Apparatus and method for assembling sheet material mounting device components

Abstract

The present invention provides a sheet material mounting device having two channels, namely, a mounting channel for receivably engaging a rod for gripping the sheet material and a spacer channel for receivably engaging a spacer support configured to engage a lift cord and, optionally, a spacer cord. The spacer channel may be positioned above the mounting channel such that the center of gravity of the mounting device is located above the center of the mounting channel, thereby reducing asymmetric tilt of the sheet material engaged by the mounting channel and reducing friction against the lift cord. Alternatively, the mounting channel may be positioned above the spacer channel. The mounting channel and the spacer channel are preferably both C-shaped, and each channel has an opening which faces in a direction opposite the direction faced by the opening of the other channel. Thus, a side view of the mounting device may resemble either an “S” or a reverse “S”. In accordance with another aspect of the invention, there is provided an apparatus and method for assembling the components of a sheet material mounting device, such that the assembled components of each sheet material mounting device are capable of maintaining vertical alignment with respect to every other sheet material mounting device comprised by the window covering system. Moreover, there is provided an apparatus and method for adjusting and re-aligning assembled components of a sheet material gripping apparatus.

Description

FIELD OF THE INVENTION

[0002] The present invention relates generally to an apparatus and method for mounting sheet material to a support structure and, more particularly, to an apparatus and method for assembling the components of a window covering system, such as a Roman shade window covering system.

BACKGROUND OF THE INVENTION

[0003] The prior art contains various devices for mounting, lifting, and folding flexible sheet material in association with blinds, curtains, draperies, and other window coverings. Some of these window shade devices include guide cables and lift cords in conjunction with a fabric-gripping device. These cables/cords are typically threaded through rings sewn to the shade fabric. Alternatively, the cables/cords are threaded through apertures in the fabric pleats, wherein the pleats may be formed or stiffened with slats. The lattice formed by the attachment of the shade fabric to these guide cables and lift cords constitutes a mobile support structure which allows the shade to travel between raised and lowered positions.

[0004] Roman shades are a particular type of window covering which incorporates a mobile support structure such as a lattice for gathering sheet fabric into substantially horizontal folds. One example of the construction of a contemporary Roman shade is a cloth fabric hanging from a head rail, with a lower end having weights at predetermined lateral intervals. This type of Roman shade can be raised by drawing up a lift cord such that large, loose folds in the fabric are formed at approximately equal vertical distances to provide a neatly pleated aesthetic appearance. A common configuration for connecting the cord to the shade is to sew at least two sets of rings or connectors in vertical lines along the back of the fabric material as shown in U.S. Pat. No. 1,321,800 entitled CURTAIN HANGER issued to Andress, et al. on Nov. 18, 1919. In this type of Roman shade, a lift cord passes from a head rail through each set of rings and is then either fastened to the bottom edge of the fabric or wrapped around the bottom edge of the fabric and returned up the front face of the shade to the head rail. Alternatively, each set of rings or connectors is sewn to the sheet fabric and attached to a lift cord at predetermined vertical intervals. As the shade travels through raised positions, the interval between the connectors may be reduced.

[0005] However, due to the extensive time and labor to sew connectors to the back of the sheet material of a Roman shade, the art has developed other methods and devices to connect sheet fabric to a mobile support structure. In the shade system disclosed in U.S. Pat. No. 4,694,545 entitled ATTACHMENT OF RINGS WITHOUT SEWING issued to Dernis on Sep. 22, 1987, a set of U-shaped filaments are inserted through the fabric from the front face. The ends of each filament are gathered in a tube, bent over the end of the tube and held in place by a sleeve that fits over the tube.

[0006] Another alternative for attachment includes one or more horizontal ribs to provide support and to maintain spacing between the cords which are oriented vertically across the back of the fabric. For example, in U.S. Pat. No. 5,207,256 entitled SAFETY DEVICE FOR A RAISABLE CURTAIN DOOR issued to Kraeutler on May 4, 1993, the ribs are placed in vertically spaced, transverse pockets in the sheet material. However, in this system, the pockets must be sewn into the sheet material, thereby substantially adding to the time, effort, and expense of manufacture.

[0007] U.S. Pat. No. 5,273,096, entitled APPARATUS FOR GRIPPING SHEET FABRIC issued to Thomsen et al. on Dec. 28, 1993, discloses a tubular member having a longitudinal opening which receives the fabric and a rod, thereby gripping the fabric between the member and the rod. The backside of the tubular members each include loops through which the lift cords pass. However, as shown in FIG. 10, if this system is used on a Roman shade for a large window, the combined weight of the tubular member and the rod will often cause tilting of the mounting device, thereby adding substantial friction to the lift cord and making it more difficult to raise the shade. More particularly, the fabric mounting device found in Thomsen et al. and other Roman shade systems employ designs wherein the center of gravity of the fabric mounting device causes the device to tilt asymmetrically as the shade is raised, distorting the fabric being held and thereby adding friction to the lift cord. Thus, the size of a Roman shade is often limited by the friction incident upon the lift cord caused by the tilting of one or more of the rings, connectors, loops, or spacers used to mount the fabric to the lift cord.

[0008] A need exists for a light-weight, sheet-material gripping apparatus which can be quickly assembled by the manufacturer and which includes both light-weight and inexpensive spacers that can be connected to the sheet material without sewing. Moreover, the gripping apparatus components should reduce the lift cord friction which often increases asymmetric tilting of the sheet-material connectors as the apparatus is raised. Additionally, there is a need for an apparatus and method for easily and rapidly assembling tightly fitted components of a sheet material gripping apparatus such that, once assembled, the components of each sheet material gripping apparatus are capable of maintaining vertical alignment with respect to other sheet material gripping apparatus comprised by the window covering system. Moreover, there is a need for an apparatus and method for easily adjusting and re-aligning assembled components of a sheet material gripping apparatus.

SUMMARY OF THE INVENTION

[0009] The present invention provides a sheet material mounting device having two channels, namely, a mounting channel for receivably engaging a rod for gripping the sheet material and a spacer channel for receivably engaging a spacer support configured to engage a lift cord and, optionally, a spacer cord. The spacer channel may be positioned above the mounting channel such that the center of gravity of the mounting device is located above the center of the mounting channel, thereby reducing asymmetric tilt of the sheet material engaged by the mounting channel and reducing friction against the lift cord. Alternatively, the mounting channel may be positioned above the spacer channel. The mounting channel and the spacer channel are preferably both C-shaped, and each channel has an opening which faces in a direction opposite the direction faced by the opening of the other channel. Thus, a side view of the mounting device may resemble either an “S” or a reverse “S”. In accordance with another aspect of the invention, there is provided an apparatus and method for assembling the components of a sheet-material mounting device, such that the assembled components of each sheet material mounting device are capable of maintaining vertical alignment with respect to every other sheet material mounting device comprised by the window covering system. Moreover, there is provided an apparatus and method for adjusting and re-aligning assembled components of a sheet material gripping apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The features and advantages of the present invention reside in the details of construction and operation as more fully depicted, described, and claimed below, with particular reference to the accompanying drawings, wherein like numerals refer to like parts throughout, and wherein:

[0011] FIG. 1 is a three-quarter perspective view of an exemplary shade clamp according to one embodiment of the present invention;

[0012] FIG. 2A is a perspective view of an exemplary spacer according to one embodiment of the present invention;

[0013] FIG. 2B is a perspective view of an exemplary spacer with the lug portion removed according to one embodiment of the present invention;

[0014] FIG. 3 is a three-quarter perspective view of a portion of an exemplary rod according to one embodiment of the present invention;

[0015] FIG. 4 is a three-quarter perspective, exploded view of an exemplary sheet-material mounting apparatus depicting the positional relationship of the component parts according to one embodiment of the present invention;

[0016] FIG. 5 is a three-quarter perspective view with arrows depicting an exemplary method of receivably engaging a V-spring and spacer within opposed shade clamp channels according to one embodiment of the present invention;

[0017] FIG. 6 is a side elevation view of an exemplary shade clamp prepared to receive a welting of sheet material for subsequent gripping with a rod according to one embodiment of the present invention;

[0018] FIG. 7 is a side elevation view of an exemplary shade clamp having receivably engaged a V-spring and a welting of sheet material according to one embodiment of the present invention;

[0019] FIG. 8 is a side elevation view of an exemplary shade clamp attached to a support structure and having receivably engaged a V-spring, a welting of sheet material and a spacer, wherein the spacer includes a lift cord and spacer cord, according to one embodiment of the present invention;

[0020] FIG. 9 is a side elevation view of an exemplary shade clamp attached to a support structure and having receivably engaged a v-spring, a welting of fabric and a spacer, wherein the spacer includes a lift cord and spacer cord, according to an alternative embodiment of the present invention;

[0021] FIG. 10 is a side view of a prior art device showing the asymmetric tilting of the gripping devices;

[0022] FIG. 11A is a bottom view of a center support bracket according to one embodiment of the present invention;

[0023] FIG. 11B is a front view of a center support bracket according to one embodiment of the present invention;

[0024] FIG. 11C is a rear view of a center support bracket according to one embodiment of the present invention;

[0025] FIG. 12 is an exploded view of the housing assembly showing the end caps and wall brackets according to one embodiment of the present invention; and,

[0026] FIG. 13 is a side cut-away view of a support assembly showing a center support bracket, housing and shade clamp according to one embodiment of the present invention.

[0027] FIGS. 14A-E illustrate a side perspective view of an exemplary tool for assembling and aligning the components of a sheet material mounting device.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0028] The following detailed description of exemplary embodiments of the present invention makes reference to the accompanying drawings, which form a part hereof and in which are shown, by way of illustration, exemplary embodiments in which the invention may be practiced. These exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it should be understood that other embodiments may be utilized and that logical and mechanical changes may be made without departing from the spirit and scope of the present invention. Thus, the following detailed description is presented for purposes of illustration only and not of limitation, and the scope of the present invention is defined solely by the appended claims.

[0029] The present invention preferably includes an apparatus and method for reducing a shade clamp's tilt and reducing the excess friction between a shade clamp (or channel guide) and a lift cord. One skilled in the art will appreciate that the shade clamp may be any device or combination of devices suitably configured to hold sheet material. For example, any clamp, clip, ring, fastener, mechanical device, electrical device, magnetic device, VELCRO™ device and/or the like. Moreover, the shade clamp is comprised of any suitable material which provides sufficient characteristics for holding the sheet material, such as, for example, any type or combination of plastic, metal, rubber, wood, magnet, textile, glass and/or the like. Further, one skilled in the art will appreciate that the sheet material is any material capable of being held by shade clamp, such as, for example, any type or combination of cloth, textile, roman shade, pleated roman shade, wood, metal, animal skin, plastic, mesh, weave, and/or the like. In an exemplary embodiment, the sheet material is a piece of material in the form of a roman shade.

[0030] A suitable support structure is any structure capable of supporting the shade clamp and material, such as a headrail, cord, and/or spacers. With momentary reference to FIG. 13, an exemplary shade system includes shade clamp 1 (only one shown), housing 90, center bracket 71, lift tube 112, facie 110, and other components of the system which will be described in more detail below. The present system may be used in conjunction with any shade operator device, such as a wrap spring shade operator as in “Wrap Spring Shade Operator” with inventors Joel Berman, Vincent J. Brown, Victor Erlikh and John Wilk filed on Aug. 23, 1999 having U.S. Ser. No. 09/379,065, the entire application is incorporated herein by reference.

[0031] Referring now to FIG. 1, in accordance with one embodiment, a shade clamp 1 grips and mounts flexible sheet material 60 to a hanging support structure. The S-shaped shade clamp 1 is preferably rotationally symmetric about the central axis of clamp 1 and has opposed channels 45a, 45b, wherein mounting channel 45b reciprocally receives a welting of sheet material 60 and spacer channel 45a receives a spacer support 5, shown in FIG. 4. The clamp 1 preferably includes interior retaining lips 35a, 35b and peripheral retaining lips 40a, 40b wherein an interior and peripheral retaining lip pair secures the welting of sheet material 60 or the spacer support 5 within opposed channels 45a, 45b by restricting the exit path. Each interior lip 35 and peripheral lip 40 pair defines opposed lateral openings 30a, 30b which provide access to opposed channels 45a, 45b, respectively. The welting of sheet material 60 is releasably nested in the mounting channel 45b with a positive pressure against the inside surface of the channel requiring no further tension or clamping. The interior lip 35b and peripheral lip 40b of the mounting channel lateral opening 30b serve the dual purpose of preventing random release of the secured welting and providing for the 30 neat pinching of the exterior sheet material so as to obscure the view of rod 10, shown in FIG. 3, within the mounting channel 45b. In a preferred embodiment, the welting of sheet material 60 and the spacer support 5 are removably held within opposing channels 45a, 45b by interior lips 35a, 35b and peripheral lips 40a, 40b, respectively; however, those skilled in the art will also recognize various other means and methods that may be alternatively or conjunctively used within the scope of the present invention, such as any device or combination of devices suitably configured to restrict the exit path of material 60 or spacer support 5. For example, a release pin, clasp, snaps, adhesive and/or the like.

[0032] As shown in FIGS. 2A and 2B, spacer support 5 is configured for guiding the lift/guide cord 65, optionally attaching to spacer cord 70, and being receivably engaged by spacer channel 45a. As best shown in FIG. 2A, the spacer support 5 has an enlarged cylindrical end 25 which tapers down on its outside edge, thereby forming an arrowhead like configuration. Cylindrical end 25 is configured for nesting within spacer channel 45a between the inside surface of spacer channel 45a, the interior channel lip 35a and the peripheral channel lip 40a. Those skilled in the art will also recognize various other means and shapes that may be alternatively or conjunctively used which are considered as being within the scope of the present invention, such as any device or combination of devices suitably configured to engage the spacer channel 45a. For example, a pin, rod, clasp, adhesive, and/or the like. Moreover, spacer support 5 can be integral with shade clamp 1 as a single-piece construction. Spacer support 5 itself can also be of single piece construction. In a preferred embodiment, spacer support 5 is clear rigid PVC material with UV protection; however, any suitable material such as plastic, metal, wood and/or the like is within the scope of the present invention.

[0033] With reference to FIGS. 2A and 4, a planar flange 50 is attached to the longitudinal surface of cylindrical end 25, such that flange 50, when spacer support 5 is inserted into spacer channel 45a, protrudes outwardly from the channel opening 30a. In a preferred embodiment, spacer flange 50 includes an aperture 20 which receives lift cord 65 therethrough. The lift cord aperture 20 is positioned on the spacer flange 50 at a predetermined distance away from cylindrical end 25. In a preferred embodiment, spacer support 5 is molded around spacer cord 70, thereby providing a secure attachment between cord 70 and spacer support 5. In a particularly preferred embodiment, spacer support 5 includes a cylindrical projection 53 which extends above and below spacer support 5. In this embodiment, cylindrical projection 53 is also molded around spacer cord 70, thereby increasing the support by spacer support 5 around spacer cord 70. Cylindrical projection 53 may be any suitable material, may project above and/or below spacer support 5, may be molded as a single unit with spacer support 5, may be a separate component (such as a dowel, washer, etc.), and may be located anywhere on spacer support 5. One skilled in the art will appreciate that the present system can include more than one lift cord 65 or more than one spacer cord 70, and aperture 20 can be of any size, located anywhere on spacer support 5, additional apertures can exist on spacer support 5 or cords 65, 70 may be suitably attached, by clip, glue and/or the like, to any portion of the spacer support 5. Moreover, spacer support 5, or any portion of spacer support 5, may be formed around, and fused to, spacer cord 70 and/or lift cord 65, thereby eliminating the need for the aperture 20.

[0034] With particular reference to FIG. 2B, spacer support 5 preferably includes an elliptical notch 54 on the cylindrical end 25 which receives a plate 52. Notch 54 preferably includes a protruding, convex ridge along its inner circumference for receiving the side-slotted groove along the outer circumference of the side surface of plate 52. Plate 52 is preferably an elliptical device with a first rounded end with a flat upper and lower surface and a second enlarged cylindrical end 25 which tapers down on its outside edge, thereby forming an arrowhead like configuration. In a preferred embodiment, if a spacer cord 70 is used, plate 52 and cylindrical projection 53 (as discussed above) is molded around spacer cord 70 such that spacer cord 70 travels through the flat upper and lower surface of plate 52. One skilled in the art will appreciate that the plate 52 and notch 54 configuration can be any configuration and can include any suitable means for attaching plate 52 to spacer support 5 (groove, clip, etc.), or alternatively, spacer support 5 can be a one piece configuration without a removable plate 52.

[0035] More particularly, if it is desired that sheet material 60 lay flat without pleating or the like (for example, in the case of sheet material 60 comprising a detailed pattern), plate 52 and spacer cord 70 may be eliminated from the system. However, if pleating or the like is desired (for example, in the case of sheet material 60 comprising a solid color), the incorporation of plate 52 and spacer cord 70 into spacer support 5 helps form the pleats.

[0036] Rod 10 is any device configured for securing sheet material 60 within the mounting channel 45b of the shade clamp 1. As best shown in FIG. 3 (which shows a portion of the elongated rod 10 in a V-spring clip embodiment), rod 10 is preferably one piece and has a length equal to the width of the shade. Alternatively, rod 10 is many clips, rods, or the like which are inserted into mounting channel 45b at various locations. Rod 10 is preferably a V-spring having depressible wings 55a, 55b for releasably securing a welting of the sheet material 60. As best shown in FIG. 6, the V-spring wings 55a, 55b are compressed to collapse the rod 10 for subsequent insertion into the mounting channel 45b through the mounting channel lateral opening 30b. After insertion into channel 45b, the rod 10 is released and the wings 55a, 55b expand to provide a force against the inner surface of channel 45b, thereby sandwiching the sheet material 60 in mounting channel 45b and restricting the movement of sheet material 60. Those skilled in the art will also recognize various other means and shapes that may be alternatively or conjunctively used which are within the scope of the present invention, such as, for example, a rod, a pin, clasp, VELCRO™, adhesive, snaps and/or the like. Alternatively, rod 10 could be eliminated and material 60 can be wrapped around the outside of mounting channel 45b and optionally clamped to the outside of mounting channel 45b by any of the aforementioned clamping devices.

[0037] The positional arrangement of the component parts of the sheet material mounting apparatus is best shown in FIG. 4. Spacer support 5 receivably engages through side insertion into spacer channel 45a of shade clamp 1 and the rod 10 receivably engages through side insertion the mounting channel 45b of the clamp 1. An alternative method of receivably engaging both the spacer support 5 and the rod 10 in their respective channels 45a, 45b is shown by the arrows of FIG. 5 wherein the components are pushed into their respective channels through openings 30a, 30b, respectively. Those skilled in the art will also recognize various other methods that may be alternatively or conjunctively used which are within the scope of the present invention, such as any arrangement or methods for receivably engaging, such as, for example, rotating the components into the channels, permanent single-piece construction and/or the like.

[0038] As is best shown in FIG. 6, prior to receivably engaging a welting of sheet material 60, the sheet material 60 is placed between the mounting channel 45b and the rod 10. As the upper wing 55a and lower wing 55b of the rod 10 are compressed, the rod 10 is pushed through the lateral opening 30b of the mounting channel 45b or slid through the side, forcing a welting of fabric 60 into the mounting channel 45b as shown in FIG. 7. Alternatively, a welting of sheet material 60 can be wrapped around the exterior surface of the rod 10 and then depressed and forced through the lateral opening 30b (or slid through the side).

[0039] With the guide spacer channel 45a opening the opposite direction to the sheet-material mounting channel 45b, the receivably engaged spacer support 5 is positioned to bear a large percentage of the weight of the sheet material 60 at a point approximately directly above the point of sheet material attachment within channel 45b. This configuration positions the center of gravity of the apparatus more directly above the mounting channel 45b which has the effect of reducing asymmetric tilting of the sheet-material mounting apparatus as the lift cord 70 is raised. This in turn reduces the friction incident upon the lift cord 70 as the shade travels through raised positions and reduces the pulling force needed to lift the shade.

[0040] One method of attachment of clamp 1 to the support structure of a lift cord 65 and spacer cord 70 is shown in FIG. 8. As the lift cord 65 is raised, the spacer support 5 is engaged at a predetermined point to raise and travel with the lift cord 65. The spacer cord 70 is a static line that provides a guide for a plurality of spacer supports 5 to travel along as the shade is moved through raised positions. The spacer cord 70 also assists with preventing torquing of the spacer supports 5 as the lift cord 65 is raised.

[0041] FIG. 9 shows an alternative configuration for reducing friction incident upon the lift cord 70. In this alternative embodiment of the present invention, the receivably engaged spacer support 5 is positioned to bear the weight of the sheet material 60 at a point directly below the point of sheet material attachment to mounting channel 45b. This configuration positions the center of gravity of the apparatus more directly below the mounting channel 45b which similarly has the effect of reducing asymmetric tilting of the sheet-material mounting apparatus as the lift cord 65 is raised. The alternative embodiment of the present invention depicted in FIG. 9 reduces the friction incident upon the lift cord 65 as the shade travels through raised positions as well.

[0042] With respect to FIGS. 11A-C, various views of a center support bracket 71 is shown. Center support bracket 71 is any suitable device configured to support the lift tube 112 (shown in FIG. 13), housing 90, facie 110 (shown in FIG. 13), spacer support 5, and fabric mount while providing a guide for the lift cords 65. One skilled in the art will appreciate that bracket 71 is of any configuration and comprised of any suitable material. Moreover, bracket 71 can be one molded multi-functional component or can be a plurality of components which perform one or more of the aforementioned functions. In a preferred embodiment, bracket 71 includes a central circular opening 76 for supporting the lift tube 112. Top and rear rectangular plates 78 are attached to opening 76 by a lattice structure which is perpendicular to the surface of opening 76. Rectangular plates 78 include lips around its periphery such that plates 78 are suitably configured to attach bracket 71 to housing 90 by slidably engaging the lips into channels 94. The front of bracket 71, as best seen in FIG. 11B, preferably includes a rectangular facie plate 80 with a lip on its periphery for slidably engaging facie. One skilled in the art will appreciate that plates 78 and 80 can attach to other parts by any suitable means, including for example, snaps, VELCRO™, adhesives and/or the like, or can be integral with the other components. Below plate 80, towards the bottom of bracket 71, is an angled ledge 82 which is configured to support the fabric mounting spline. As best seen in FIG. 11A, below ledge 82, and on the bottom of bracket 71, are two opposing notches 72 which open to the outside surfaces of bracket 71 and a circular slot 73. Notches 72 and slot 73 are suitably configured to retain spacer support 5. Also, on the bottom of bracket 71 and further towards the rear surface, there are preferably four apertures 74 which are suitably configured to guide the lift cord 65, wherein two of the holes on the same side are for two different cords depending on the left or right configuration of the cords.

[0043] With respect to FIG. 12, an exemplary housing assembly 90 is shown. Housing assembly 90 is any suitable device or combination of devices in any suitable configuration for supporting center bracket 71 and facie 110 and comprised of any suitable material such as plastic, PVC, metal, aluminum, wood, and/or the like. In a preferred embodiment, housing 90 includes L-shaped plate 92 comprised of extruded aluminum, end caps 96 comprised of plastic, and wall brackets 104 comprised of metal. Plate 92 includes various channels 94 for slidably engaging plates 78 and 80 of center bracket 71, wall bracket 104, and plates 98 of end caps 96. End caps 96 preferably include plates 98 for slidably engaging plate 92 and pins 100 for attaching to the shade drive end bracket.

[0044] In accordance with another exemplary aspect of the present invention, FIGS. 14A-E illustrate an exemplary insertion tool 200. Insertion tool 200 may be used for assembling components of a sheet material mounting device, such as shade clamp 201 and spacer support 205. However, it will be appreciated that insertion tool 200 may be used in any of several contexts. For example, insertion tool 200 may be used to insert or assemble hardware components within an opening in a wall or similar structure. Insertion tool 200 may also be configured for use with components used in microdevices, such as integrated circuits. Referring now to FIG. 14A, in accordance with one exemplary embodiment, tool 200 comprises a base member 202 having a working end 204 and a handle end 206. One skilled in the art will appreciate that tool 200 may be comprised of any suitable material or combinations of materials, such as, for example, plastic, metal, wood, concrete, rock, and/or the like. In an exemplary embodiment, tool 200 is molded of Delrin. Moreover, tool 200 may be comprised of a single molded, shaped, or formed unit, or it may comprise any number of pieces permanently or releasably attached to each other.

[0045] In accordance with one aspect of the invention, handle end 206 is configured to be gripped by the hand of a person, though other embodiments of handle 206 may permit use of tool 200 by a machine or automated device. In one embodiment, handle end 206 permits insertion of a hand through an open center portion 208 and around handle portion 210. Handle portion 210 may comprise any suitable surface contour or configuration, such as rounded or bulbous, cylindrical, rectangular, conical, and/or the like. In another embodiment, center portion 208 is a solid portion which permits handle end 206 to be grasped in the palm of the hand. For example, in this embodiment, handle portion 210 may be held by being pressed against the palm of the hand while the fingers of the hand grasp one side of center portion 208 and the thumb grasps an opposite side of center portion 208. Handle end 206 may be of any suitable dimension or size. In one embodiment, handle end 206 is thicker than working end 204 to suitably accommodate the grip or grasp of a human hand, a machine, or an automated device.

[0046] Working end 204 is distal from the handle end 206 and is configured to receivably engage and releasably retain a part or component, such as spacer support 205, such that working end 204 and the component are then capable of being inserted into and receivably engaged by an opening, such as spacer channel 245a for example. As described herein, the insertion of a component into a spacer channel illustrates an exemplary use for and method of using tool 200 in accordance with the present invention. However, tool 200 may be used to insert and adjust or align parts or components in conjunction with other types of openings, channels, or holes having a variety of shapes or configurations, such as circular, rectangular, square, oblong, triangular, etc., and still fall within the scope of the present invention. In one embodiment, working end 204 includes a pair of spaced apart protruding members 212 which are each configured to be inserted into or slid through the spacer channel 245a of shade clamp 201, as best illustrated in FIG. 14D. The protruding members 212 extend outwardly from the working end 204 of base member 202 and may be of any suitable shape or configuration, such as rectangular, cylindrical, conical, square, and/or the like.

[0047] In one embodiment, protruding members 212 are substantially rectangular. In this embodiment, the protruding members 212 each comprise an outer edge 214, an inner edge 215, an upper surface 216, a lower surface (not shown), an inner side surface 218, and an outer side surface 219. In one embodiment, outer edge 214 has a rounded surface. In another embodiment, upper surface 216 is gradually sloped upward relative to a level lower surface, such that thickness T of protruding member 212 gradually increases along the width of protruding member 212 between outer edge 214 and inner edge 215. In one embodiment, upper surface 216 is gradually sloped upward at an angle ranging from about 2 degrees to about 15 degrees relative to the lower surface and the longitudinal axis of the base member 202. Preferably, upper surface 216 is sloped upward at an angle of from about 3 degrees to about 7 degrees and, more preferably, from about 3 degrees to about 4 degrees. In another embodiment, the lower surface (not shown) of the protruding member 212 is gradually sloped downward relative to a level upper surface 216, such that thickness T of protruding member 212 gradually increases along the width of protruding member 212 between outer edge 214 and inner edge 215. In this embodiment, the lower surface is gradually sloped at an angle ranging from about 2 degrees to about 15 degrees relative to the upper surface 216 and the longitudinal axis of the base member 202. Preferably, the lower surface is sloped at an angle of from about 3 degrees to about 7 degrees and, more preferably, from about 3 degrees to about 4 degrees. In yet another embodiment, both the upper surface 216 and the lower surface of protruding member 212 are gradually sloped away from each other and relative to the longitudinal axis of the base member 202 such that each protruding member 212 has a substantially conical configuration.

[0048] In an exemplary embodiment, protruding members 212 are spaced apart by a recess 222 in the working end 204 of base member 202. Recess 222 may be of any suitable shape or configuration, such as square, rectangular, semi-circular, and/or the like. In one embodiment, recess 222 is defined by a rear surface 224 and a pair of opposing side surfaces 226 in the working end 204. In an exemplary embodiment, opposing side surfaces 226 each include means for engaging and retaining a spacer support 205, which means may include a plurality of retaining members adapted to support the spacer support 205 within recess 222, a suitably dimensioned channel or track which may be inset into each of the opposing side surfaces 222 and into which the spacer support 205 may be inserted, or the like. In an alternate embodiment, rear surface 224 may also include suitable means for releasably retaining spacer support 205, such as retaining members or a suitably dimensioned inset channel or track. Recess 222 and the means for engaging and retaining spacer support 205 are suitably adapted to releasably engage the spacer support 205.

[0049] In one embodiment, the means for engaging and retaining a spacer support 205 comprise a plurality of retaining members 228 extending from each of the opposing side surfaces 226. The retaining members 228 may be arranged in any suitable configuration capable of receivably engaging and retaining the spacer support 205 within recess 222. As illustrated in FIG. 14B, retaining members 228 may be arranged in a V-shaped configuration such that a pair of spaced apart upper retaining members 228a are coupled with a lower retaining member 228b which is placed beneath the space 230 that separates the pair of upper retaining members 228a. A space or track having height H2 is created between upper retaining members 228a and lower retaining member 228b. Height H2 is slightly greater than the thickness H1 of spacer support 205. In this manner, the spaces or tracks created by the opposing side surfaces 226 may stabilize and retain the spacer support 205 within the recess 222, such that when spacer support 205 is inserted within the recess 222, an upper portion, such as that provided by the retaining members 228a, exerts a downward force on spacer support 205 while a lower portion, such as provided by retaining member 228b, exerts an upward force on spacer support 205. Alternatively, retaining members 228 may be arranged such that a pair of spaced apart upper retaining members are coupled with a spaced apart pair of lower retaining members. In a further embodiment, retaining members 228 may be adapted such that a single upper retaining member on each of the opposing sides 226 is coupled with a single lower retaining member on each of the opposing sides 226 to suitably engage and retain spacer support 205 within recess 222. Recess 222 and retaining members 228 are suitably dimensioned to permit spacer support 205 to be slidably inserted within and removed from the recess 222. In one embodiment, recess 222 has a width W2 that is slightly greater than a width W1 of spacer support 205 and a length L2 that is substantially similar to a length L1 of spacer support 205. One skilled in the art will appreciate that retaining members 228 illustrate an exemplary means for engaging and retaining a spacer support 205 within recess 222 in accordance with the present invention and that other structures, such as an inset track or channel within each of opposing side surfaces 226, which perform similar functions may be employed and still fall within the scope of the present invention.

[0050] As seen in FIG. 14C, spacer support 205 may be inserted within recess 222 such that planar flange 250 is supported by retaining members 228 and cylindrical end 225 occupies the space between the protruding members 212. In one embodiment, the outer edge 227 of cylindrical end 225 is substantially flush with the outer edges 214 of protruding members 212. Spacer support 205 may be inserted into the tool 200 either with or without a spacer cord (not shown) being inserted through cylindrical projection 253 and/or a lift cord (not shown) being inserted through lift cord aperture 220.

[0051] Referring next to FIG. 14D, tool 200, with spacer support 205 retained within recess 222, can be used to insert spacer support 205 within spacer channel 245a of shade clamp 201. In one embodiment, one of the protruding members 212 of the working end 204 of tool 200 is brought into contact with a spacer channel end 247 and is inserted or slid into spacer channel 245a between peripheral lip 240a and inner lip 235a. In this embodiment, the protruding member 212 may be used to open or slightly pry apart the lips 240a and 235a at one end 247 of the spacer channel 245a, such that a first protruding member 212 slides into the spacer channel 245a, followed by spacer support 205 and then a second protruding member 212.

[0052] Alternatively, the working end 204 of tool 200 with spacer support 205 retained within recess 222 may be brought into contact with the spacer channel 245a such that the protruding members 212 and the spacer support 205 exert a perpendicular force in the direction of arrow 232 against lips 240a and 235a. As one skilled in the art will appreciate, in the context of using tool 200 with other types of openings and other types of parts or components, the working end 204 of tool 200 may be brought into contact with the outer edges of the opening, such that the protruding members 212 and the component exert a perpendicular force against the outer edges of the opening to enable the tool 200 and the component to be inserted into the opening. The tool 200 may be inserted into an opening with or without the aid of an additional tool, such as a hammer or mallet for example (not shown). In the embodiment depicted in FIG. 14D, the working end 204 of the tool 200 may be used to insert the spacer support 205 substantially at the desired location or position within the spacer channel 245a. That is, protruding members 212 are used substantially simultaneously to open or pry apart lips 240a and 235a at a selected location along spacer channel 245a to permit the insertion of the protruding members 212 and spacer support 205 into the spacer channel 245a. However, in either of these embodiments, once inserted within the spacer channel 245a, tool 200 permits the spacer support 205 to be suitably moved or selectively positioned within spacer channel 245a. Thus, tool 200 may be used to selectively position spacer support 205 within the spacer channel 245a during the insertion step or, alternatively, the tool 200 may be used to selectively position spacer support 205 anywhere along the length of spacer channel 245a subsequent to the insertion step. Moreover, tool 200 may be used consecutively to similarly insert and position multiple spacer supports 205 within spacer channel 245a.

[0053] Once spacer support 205 has been suitably positioned within spacer channel 245a, the tool 200 may be suitably removed from the spacer channel 245a. In one embodiment, tool 200 is removed by the exertion of a force on tool 200 that is perpendicular to and away from the spacer channel 245a. In this manner, the tool 200 is pulled directly out of and away from the spacer channel 245a in the direction of arrow 234 of FIG. 14E. As further illustrated in FIG. 14E, since recess 222 and retaining members 228 are adapted to releasably engage spacer support 205, spacer support 205 remains suitably positioned within spacer channel 245a when tool 200 is removed from the spacer channel 245a.

[0054] Once a part or component has been inserted into the appropriate opening, such as spacer channel 245a, the component may require adjustment or re-alignment with respect to other components of the window covering system. The tool 200 also may be used to adjust or re-align these already-assembled components. The tool 200 provides leverage and a gripping surface to assist in shifting the arrangement of assembled components. To accomplish this, the tool 200 is extended into the opening and brought into contact with the component such that the component is retained by the working end 204 and capable of being moved by the tool 200 to an alternate position within the channel or opening without being bound by the opening. In this manner, the tool 200 permits adjustment and realignment of tightly fitting assembled components.

[0055] While the invention has been particularly shown and described above with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made without departing from the spirit and the scope of the present invention and that the invention encompasses all such modifications. No single feature, function, or property of any disclosed embodiment is required for the practice of the present invention unless specifically described herein as “essential” or “critical”.

Claims

1. A device comprising: a base member including a handle end and a working end distal from said handle end; wherein said working end comprises: a recess defined by a rear surface and opposing side surfaces which are configured to receive and releasably retain a component; and a pair of protruding members extending outwardly from said working end and spaced apart by said recess.

2. The device of claim 1, wherein said handle end is configured to be gripped by at least one of a human hand, a machine, and an automated device.

3. The device of claim 2, wherein said base member further comprises one of an open center portion and a solid center portion.

4. The device of claim 1, wherein at least one of an upper surface of each of said protruding members and a lower surface of each of said protruding members has an increasing slope relative to a longitudinal axis of said base member.

5. The device of claim 1, wherein at least one of said rear surface and said opposing side surfaces comprises a track configured to slidably receive and releasably retain the component within said recess.

6. The device of claim 1, wherein each of said opposing side surfaces comprises a plurality of retaining members, each of which extends from said opposing side surfaces and into said recess and is configured to receive and releasably retain the component.

7. The device of claim 6, wherein said plurality of retaining members is arranged in a V-shaped configuration.

8. The device of claim 1, further comprising a component releasably retained within said recess and between said protruding members.

9. The device of claim 8, wherein said component comprises a spacer support.

10. The device of claim 9, wherein an outer edge of said spacer support is substantially flush with each outer edge of said protruding members.

11. A method of inserting a component into an opening, the method comprising: providing an insertion tool including a handle end and a working end; inserting a spacer support within a recess in said working end of said insertion tool; contacting an opening with said insertion tool and said spacer support; inserting said spacer support and said insertion tool within said opening; removing said insertion tool from said opening while leaving said spacer support within said opening.

12. The method of claim 11, wherein the step of contacting said opening further comprises using said insertion tool to exert a perpendicular force against outer edges of said opening.

13. The method of claim 12, wherein the step of contacting further comprises selectively positioning said spacer support relative to said opening.

14. The method of claim 12, wherein the step of inserting said spacer support further comprises prying apart said outer edges with protruding members of said insertion tool and inserting said spacer support and said protruding members through said outer edges and into said opening.

15. The method of claim 14, further comprising positioning said spacer support within said opening after inserting said spacer support and said protruding members within said opening.

16. The method of claim 14, wherein the step of removing further comprises applying to said insertion tool a perpendicular force away from said opening such that said insertion tool is pulled out of said opening.

17. The method of claim 12, wherein said opening comprises a spacer channel and said outer edges comprise lips.

18. The method of claim 17, wherein the step of contacting a spacer channel further comprises contacting a spacer channel end with a first end of said working end of said insertion tool, and wherein the step of inserting said spacer support further comprises sliding said first end, said spacer support, and a second end of said working end of said insertion tool into said spacer channel from said spacer channel end.

19. The method of claim 17, further comprising selectively positioning said spacer support within said spacer channel after inserting said spacer support and said insertion tool within said spacer channel.

20. The method of claim 18, wherein the step of removing further comprises applying to said insertion tool a perpendicular force away from said spacer channel such that said insertion tool is pulled out of said spacer channel.

21. A method of adjusting and re-aligning a component within an opening, the method comprising: providing an insertion tool including a handle end and a working end; contacting an opening and a component retained within said opening with said working end of said insertion tool; engaging said component with said working end; and moving said component to an alternate location within said opening.