Build-Out Dowel Mounting for Rolling Shutters on Uneven Walls
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Solution Overview
Problem
Existing methods for installing rolling protective shutters on uneven exterior surfaces compromise the structural integrity and require significant time and effort, as they often necessitate cutting or piercing materials like siding, which can lead to vulnerability and damage.
Innovation Solution
The use of build-out dowels that are inserted through holes in the external protective surface, allowing for secure attachment of the shutter assembly without damaging the surface, by providing a support mechanism that aligns with the underlying subsurface and support structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mounting methods are used to secure rolling shutters on uneven exterior surfaces, then the shutter can be attached to the structure, but the external protective surface material must be cut into or penetrated significantly, which damages the structure and requires time-consuming repairs
Solution Approach 1:
The patent introduces a mounting plate as an intermediary component between the shutter and the exterior surface. The mounting plate is inserted into a cavity formed by the uneven exterior surface (such as between siding and sheathing) and secured with fasteners, while the shutter is then attached to the mounting plate. This intermediary approach allows secure shutter attachment without cutting into or damaging the external protective surface material.
2Reliability
If conventional mounting methods are used to secure rolling shutters on uneven exterior surfaces, then the shutter can be attached to the structure, but the installation process becomes time-consuming and expensive due to surface preparation and repair requirements
Solution Approach 1:
The mounting plate serves as a pre-fabricated intermediary component that is designed to fit within cavities created by typical uneven exterior surfaces. By inserting the mounting plate into these existing cavities and securing it with fasteners, the installation process bypasses the need for time-consuming surface preparation, cutting, and repair work, significantly reducing installation time while maintaining secure attachment.
3Ease of manufacture
If the shutter is mounted flush against the uneven exterior surface, then the attachment can be simplified, but the shutter cannot be properly positioned or secured without cutting into the surface material
Solution Approach 1:
The mounting plate acts as an intermediary that eliminates the need for the shutter to be mounted flush against the uneven exterior surface. The mounting plate is positioned within the cavity formed by the exterior surface layers, and the shutter is attached to the mounting plate, which provides a stable mounting surface without requiring cuts into the protective surface material.
4Strength
If fasteners are used to penetrate the external protective surface to secure the shutter, then the shutter can be anchored to the subsurface structure, but the external protective surface is compromised and requires repair
Solution Approach 1:
The mounting plate serves as an intermediary that redirects the anchoring function away from the external protective surface. Fasteners penetrate the mounting plate and engage with the subsurface structure (such as sheathing or framing) within the cavity, while the mounting plate itself protects the exterior surface material from direct fastener penetration, eliminating the need for surface repairs.
Data Source
AI summary
An improvement in a rolling shutter assembly for covering an opening of a structure having an external protective surface, an underlying support structure and a subsurface disposed therebetween. The rolling shutter assembly includes a shutter housing, a shutter support member rotatably disposed within the shutter housing, a shutter coupled to the shutter support member, and a pair of side tracks. The improvement includes a plurality of dowels and corresponding openings through the external protective surface configured to receive the dowels. The dowels are disposed between the subsurface of the wall and the side tracks when the rolling shutter assembly is installed to minimize the portion of the external protective surface that is removed to accommodate the installation of the shutter assembly.