitudinal axis and the longitudinal axes of the louvres may be parallel to each other and the longitudinal axes of the first and second rails. Optionally, each of the louvres rotates about its longitudinal axis.

[0020] The skilled person will appreciate that the features described and defined in connection with the aspects of the invention and the embodiments thereof may be combined in any combination, regardless of whether the specific combination is expressly mentioned herein. Thus, all such combinations are considered to be made available to the skilled person.

[0021] An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0022] Figures la and lb show an adjustable shutter frame rail according to the first aspect of the invention in a fully intact configuration;

[0023] Figures 2a and 2b show the shutter frame rail as shown in Figure 1 with the opposed side walls cut down to reduce the height of the rail; and

[0024] Figures 3a and 3b show a shutter assembly according to the fourth aspect of the invention which includes the shutter frame rail shown in Figures 2a and 2b. For the avoidance of doubt, the skilled person will appreciate that in this specification, the terms "up", "down", "front", "rear", "upper", "lower", "width", etc. refer to the orientation of the components as found in the example when installed for normal use as shown in the Figures.

[0025] Figures la and lb show an adjustable shutter frame rail 2 which comprises a frame body 4 and a cover member 6.

[0026] The frame body 4 is formed from a pair of opposed side walls 8, 10 which are joined by a curved base wall 12. Each of the side walls 8, 10 defines a distal portion at the opposite end to curved base wall 12.

[0027] Three reinforcing struts 14, 16, 18 are disposed between the opposed side walls.

[0028] Along the inwardly facing surface of the distal portion of each of the side walls 8, 10 is provided a number of spaced apart elongate frame ribs 20. The frame ribs 20 extend the entire length of the frame body 4 and are formed when the frame body 4 is extruded. The frame ribs 20 are parallel to each other and to a longitudinal axis defined by the frame body 4.

[0029] Each of the frame ribs 20 has a triangular cross-section and is spaced from its neighbour to define a channel therebetween.

[0030] The cover member 6 comprises a substantially planar portion 22 with a pair of downwardly depending side edge portions 24a, 24b (or upstanding side edge portions if the rail 2 is a bottom rail and is rotated through 180° about its longitudinal axis). Spaced inwardly from each side edge portion 24a, 24b is an engagement wall 26a, 26b. Each of the engagement walls defines a pair of spaced apart elongate cover ribs 28. As with the frame ribs 20, the cover ribs 28 extend the entire length of the respective engagement wall 26a, 26b, which in turn extend the entire length of the cover member 6. The engagement walls 26a, 26b and the associated cover ribs 28 are formed when the cover member 6 is extruded. The cover ribs 28 are parallel to each other and to the longitudinal axis defined by the frame body 4.

[0031] Each of the cover ribs 28 also has a triangular cross-section and is spaced from its neighbour to define a channel therebetween. As shown in Figures la and lb, each of the cover ribs 28 is disposed in a gap between a pair of adjacent frame ribs 20, and a frame rib 20 is disposed between the two adjacent cover ribs 28 to form a snap-fit arrangement between the cover member 6 and the distal portion of the frame body 4.

[0032] As shown in Figure lb, a gap defined between the top of the cover member 6 and then proximal end of the side walls 8, 10 has a length di.

[0033] However, an noted hereinabove, it may be desired to reduce the height of the shutter frame rail 2 to maintain a fixed louvre pitch of a shutter assembly (shown in Figures 3a, 3b).

[0034] Figures 2a and 2b show the shutter frame rail 2 shown in Figures la and lb where the height of the side walls 8, 10 has been reduced. In order to achieve this, a user cuts each side wall 8, 10 along a line parallel to the longitudinal axis in the distal portion of the side walls 8, 10.

[0035] As shown in Figure 2b, the height of the side walls has been reduced such that the gap defined between the top of the cover member 6 and then proximal end of the side walls 8, 10 has a length d2, which is less than di.

[0036] However, there are sufficient frame ribs 20 remaining to form the snap-fit coupling between the frame body 4 and the cover member 6 as described above.

[0037] Figures 3a and 3b show a shutter assembly 30 which comprises a top shutter frame rail 2 as described above, a pair of opposed stiles (side rails) 32, 34 and a bottom shutter frame rail 36. The shutter assembly 30 further includes a central reinforcing strut 38.

[0038] As is conventional for shutter assemblies, a plurality of horizontally arranged louvres 40 are disposed between the opposing stiles 32, 34 and each louvre 40 rotates relative to the stiles about its longitudinal axis. Also conventionally, the group of louvres 40 above the central reinforcing strut 38 and the group of louvres below the central reinforcing strut are coupled together via respective operating rods 42. The arrangement of the louvres 40 and the operating rods 42 are both well known and need not be described herein in detail. The curved base wall 12 has a curvature which received therein a front edge portion or a rear edge portion of the top louvre 40. This prevents light strike between the top shutter frame rail 2 and the top louvre 40 when the louvres are in a closed configuration. The louvres have a fixed louvre pitch, as the height of the top rail 2 is adjusted to fit the shutter assembly 30 to the window or door to which it is to be secured.

Claims

Claims1. An adjustable shutter frame rail including a frame body and a cover member; wherein the frame body defines a length and includes a pair of opposed spaced apart side walls which define a channel along the length of the frame body that is open at one end; the cover member selectively closes the open end of the channel; each of the side walls includes or defines a plurality of first engagement elements; the cover member includes or defines one or more second engagement elements; and the cover member is coupled to the frame body via interengagement of the or each second engagement element with one or more respective first engagement elements.

2. An adjustable shutter frame rail according to Claim 1, wherein the channel is open along the entirety of its length.

3. An adjustable shutter frame rail according to Claim 1 or Claim 2, wherein each of the side walls includes a closed end opposite to the open end; and wherein the frame body includes a base wall which joins the closed end of a first side wall to the corresponding closed end of a second side wall.

4. An adjustable shutter frame rail according to Claim 3, wherein the cover member connects the open end of the first wall to the open end of the second wall.

5. An adjustable shutter frame rail according to any of Claims 1 to 4, wherein the frame body defines a longitudinal axis and each of the first engagement elements extends parallel to the longitudinal axis.

6. An adjustable shutter frame rail according to Claim 5, wherein each of the first engagement elements are spaced from adjacent engagement elements in a height direction.

7. An adjustable shutter frame rail according to any of Claims 1 to 6, wherein a pair of adjacent first engagement elements defines therebetween a channel; and the or each second engagement element is a rib which is sized to be received within the channel.

8. An adjustable shutter frame rail according to any of Claims 1 to 7, wherein each side wall defines an outwardly facing surface and an inwardly facing surface; and the first engagement elements are provided on the inwardly facing surface of each side wall.

9. An adjustable shutter frame rail according to any of Claims 1 to 8, wherein the cover member defines a pair of opposed elongate longitudinal channels, wherein each channel is defined by an outer wall and an inner wall.

10. A shutter frame comprising a pair of opposed stiles; a first rail which connects a first end of one of the stiles to a first end of the other stile; and a second rail which connects a second end of one of the stiles to a second end of the other stile; wherein at least one of the first and second rail is an adjustable shutter frame rail according to any of Claims 1 to 9.

11. A shutter frame according to Claim 10, wherein both the first and second rails are an adjustable shutter frame rail according to any of Claims 1 to 9.

12. A shutter assembly including a shutter frame according to Claim 10 or Claim 11; and a plurality of louvres disposed within the frame.

13. A shutter assembly according to Claim 12, wherein each of the louvres are rotatably coupled between the opposed stiles.

14. A shutter assembly according to Claim 13, wherein the louvres are arranged to be parallel to the first and second rails.

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