WO1989008767A1 - Improvements in the installation of roller shutters - Google Patents

Abstract

Roller shutters have been used for many years to cover windows and doors and the like, to provide security, privacy and assist energy saving. A shutter assembly for closing an opening (15) in a wall structure (10, 11) comprises a lintel (20) extending across an upper edge of the opening and a shutter (30). The lintel may be generally s-shaped or c-shaped including at least one substantially horizontally disposed flange means (23) for engaging and fixing the lintel to the wall structure. The lintel defines an aperture to one side ot fhe wall structure and is adapted to receive said shutter which locates under the flange means. The shutter is a roller shutter and the aperture is sufficient size to allow the shutter to pass therethrough for installation or removal in a rolled up state.

Description

  
 



   IMPROVEMENTS IN THE INSTALLATION
 OF ROLLER SHUTTERS
 This invention relates to roller shutters and the installation of such shutters in buildings having single or double skinned walls.



   Roller shutters have been widely used in continental Europe for many years.



   Roller shutters provide security, privacy and assist energy saving in a practical and decorative manner. The increase in vandalism and burglaries to property in recent years has lead to an increased demand for an effective deterrent against break-in.



  As roller shutters can be made to be self locking and cannot be pushed up from the outside they have been proven to be an effective deterrent whilst also being more aesthetic than bars or grills, which are usually fixed permanently in position across windows.



  Further advantages include absolute privacy, protection against excessive heat and radiation, excluding draughts, insulating doors and windows and can also provide for ventilation -without draughts.



  Roller shutters are also very versatile and can be used to close off windows, doors, garages, warehouses and many other forms of opening.



   The method of building houses and the like on the continent differs from that used in the UK in that the walls of continental houses tend to have a single brick or concrete skin, whereas houses built in the UK tend to have walls with two skins, with a  cavity therebetween.



   The standard method of installing roller shutters as used on the continent cannot be used on double skinned buildings particularly if exposed external brickwork is used above openings and a new approach is needed. It would be advantageous to have a single method of installation and single roller shutter unit which could be used in either double or single skinned walls.



   According to the present invention, there is provided a shutter assembly for closing an opening in a wall structure, the assembly comprising a lintel extending across an upper edge of the opening and a shutter, the lintel including at least one substantially horizontally disposed flange means for engaging and fixing the lintel to the wall structure, the lintel defining an aperture to one side of the wall structure and being adapted to receive the shutter, the shutter being located under the flange means, in which the shutter is a roller shutter comprising a rotable spindle, a multiplicity of interconnected horizontal slats at least one of whichis fixed to the spindle and operating means for rotating the spindle to move the shutter, in use, between a rest position, in which the slats are rolled up about the spindle, and an extended portion,

   wherein said aperture is of sufficient size to allow the shutter to pass through said aperture to be placed or removed from under the lintel flange means whilst in its rest position.



   Preferably the assembly further comprises support means by which the spindle is rotably supported under the flange means of the lintel, or  the support means comprise a housing in which the roller shutter is contained, the spindle being rotably supported by the housing and the housing being supported under the lintel.



   The shutter housing may comprise a sleeve element and an end cap for each end thereof to rotably support the shutter spindle or a pair of end caps to rotably support the shutter spindle, a base plate to support said end caps and adjustment means linking the end caps so that they may be moved relative to each other.



   In a preferred embodiment of the invention there are provided guide rails positioned to guide vertical edges of the shutter in which the end caps have means for engaging with said guide rails in which the engagement means may comprise spring means.



   There are preferably means for installing the shutter during construction of the wall structure or at any time thereafter, providing that the lintel has first been installed.



   A frame preferably surrounds the wall opening and the guide rails and frame are preferably fixed at a predetermined horizontal distance apart.



   The predetermined distance is preferably dependent on the avoidance of interference of the shutter with physical projections from the opening to be covered, and the accoustic and thermal requirements.



   Distancing means preferably separate the guide rails and frame by said predetermined distance, so as  to avoid interference to the operation of the shutter and the distancing means may be integrally formed with the frame or with the guide rails.



   There are preferably provided means for installing the frame during construction of the wall structure or at any time thereafter, before or after installation of the lintel, means for installing the guide rails with or after installation of the frame, and/or means for locating the frame and/or guide rails relative to the lintel or eventual lintel position.



   The shutter is preferably mounted in said housing and the housing assembled with the frame and guide rails to form a pre-assembled module for installation under the lintel flange.



   In a preferred embodiment of the invention there are provided reference means on the pre-assembled module and the lintel for correct positioning.



   The lintel preferably has a generally upright web, a lower horizontal flange attached at one end of the web and an upper horizontal flange attached at another end of the web and may be generally s-shaped having an inwardly pointing upper flange supported by an inner skin of the wall structure and an outwardly pointing lower flange supporting a part of an outer skin of the wall structure above the said opening.



   Also according to the invention there is provided a wall structure comprising an outer skin and an inner skin having a cavity therebetween, at least one lintel and a roller shutter located under  the flange means of said lintel.



   The lintel may be essentially s-shaped, a lower flange of which supports a portion of the outer skin above an opening in the wall, and the upper flange of which being supported by the inner skin, the lintel being adapted to receive a roller shutter.



   According to the invention there is also provided a wall structure comprising a single skin, at least one lintel and roller shutter located under the flange means of said lintel.



   The lintel may be essentially c-shaped and is supported by the skin, the lintel being adapted to receive a roller shutter.



   There is preferably at least one bracket affixed to the lintel capable of supporting a rotable spindle of the roller shutter or the lintel may be adapted to receive a housing containing a roller shutter.



   There is also provided a method of installing the shutter assembly to cover an opening in a wall structure comprising the steps of installing said lintel across an upper edge of the opening, and installing said shutter under the substantially horizontally disposed flange means.



   The method may further comprise the steps of rotably mounting the shutter in support means and installing the support means under the flange means, and the steps of installing vertical roller shutter guide rails, one at either vertical edge of the opening and fixing a portion of a frame to the wall  structure at a predetermined horizontal distance from said guide rails.



   Alternatively the support means, roller shutter guide rails and a frame may be pre-assembled, the guide rails and frame being assembled at a preassembly under the substantially horizontally disposed flange means of said lintel.



   A preferred embodiment of the invention will now be described in detail, by way of example, with reference to the accompanying drawings, in which:
 Figure 1 is a schematic representation of a section of a double skinned wall, with parts ommitted for clarity, showing a concealed lintel mounting for a roller shutter;
 Figure 2 is a sectional view on II-II of figure 1;
 Figure 3 is a sectional side elevation of an alternative section of wall containing a concealed lintel mounting for the roller shutter shown in figure 1;
 Figure 4 is a sectional plan view on IV-IV of
Figure 2 showing a section of wall showing the relationship between a window frame and roller shutter side guides;
 Figures 5 to 11 are sectional plan views of the section of wall of Figures 4 showing alternative arrangements of the window frame and roller shutter side guides;

  ;  
 Figure 12 is a side view of an end cap for a self-contained unit for the roller shutter of Figure 1;
 Figure 13 is a sectional front view of the roller shutter of Figure 1 mounted in a self-contained unit via the end cap shown in Figure 12 (parts have'been omitted for clarity);
 Figure 14 is a sectional end view on XIV-XIV of the end cap of Figure 12;
 Figure 15 is a sectional view on XV-XV of a spigot of the end cap of Figure 12;
 Figures 16 to 19 show an alternative mounting for the roller shutter of Figure 1;
 Figure 20 is a sectional side elevation of a single skinned wall, with parts ommitted for clarity, showing a concealed lintel mounting for a roller shutter;
 Figure 21 is a schematic representation of a section of the lintel of Figure 20;
 Figure 22 shows an alternative construction of the concealed lintel mounting of Figure 20;

  ;
 Figures 23 and 24 show the cross-sections of two alternative lintels for use in the construction of Figure 22;
 Figure 25 shows another alternative construction of the concealed lintel mounting of
Figure 20; and  
 Figure 26 is a schematic representation of a section of the lintel of Figure 25.



   Referring first to figures 1, 2 and 3 there is shown a typical double skinned building structure   comprising    an outer skin 10, formed of rows of bricks 11, joined together in a suitable manner, and an inner skin   12,    formed of rows of concrete blocks 13 also joined together in a suitable manner, with a cavity 14 therebetween.



   In the embodiment shown in figures 1 and 2, an opening 15 is provided in the skins 10, 12 for a window 25. The opening 15 could be for a window, door or any opening to be covered by a shutter, although only window openings are hereinafter referred to. The height of the opening in outer skin 10 is lower than that in inner skin 12.



   To provide support for floor joists and the rows of concrete blocks 13 across the top of the window opening 15 in the inner skin, a load bearing lintel 16, which is generally c-shaped in cross section as shown in the drawings, is incorporated into the inner skin 12 in a known manner. The lintel 16 has a vertical portion 17, at both ends of which are provided flanges 18, which are sandwiched between rows of concrete blocks 13 as shown in figure 1, at each end of the lintel 16.



   To provide support for rows of bricks 11 across the top of the window opening 15 in the outer skin 10, a second load bearing lintel 20, which is of a length greater than the width of the window opening 15 is incorporated into the structure. This lintel 20 is of the shape shown in the drawings and for ease  of convenience will be referred to as an s-lintel, as its shape in cross-section is generally s-shaped.



  The s-lintel 20 has a vertical portion 21, and outwardly pointing lower flange 22 and inwardly pointing upper flange 23. The s-lintel 20 is supported by its upper flange 23 which is fixed at either end between two rows of concrete blocks 13 of the inner skin 12. The upper flange 23 of the s-lintel 20 is positioned beneath the lower flange 18 of the c-lintel 16 and may be separated by a row of filler blocks 26, which provide additional support for the c-lintel 16. The lower flange 22 of the s-lintel 20 supports the rows of bricks 11 of the outer skin 10 across the top of the window opening 15.



   The s-lintel 20 may be of standard design or have an additional upwardly pointing lip 23a on its upper flange 23 (see Figures 1 and 2). This lip 23a is advantageous as it provides additional stability to the lintel 20 resulting in greater strength. It also prevents blocks 26 from slipping out of positioning, thus making installation simpler.



  Alternatively the two lintels 16, 20 may be formed together to form a single lintel, although manufacture of 2 separate components is easier and cheaper.



   The lintels 16, 20 are load bearing lintels of steel or a composite material of required strength.



  This gives dimensional accuracy and the ability to fit prefabricated modules which would not be possible with the traditional concrete lintels.



   The roller shutter 30 is of a known type comprising a spindle 31, which may be hollow or solid, means for rotably mounting the spindle 31, a  multiplicity of interconnected horizontal slats 32 (see figure 1) and operating means (not shown) which cause the spindle 31 to rotate either clockwise or anticlockwise about its central axis to raise or lower the shutter 37. Operation of the roller shutter 30 may be manual, or by electric motor via interior controls. Remote operation using photo electric or radio control or other similar devices may also be used.



   In a window opening 15 is fitted a window frame 27. The window frame 27 is of a standard type and is fixed in a known manner to the inner skin 12 such that the window frame 27 may be installed before or after the lintel 20.



   It is important that during the installation of roller shutters they are correctly placed with respect to the window (or door) which they are to cover to prevent interference in the operation of the shutter and the opening of the window (or   door).   



   To ensure correct positioning the frame, shutter and lintel are preferably linked to form a tailor-made unit in which the positioning of the shutter is exactly correct for the particular frame used, and installation may be carried out in a number of ways as described later to ensure this
 The roller shutter 30 requires a pair of vertical guide rails 33 positioned one at either side of window opening 15. The guide rail 33 is generally c-shaped, with the flanges of the "c" facing inwardly into the window opening so that each vertical edge of the shutter 37 travels within and along the rails 33 as it is raised and lowered. The rails 33 may be  fashioned from metal, plastic or any other suitable material.



   The guide rails 33 may be placed in any one of a number of different positions, but the distance D between the guide rails 33 and the frame 27 is preferably a predetermined distance which generally lies in the 'range 30-50mm to avoid interference to the operation of the shutter by projections such as exterior handles, vents etc. However, if the projections are particularly small or large this range may vary. Distance D may also be determined by thermal and accoustic requirements, e.g. the resulting insulation and sound barrier effects of the shutter. Examples of this relationship are shown in
Figures 4 to 11. A further aid to minimisation of interference of opening the window is the introduction of a further predetermined distance T, typically between 10 and 20mm. As above, this range may vary according to the application.



   Figure 4 shows a standard guide rail 33 with a stepped cheek piece 50 acting as a mask to the cavity 14 which is closed by the normal return of the inner blockwork 51. This means that the last block in the inner wall adjacent the opening is turned through 900 to cover over the cavity. The cheek piece 50 by its design acts as a spacer element. When the window frame 27 is affixed to the cheek piece 50 in its correct position by means 52 and side guide 33 is also affixed to cheek piece 50 in its correct position, by shoulder means 53, the distance between the frame 27 and guide rail 33 is fixed at the predetermined distance D. The height of shoulder 53 also fixes the predetermined distance T. Mastic 54 may be used to form a seal between the cheek piece 52  and the outer skin 10.



   Figure 5 shows a variation of figure 4 comprising a simple cheek piece 55. In this embodiment the guide rail 33 has an extended flange 56 which acts as a mask for the cavity 14 which is also closed by the normal return of the inner blockwork 51.



   Figure 6 shows another variation of the arrangement of Figure 5, with another differently shaped cheek piece 59. In this embodiment the guide rail 33 has an L-Shaped flange 60 for locating against and fixing to the cheek piece 59 to ensure correct positioning and a leg 61 protruding from flange 56 for locating against the brick of the front skin 10 giving the window frame 27 the correct location with respect to the later placed lintel 20 during bricking in.



   In Figure 7 the guide rail 33 is positioned inside cavity 14. The cavity 14 is partly closed by the normal return of the inner blockwork 51, but allowing a small recess   57    Leg 61 is used to locate the guide rail 33 correctly within the cavity 4. In this case the predetermined distance T is not required as there is no interference with the opening of the window as the guide rail 33 are hidden out of the way in the recess 57.



   Figure 8 shows an embodiment of the invention similar to that shown in Figure 4, except inasmuch as the cheek piece 50 in Figure 8 also acts as the cavity 14 closure, needing no return of the inner blockwork 51 as in Figure 4. Preferably the underside 58 of the cheek piece 50 is coated with a  water resistant material such as bitumastic.



   In Figure 9 the cavity 14 is closed by returning the facing brick 10. In this embodiment a simple cheek piece 55 such as that used in Figure 5 is used, but because of the location of the exposed part of cavity 14 no extended flange 56 is required as it is covered by cheek piece 50.



   Figure 10 is an alternative version of Figure 7 wherein leg 61 is used to locate the guide rail 33 correctly in cavity 14 and the guide rail 33 itself acts as the cavity closure. In this case no normal return of the blockwork 51 is required.



   In Figure 11 the jamb of the window frame 27 is extended to incorporate the guide rail 33, which may also act as the cavity closure.



   Thus the guide rail 33 may be in view or exposed. In all of these examples the guide rails 33 are positioned in front of a window. There may of course be some cases whereby the shutter is required behind a window or door, in which case the predetermined distance D will be a different measurement from the inside of the frame.



   The head of the window frame 27 and the upper flange 23 of the s-lintel 20 form a cavity 34 and the s-lintel 20 is adapted to receive the mounting means for the roller shutter spindle 31 in the cavity 34.



   The preferred mounting means comprise a box shaped structure 35 at least as long as the roller shutter 30 which is contained therein, having an opening 36 along its length through which the shutter  37 passes as it is raised or lowered. The spindle 31 is rotably mounted within the box structure 35 in support means 70a in roller end caps 70 such that in order to install the roller shutter 30 under the lintel a single unit may be placed in the cavity 34.



  This unit may be fixed in position under the lintel in any suitable manner, either with brackets or flanges or the like, such that the vertical edges of the shutter 37 run inside guide rails 33 when the shutter 37 is lowered or raised. Alternatively the unit is simply positioned, and not fixed, so that it is removable from the cavity 34.



   Each end cap 70, see Figures 12 to 15 has a spigot 71 protruding from a lower side thereof, which fits into the upper ends of the guide rails 33 to support the roller shutter 30 and to accurately locate the shutter 37 with respect to the guide rails 33 so that it runs freely and smoothly therein as it is raised or lowered.



   Springs 72 can be fitted to the spigot 71 to give a more secure push fit into the guide rails 33.



   Although the guide rails 33 can be fitted to a window frame 27, which gives a degree of dimensional stability on the width between them, the manufacturing tolerances and changes due to wood movement (where wooden frames 27 are used) can give a variation of +/- on a larger window too great for ease of insertion of the spigots 72 on the roller end caps 70 which support the roller 30.



   To overcome this problem the spigot 72 therefore has an H-section (of the order of 20mm between its two flanges) and two shaped spring steel  strips 73 are fitted inside the section with their uncompressed "bow" projecting each side. These strips 73 are held together by rivet 74. Compression of these strips as the spigot 72 is pushed into the guide rails 33 will hold the spigot 72 sufficiently firmly to support the shutter 30 whilst permitting some variation of the overall width between the guides 33. By this means the complete roller box assembly 35 can be fitted into and removed from the guides rail 33 from the inside of the building through the opening in the specially shaped lintel 20.



   The dotted line 33a on Figure 14 shows the guide rails 33 out of alignment with the adjustments accordingly made to the spring strips 73a.



   In an alternative embodiment, see Figures 16 to 19, the springs 73 are not used. In this embodiment the spindle 31 of the roller shutter 30 is supported by means of a pair of roller end caps 70, the end caps 70 being held together by means of a base plate 75. There are a pair of elongated holes 76 at each end of the base plate 75 through which fixing screws screw into the end caps 70. The holes 76 are elongated in the direction of the spindle 31 axis and thus the end caps 70 are allowed some longitudinal movement along the axis of the roller 30 to permit the spigots 71 to engage in the guide rails 33. Once the correct fitting is found, a pair of tie bars 77 with turn buckles 78 attached at between its end of the end caps 70, are tightened or loosened to ensure that the end caps 70 are square with the roller shutter and base plate.



   In yet another embodiment the springs 73 may be used in the arrangement shown in Figures 16 to 19.  



   Insulating material 39 may be provided to surround a part of or the whole unit (see figure 2) before a screen 38 of plaster board or other suitable material is placed on the inside of the inner skin 12, as shown in figure 1, to provide a suitable internal wall for the building. The insulation should preferably be removably either in part or in total to allow complete access to the shutter and to allow its removal from the cavity 34.



   The screen 38 may have a hole or gap therein, through which a cord 40 or a shaft (not shown) passes, which activates the roller operating means.



  Alternatively electric cable may pass through the hole to an electric or electronic switch mounted on the screen 38, the shutter roller shaft containing an electric motor to rotate the shaft. If the building had solar panels, the energy stored therein could be used to operate the shutter.



   The main advantage of this construction is that the roller shutter 30 may be installed during construction of a building, or as long as the lintel mounting is fitted during construction, the roller shutter 30 may be installed at any time thereafter.



   The roller shutter 30 and mounting means are preferably provided as a single unit which slides into position in the cavity 34. In an alternative embodiment of the invention (not shown) the s-lintel 20 has mounting means for spindle 31 fitted thereto, which obviates the need for the box structure 35.



  During installation, the spindle 31 is simply fitted into its mountings and the operating means installed in a suitable position. In yet another embodiment rigid preformed insulation may be used to fully or  partially hold the mounting of the spindle 31, which obviates the need for all or some of the box structure and loose insulation. However such insulation would need to be at least in part removable to allow access to the shutter 30.



   It is very advantageous that the roller shutter 30 (whether in'a box structure 35 or not) may be installed or removed after the building work is completed in its rolled up state, which prevents damage to the slats and the roller mechanism which may occur if it was required to be installed or removed in its unrolled state. Thus repair work to the shutter 30 may be carried out in site or remote from the building.



   Figure 3 shows another embodiment of the invention, in which the window 25 is positioned under roof eaves 41. In this embodiment, a c-lintel 16 cannot be fitted so the s-lintel 20 is adapted to provide extra support. The adapted lintel 20a is basically s-shaped but incorporates an additional c-shaped portion 20b which is supported by a row of concrete blocks 13, as shown in figure 3. The inwardly pointing upper flange 20c of the adapted lintel 20a is sandwiched between the roof joists 42 and the concrete blocks 13 to provide support for the bricks 11 of the outer skin 10 over the window opening 15.



   The mounting lintel may therefore be adapted to a variety of shapes to make it more versatile, although the s-shape is preferably retained for double skinned walls. Additional flanges may also be incorporated, for example, to create an inverted   "utV    which comprises two s-shaped lintels back to back.  



   The adaptation of the s-lintel 20, 20a to receive the roller shutter 30 may be such that the roller shutter 30 is mounted on either side of the vertical portion 21 of the s-lintel 20, 20a and thus the shutter 37 may be positioned such that it falls inside or outside the glazing or door.



  The method of mounting depends on the building requirements and space available.



   The skins 10, 12 may be constructed from materials other than brick and concrete, as long as suitable means for supporting the s-lintel are provided.



   Referring now to Figures 20 to 26, the lintel and shutter assembly may also be installed in a single skinned wall 90. In this case the s-lintel 20 requires adaptation.



   The lintel 91 suitable for use in a single skinned wall 90 is no longer s-shaped, but is generally c-shaped with additional flanges. In
Figure 21 the c-shaped lintel is shown having a pair of upright flanges 92. As shown in Figure 20, the c-part of the lintel 91 houses the roller shutter 30 with or without its box structure 35, whilst the upright flanges 92 support the row of bricks/blocks 93 above the window opening 15. The c-shaped lintel 91 is installed such that the opening 94 allows access to the shutter 30 from the inside of the wall   90.   



   As previously described a screen 38 may be placed over the opening 94 to conceal the lintel 91 and loose or preformed insulating material 39 may be used to surround the unit 30. In the embodiment  shown in Figure 20 the insulation 39 is preformed in two slabs 39a, 39b which can be split to allow the unit 30 to be removed. Provision may be made for a cord 40 or other means for activating the roller operating means.



   In this embodiment of the invention the window frame 27, the guide rails 33 and the shutter 30 are pre-assembled to form a tailor-made unit as previously described with distance D between the guide rails 33 and the frame 27. The unit may then be installed in a lintel 91 already incorporated in the wall. Reference points on the lintel 91 and the unit allow a quick and virtually error free installation. This method of installation may also be used with a modified s-lintel and double-skinned wall.



   In the embodiment shown in Figures 20 and 21 the lower flange of the c-shaped lintel 94 has a slot 95 therein extending at least the length of the shutter 37. This slot 95 provides the reference for the positioning of the roller shutter 30, since the spigots 71 from the end caps 70 must pass through the slot into the ends of the guide rails 33 as does the shutter 37. In this embodiment of the lintel 94, the lower flange of the lintel 94 may be thinner than the other flanges as it is not load-bearing.



   Figures 22 to 24 show an alternative arrangement in which there is access to the shutter 30 from outside. Here the lintel 100 is again generally c-shaped, this time with the opening 103 facing outwards. A screen 38 which can be board or surface rendered may be used to conceal the shutter 30. The screen 38 shown in Figure 22 has an inner  lip 38a to give it a vertical reference and a lip   104 is    provided on the lintel 100 for the lintel position reference on the front face of the brick or blockwork 93.



   The front lip 105 of the lintel 100 is the key reference for the lateral and vertical positioning of the shutter 30/window frame 27 assembly. The roller box 35 or roller shutter 30 can be clamped or loose on the side guides 33 and a weather strip 106 positioned between the side guides 33 and screen 38 to prevent the ingress of rain or snow etc.



   The actual lintel 100 shape chosen will be the most economic form for its given duty. Figures 23 and 24 show two alternatives. The additional flanges 101, 102 are strengthening pieces.



   Figures 25 and 26 show yet another alternative version of the lintel and shutter arrangement, having access to the shutter 30 from the inside. The lintel 106 is similar to lintel 91, except that the lower flange is substantially shortened to form a lip 107.



  This lip 107 is the key reference for the lateral and vertical positioning of the shutter 30/window frame 27 assembly. Since there is no lower flange to the lintel 106 a plate 108 is attached to the top of the frame 27 to act as a closure and to locate on the reference lip 107 of the lintel 106.



   Thus, access for repair/replacement of the shutter 30, or components thereof, is available at any time without the necessity of removing the window 25 and frame 27. Only the cover screen 28, the insulator 39 and the connecting mechanism to the roller drive gear need be removed to obtain access  and spigots 71 allow the shutter box 35 to be easily removed from the side guides 33 by lifting the box 35 off the side guides 33, which remain attached to the window frame 27.



   The pre-assembled unit comprising the shutter 30 in its casing 35, the frame 27 and the side guides 33 can be   ased    to construct the opening or a temporary frame can be used to allow installation of a pre-assembled unit comprising the frame 27 and side guides 33 with or without the shutter 30 at this stage, since the shutter 30 can also be positioned at a later date.



   If the openings 15 are bricked in the side guides 33 may be protected by factory applied plastic film which is easily removed after all mortar work is complete.



   Reference points may also be incorporated in the s-lintel 18 or other variations of lintel to allow easy installation of the pre-assembled unit in any double or single skinned wall. 

Claims

1. A shutter assembly for closing an opening in a wall structure, the assembly comprising a lintel extending across an upper edge of the opening and a shutter, the lintel including at least one substantially horizontally disposed flange means for engaging and 'fixing the lintel to the wall structure, the lintel defining an aperture to one side of the wall structure and being adapted to receive the shutter, the shutter being located under the flange means, in which the shutter is a roller shutter comprising a rotable spindle, a multiplicity of interconnected horizontal slats at least one of which is fixed to the spindle and operating means for rotating the spindle to move the shutter, in use, between a rest position, in which the slats are rolled up about the spindle, and an extended portion,

wherein said aperture is of sufficient width to allow the shutter to pass through said aperture to be placed or removed from under the lintel flange means whilst in its rest position.

2. A shutter assembly as claimed in claim 1 further comprising support means by which the spindle is rotably supported under the flange means of the lintel.

3. A shutter assembly as claimed in claim 2 in which the support means comprise a housing in which the roller shutter is contained, the spindle being rotably supported by the housing and the housing being supported under the lintel.

4. A shutter assembly as claimed in claim 3 in which the shutter housing comprises a sleeve element and an end cap for each end thereof to rotably support the shutter spindle.

5. A shutter assembly as claimed in claim 3 in which the shutter housing comprises a pair of end caps to rotably support the shutter spindle, a base plate to support said end caps and adjustment means linking the end caps sp that they may be moved relative to each other.

6. A shutter assembly as claimed in any one of the preceding claims further comprising guide rails positioned to guide vertical edges of the shutter.

7. A shutter assembly as claimed in claim 6 in which the end caps have means for engaging with said guide rails.

8. A shutter assembly as claimed in claim 7 in which said engagement means comprise spring means.

9. A shutter assembly as claimed in any one of the preceding claims, further comprising means for installing the shutter during construction of the wall structure or at any time thereafter, providing that the lintel has first been installed.

10. A shutter assembly as claimed in any one of the preceding claims further comprising a frame to surround the wall opening.

11. A shutter assembly as claimed in claim 10 in which the guide rails and frame are fixed at a predetermined horizontal distance apart.

12. A shutter assembly as claimed in claim 11 in which the predetermined distance is dependent on the avoidance of interference of the shutter with physical projections from the opening to be covered, and the accoustic and thermal requirements.

13. A shutter assembly as claimed in claim 11 or claim 12 further comprising distancing means to separate the guide rails and frame by said predetermined distance, so as to avoid interference to the operation of the shutter.

14. A shutter assembly as claimed in claim 13 in which the distancing means are integrally formed with the frame.

15. A shutter assembly as claimed in claim 13 or claim 14 in which the distancing means are integrally formed with the guide rails.

16. A shutter assembly as claimed in any one of claims 10 to 15 further comprising means for installing the frame during construction of the wall structure or at any time thereafter, before or after installation of the lintel.

17. A shutter assembly as claimed in any one of claims 10 to 16 further comprising means for installing the guide rails with or after installation of the frame.

18. A shutter assembly as claimed in any one of claims 10 to 17 further comprising means for locating the frame and/or guide rails relative to the lintel or eventual lintel position.

19. A shutter assembly as claimed in any one of claims 6 to 18 in which the shutter is mounted in said housing and the housing assembled with the frame and guide rails to form a pre-assembled module forinstallation under the lintel flange.

20. A shutter assembly as claimed in claim 19 in which there are provided reference means on the pre-assembled module and the lintel for correct positioning.

21. A shutter assembly as claimed in any one of the preceding claims in which the lintel has a generally upright web, a lower horizontal flange attached at one end of the web and an upper horizontal flange attached at another end of the web.

22. A shutter assembly as claimed in claim 21 in which the lintel is generally s-shaped having an inwardly pointing upper flange supported by an inner skin of the wall structure and an outwardly pointing lower flange supporting a part of an outer skin of the wall structure above the said opening.

23. A wall structure comprising an outer skin and an inner skin having a cavity therebetween, at least one lintel as claimed in any one of the preceding claims and a roller shutter located under the flange means of said lintel.

24. A wall structure as claimed in claim 23 in which the lintel is essentially s-shaped, a lower flange of which supports a portion of the outer skin above an opening in the wall, and the upper flange of which being supported by the inner skin, the lintel being adapted to receive a roller shutter.

25. A wall structure comprising a single skin, at least one lintel as claimed in any one of claims 1 to 21 and roller shutter located under theflange means of said lintel.

26. A wall structure as claimed in claim 25 in which the lintel is essentially c-shaped and is supported by the skin, the lintel being adapted to receive a roller shutter.

27. A wall structure as claimed in any one of claims 23 to 26 in which at least one bracket is affixed to the lintel capable of supporting a rotable spindle of the roller shutter.

28. A wall structure as claimed in any one of claims 23 to 26 in which the lintel is adapted to receive a housing containing a roller shutter.

29. A wall structure as claimed in any one of the claims 23 to 28 in which the opening is a door or a window opening.

30. A method of installing the shutter assembly as claimed in any one of claims 1 to 22 to cover an opening in a wall structure comprising the steps of installing said lintel across an upper edge of the opening, and installing said shutter under the substantially horizontally disposed flange means.

31. A method of installing a shutter assembly as claimed in claim 30 further comprising the steps of rotably mounting the shutter in support means and installing the support means under the flange means.

32. A method of installing a shutter assembly as claimed in claim 30 or claim 31 further comprising the steps of installing vertical roller shutter guide rails, one at either vertical edge of the opening and fixing a portion of a frame to the wall structure at a predetermined horizontal distance from said guide rails.

33. A method of installing a shutter as claimed in any one of claims 30 to 32 comprising the steps of preassembling the support means, roller shutter guide rails and a frame, the guide rails and frame being assembled at a preassembly under the substantially horizontally disposed flange means of said lintel.

34. A shutter assembly substantially as hereinbefore described with reference to or as shown in the accompanying drawings.

35. A wall structure substantially as hereinbefore described with reference to or as shown in the accompanying drawings.

36. A method of installing a shutter assembly substantially as hereinbefore described with reference to or as shownin the accompanying drawings.