AU2015210490A1 - Retention system for a roller shutter - Google Patents

Abstract

A side track for a roller shutter that can accommodate changes in angle at the time of installation and still provide a secure and resilient channel to securely and effectively hold the roller shutter in place, in line with the track. The side track includes an outer side track portion having a longitudinal channel defined by a pair of substantially parallel side walls and an end wall and a inner side track portion having a longitudinal guide channel defined by pair of substantially parallel side walls and an end wall wherein the inner side track portion resides within the channel of the outer side track portion.

Description

1 FIELD OF THE INVENTION The present invention relates to a support and retention arrangement for securing a plurality of pivotally connected slats forming a roller shutter. BACKGROUND Roller shutters are conventionally used to provide protection to a building or house against extreme weather conditions as well as to entry by intruders. In a conventional roller shutter system a portion of the shutter arrangement, a number of the individual slat elements that make up the shutter have end caps fitted to them and the end cap resides in a side track section positioned within a window or door opening, with the individual shutter elements moving up and down alongside the side track. The end caps is attached to an individual shutter element or slat and profiled so that they can be inserted through an upper opening of the side track and guide the slats between an open and closed position and it is the side track that is responsible for restricting the movement of the horizontal slats of the roller shutter system to movement either by extreme weather events, such as wind, or forceful opening by an intruder such as when using a prying bar. In the conventional arrangement of roller shutters slats (Figure 1, US5253694), the end cap resides in the single side guide track that bears all the force of any movement and as the side track within which the end cap resides is typically securely fixed into the side of the dwelling then external forces onto the horizontal slats result in high forces being applied to the end caps in the side track and this can result in the horizontal slat being removed from the side track with relatively little force. In addition, due to the loose fit of end caps in conventional side track arrangements there can be an excessive amount of play or movement of the horizontal slats resulting in an increase in the noise of the slats when it is windy. The excessive noise created from poor or overly loose fitting of the end caps in the side track can have a detrimental effect on the usage of the 2 roller shutters with some users electing to avoid the noise by keeping their roller shutter in an open configuration, that is rolled up and hidden in the pelmet above the opening so that there is less noise during windy times. Another issue faced with conventional roller shutter arrangements is that during installation of the roller shutter side tracks in a window or door opening, care must be taken to ensure that the vertically orientated side tracks are both substantially parallel and aligned with each other along their lengths to ensure smooth and reliable movement of the horizontal slats from the open to the closed position. Problems however can arise when the window or door opening itself is either slightly wider than originally desired or where the vertical sides of the window or door opening are not substantially parallel in which case when the conventional side tracks are fitted then additional filling material between the side track and the window or door opening are required to fill any undesired openings or alternatively in order to accommodate irregularities in the dimensions of the door or window opening it is not uncommon for installers to position the side track at an angle, which can result in the movement of the roller shutter system being restricted at some point. OBJECT OF THE INVENTION It is an object of the present invention to provide a roller shutter with increased retention and/or security of the slats. It is an object of the present invention to overcome, or at least substantially ameliorate, the disadvantages and shortcomings of the prior art. Other objects and advantages of the present invention will become apparent from the following description, taking in connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed. SUMMARY OF THE INVENTION 3 According to the present invention, although this should not be seen as limiting the invention in any way, there is provided a roller shutter side track including a outer side track portion having a longitudinal channel defined by a pair of substantially parallel side walls and an end wall and a inner side track portion having a longitudinal guide channel defined by pair of substantially parallel side walls and an end wall wherein the inner side track portion resides within the channel of the outer side track portion. In preference, the longitudinal guide channel of the inner side track portion is shaped to retain an end cap of a roller shutter slat. In preference, the longitudinal guide channel of the inner side track portion has a pair of inwardly projecting ribs defining a slit within which an end cap can reside. In preference, the inner side track portion is captivly held within the outer side track portion when in an installed configuration in a window or door opening. In preference, the outer side track portion has a pair of inwardly projecting flanges in the longitudinal channel to hold the inner side track portion in the outer side track portion. In preference, the inner side track portion has a nesting fit within the longitudinal channel of the outer side track portion. In preference, the inner side track portion slidably engages with the outer side track portion In preference, the outer side track portion and inner side track portion are extruded from a rigid material. In preference, the inner side track portion is releasably secured in the outer side track portion by a fastening means. In preference, the fastening means is a screw, clip, nail or staple. In a further form of the invention there is an end retention system for a roller shutter assembly, the system consisting of a plurality of slats, at least one slat 4 having an end cap attached or formed thereon, the end cap being shaped to fit within a channel in a first guide track element, the first guide track element positioned in a channel in a second guide track element. BRIEF DESCRIPTION OF THE DRAWINGS By way of example, an embodiment of the invention is described more fully hereinafter with reference to the accompanying drawings, in which: Figure 1 is a view of a prior art side track. Figure 2 is a view perspective view of a roller shutter assembly of the present invention. Figure 3 is a perspective cross sectional view of a number of slat elements of the roller shutter showing the end caps at one end. Figure 3A is a side view of an end cap. Figure 4 is an exploded perspective view of the assembly of a number of the slats and insertion of the end caps into the inner side track, which resides in the outer side track. Figure 5 is a cut away view of the present invention showing the location of the end caps in the side track. Figure 6 is cross section view of an end cap in the side track of the present invention in a nesting arrangement. Figure 7 - 8 is cross section view of an end cap (slat not shown) in the side track of the present invention where the inner side track showing some pivoting movement within the outer side track channel. DETAILED DESCRIPTION OF THE INVENTION Figure 1 shows a prior art arrangement (1) with a end cap (2) being inserted into an individual slat (3), the end cap (2) residing in the side guide track 4 and the inwardly projecting ribs (5) retaining the end cap (2) in the channel (6).

5 With reference to Figure 2 there is a roller shutter assembly (9) having a pair of side guide tracks (10) and (11) and a shutter (15) composed of a plurality of individual elongate slats (20), each elongate slat (20) being connected by a hinged arrangement to provide articulation between each of the respective slats (20). At an upper end of each of the side tracks (10) and (11) is a pelmet (pelmet side frame (24) shown only) within which the shutter (15) is housed when in a rolled up configuration. The shutter (15) constructed from a number of the elongate slats (20) is shown in Figure 3, each of the elongate slats (20) being substantially horizontal with respect to one another and pivotally connected so as to allow them to articulate. In the arrangement shown in Figure 3, an upper edge of the slat (20) has a hook profile (28) that is adapted to pivotally engage with a lower edge (30) of an adjacent identical slat. Other means of joining the slats (20) to one another to form the shutter (15) are considered to be within the scope of the invention, such as hinge elements and other articulating joining means that are well known to those skilled in this particular field. The slats (20) can be generally hollow formed by extruding aluminium or roll formed, although other materials such as plastic may be utilised. The hollow portion of the extrusion may be partially filled with an insulating material. Located at an outer end (32) of the slat (20) is an end cap (34) (slat end, retainer/lock) comprised of a unitarily formed or molded ridged plastic (PVC or nylon) body (36), which has a first segment (38) shaped to be inserted into the hollow outer end (32) of the slat (20) a flange (40) whose shape matches that of the outer end (32) so that when the body (36) is inserted into the outer end (32) there is little or no unsightly gaps. In Figure 3 the end caps (34) are shown as being inserted into alternating slats (20) however this is not restrictive in any way and any configuration of end caps (34) may be used as required. The body (36) of the end caps (34) has an outer segment (42) has an outer flange (44), a slot (45) formed between the outer flange (44) and flange (40).

6 The end cap (34) can be retained within the outer end (32) of the slat (20) by a fastening means (screw, staple) or alternatively can be retained by way of crimping. The vertical side track (10) comprises an outer side track portion (50) having opposite side walls (51) a connecting wall (53) and a pair of slots or flanges (55) for receiving weather sealing strips (not shown) within. The outer side track portion (50) also includes an inner side track portion (60) (floating lock channel) having side walls (62), a rear wall (64) and inwardly projecting ribs (66). The inner side track (60) is sized to fit within the channel (52) of the outer side track portion (50) and the outer segment (42) of the end cap (34) fits within the channel (68) of the inner side track portion (60). Note that in Figures 6-8 the slat attached to the end cap (34) is not shown. The size of the inner side track portion (60) is such that there is a degree of movement of the inner side track portion (60) within the outer side track portion (50) such that when the outer side track portion (50) is fitted to or installed in an opening that has non-parallel vertical sides the inner side track portion (60) may sit either further within the channel (52) or closer to the slots (55) as the case may be. This arrangement of the inner side track portion (60) residing within the outer side track portion (50) then provides an extremely useful way of dealing with window or door openings that do not have vertical sides that are exactly parallel whilst still maintaining a flush appearance between a wall of the opening and the side of the side track housing (10) at all times without compromising the look and feel of the operation of the shutter unit (15) due to the relative movement of the inner side track portion (60). Additionally, the inner side track portion (60) may be fixed into a suitable position within the channel (52) of the outer side track portion (50) by way of a fastening means such as a screw or clip element (not shown). For example, a cap element (not shown) may be placed over the open track once the inner side track portion (60) has been inserted into the channel (52), the cap element can then be riveted in place. Alternatively, a compressible material (not shown) can be positioned between the rear wall (64) of the inner side 7 track portion (60) and the wall (53) of the outer side track portion (50) in order to buffer movement of the inner side track portion (60) inside the channel (52). An additional and unexpected advantage of the arrangement as described is the increase of the strength of retention of the end cap (34) within the side track (10) when a force (F) is applied on an outer surface of the shutters (15). The movement of the inner side track portion (60) within the outer side track portion (50) can absorb some of the externally applied forces as the inner side track portion can move back and forth within the channel (52) of the outer side track portion (50) and also, when the inner side track portion is sized appropriately, rotate slightly within the channel (52) without compromising the retention of the end cap (34) inside the channel (68) of the inner side track portion (60). This slight rotation keeps the inner side track portion locked within the outer side track portion (50) and greatly increases the force required to pull the end cap (34) out of the channel (68). This particular arrangement therefore provides a great increase in the security of the retention of the slats (20) in the side track (10) without compromising in any way the vertical movement of the slats (20) and end caps (34) within the channel (68) of the inner side track portion (60) therefore providing a smooth opening and closing action. Although the invention has been herein shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures can be made within the scope of the invention, which is not to be limited to the details described herein but it is to be accorded the full scope of the appended claims so as to embrace any and all equivalent devices and apparatus. Various modifications may be made in details of design and construction [and process steps, parameters of operation etc] without departing from the scope and ambit of the invention.

Claims (11)

1. A roller shutter side track including a outer side track portion having a longitudinal channel defined by a pair of substantially parallel side walls and an end wall and a inner side track portion having a longitudinal guide channel defined by pair of substantially parallel side walls and an end wall wherein the inner side track portion resides within the channel of the outer side track portion.

2. The roller shutter side track of claim 1, further characterised in that the longitudinal guide channel of the inner side track portion is shaped to retain an end cap of a roller shutter slat.

3. The roller shutter side track of claim 2, further characterised in that the longitudinal guide channel of the inner side track portion has a pair of inwardly projecting ribs defining a slit within which an end cap can reside.

4. The roller shutter side track of any one of the above claims, further characterised in that the inner side track portion is captivly held within the outer side track portion when in an installed configuration in a window or door opening.

5. The roller shutter side track of any one of the above claims, further characterised in that the outer side track portion has a pair of inwardly projecting flanges in the longitudinal channel to hold the inner side track portion in the outer side track portion.

6. The roller shutter side track of any one of the above claims, further characterised in that the inner side track portion has a nesting fit within the longitudinal channel of the outer side track portion.

7. The roller shutter side track of any one of the above claims, further characterised in that the inner side track portion slidably engages with the outer side track portion 9

8. The roller shutter side track of any one of the above claims, further characterised in that the outer side track portion and inner side track portion are extruded from a rigid material.

9. The roller shutter side track of any one of the above claims, further characterised in that the inner side track portion is releasably secured in the outer side track portion by a fastening means.

10. The roller shutter side track of any claim 9, further characterised in that the fastening means is a screw, clip, nail or staple.

11. An end retention system for a roller shutter assembly, the system consisting of a plurality of slats, at least one slat having an end cap attached or formed thereon, the end cap being shaped to fit within a channel in a first guide track element, the first guide track element positioned in a channel in a second guide track element.