Information
-
Patent Grant
-
6615895
-
Patent Number
6,615,895
-
Date Filed
Tuesday, January 22, 200222 years ago
-
Date Issued
Tuesday, September 9, 200320 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
- Ohlandt, Greeley, Ruggievo & Perle, L.L.P.
-
CPC
-
US Classifications
Field of Search
US
- 160 173 R
- 160 173 V
- 160 1661 R
- 160 1681 R
- 160 1681 V
- 160 172 R
- 160 1781 R
- 160 1781 V
-
International Classifications
-
Abstract
An extruded plastic head rail for a blind of the type having blind elements suspended from such head rail, in which the head rail is reinforced to prevent sagging of the head rail under the load of the blind elements, and in which the head rail is suitable for trimming to length by a point of sale trim cutting apparatus, the head rail having a head rail extrusion extruded from plastic material and, a reinforcement member in the head rail, the reinforcement member extending along at least a median portion of length of the head rail, the reinforcement member supporting the head rail and the blind elements, to prevent bending of the head rail under the load of the blind elements.
Description
FIELD OF THE INVENTION
The invention relates to blinds of the kind having a head rail, and a plurality of blind slats suspended from the head rail, and in particular to such a blind in which the head rail is formed of plastics material, such as extruded polyvinyl chloride material, and is reinforced along its interior, with reinforcement members, preferably, though not exclusively, with metal reinforcements.
BACKGROUND OF THE INVENTION
Blinds having a head rail and blind slats suspended from the head rail are well known. Such blinds include “venetian” blinds in which the slats run from side to side, horizontally, and also vertical blinds in which the slats hang vertically down from trollies carried in the head rail.
For many years such head rails have been made of metal. Usually they have been formed in the shape of a rectangular U-shaped channel, with the blind operating and control mechanism located in the channel.
In recent years however customers have been seeking a more economical form of blind. Head rails for less expensive blinds are now commonly made of extruded plastics material, such as polyvinyl chloride materials. Such materials have their advantages such as low cost and freedom from maintenance and the like. However customers are always seeking for new and different visual effects in blinds. In one case it has become the practice to make the blind slats themselves of extruded plastic materials. These are both less expensive than metal blind slats, and also provide a more solid look than conventional thin metallic blind slats.
However the use of such thicker plastic blind slats carries with it the penalty of greater weight. In fact for a given size of window the use of thicker plastic slats, can increase the weight to the point where they will impose bending stresses on the extruded plastic head rail, and it will bow downwardly in the centre.
This is both unsightly, and may also cause malfunction of the blind control mechanism located within the head rail.
The problem could be overcome by using a conventional metallic head rail, but this would increase the cost, and might also affect the appearance of the blind.
Another factor in the marketing of such blinds is that is becoming the custom to market these blinds through department stores. Blinds are supplied to the store in standard widths. A customer will measure the actual window or door opening in which he wishes to erect a blind. He will then place his order in the store. The sales clerk will then select a blind having a width greater than that required by the customer.
He will then trim the ends of the blind head rail and the blind slats (and the bottom rail if provided) so as to fit the customer's requirement.
Various machines are available for trimming blinds. Some use cutting blades. Others use actual profiled cutting dies, especially for cutting metallic head rails.
Examples of such in store point of sale blind trimming machines can be seen in U.S. Pat. No. 5,806,394, 6,196,099, 6,178,857, 6,089,134, all of which are owned by Shade-O-Matic Llimited, also the owner of the present application.
However, where the blinds have a plastic head rail, and extruded plastic slats, and a bottom rail in some cases, it is preferable to cut them with a saw. The plastic is softer and at the same time thicker than the metal used for conventional head rails. Thus in the case of a blind having a plastic head rail, and plastic blind slats, the length of the cutting stroke required to cut a given number of plastic blind slats is increased compared with cutting the same number of metal blind slats. Cutting such plastic slats with a knife edge requires considerable effort. It also tends to damage the plastic at the ends of the slats. Because the stroke required to cut the stack of thicker plastic blind slats is much longer than the stroke required to cut thin metal blinds slats, then either the manual effort required to make the cut must increase, or the leverage available in the cutting machine must be increased. Neither is desirable or practical. It is in fact found that the use of a saw, typically a rotary saw disc will provide a quick clean cut through the relatively softer plastic blind slats, and also the plastic head rail, with a minimum of physical effort.
This also has the added advantage that the head rail, usually a U-shaped channel, can be cut cleanly with a saw, without the need for supporting it in a special die. Such rotary saw cut down equipment is now becoming widely available in retail stores, rendering it possible to such stores to meet public demand for low cost blinds, trimmed to size on demand, in the store.
However, if the plastic head rail is not capable of supporting the weight of the blind slats then it should preferably be given some kind of reinforcement such that it will be effective to prevent sagging under the weight of the plastic blind slats.
However, the reinforcement must be such that it does not prevent the head rail from being cut down or trimmed in the in store trimming apparatus, of which the saw cutting equipment now available is one example, in the retail stores.
BRIEF SUMMARY OF THE INVENTION
An extruded plastic head rail for a blind of the type having blind elements suspended from such head rail, in which the head rail is reinforced to prevent sagging of the head rail under the load of the blind elements, and in which the head rail is suitable for trimming to length by point of sale trim cutting apparatus, the head rail having a head rail extrusion extruded from plastic material and, a reinforcement member attached to the head rail, the reinforcement member extending along at least a median portion of length of the head rail, the reinforcement member supporting the head rail and the blind elements, to prevent bending of the head rail under the load of the blind elements.
The invention further seeks to provide an extruded plastic head rail for a blind wherein said head rail defines a front side wall and a rear side wall and a bottom wall.
The invention further seeks to provide an extruded plastic head rail for a blind wherein said reinforcement member comprises a three sided channel of reinforcement material.
The invention further seeks to provide an extruded plastic head rail for a blind wherein said reinforcement material is metallic.
The invention further seeks to provide an extruded plastic head rail for a blind wherein said reinforcement material is rigid strip of plastic material.
The invention further seeks to provide an extruded plastic head rail for a blind wherein said reinforcement member is a generally three sided channel fitting within said head rail.
The invention further seeks to provide an extruded plastic head rail for a blind wherein said reinforcement member comprises a planar strip of metallic material
The invention further seeks to provide an extruded plastic head rail for a blind wherein the head rail has at least a front wall and a bottom wall, and reinforcement attached thereto.
The various features of novelty which characterize the invention are pointed out with more particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated and described preferred embodiments of the invention.
IN THE DRAWINGS
FIG. 1
is a general perspective of a typical venetian blind, for the purposes of illustrating the invention;
FIG. 2
is a top plan view of a head rail illustrating one embodiment of the invention;
FIG. 3
is a section along line
3
—
3
of
FIG. 2
;
FIG. 4
is a top plan view of a head rail illustrating another embodiment of the invention;
FIG. 5
is a section along line
5
—
5
of
FIG. 4
;
FIG. 6
is a perspective of a portion of
FIG. 4
;
FIG. 7
is a top plan view of another embodiment of head rail;
FIG. 8
is a section along line
8
—
8
of
FIG. 7
;
FIG. 9
is a section of a further form of head rail;
FIG. 10
is a section of a still further form of head rail;
FIG. 11
is a plan view of another form of head rail;
FIG. 12
is a section of a further alternate form of head rail; and,
FIG. 13
is a section of a further alternate embodiment of head rail.
DESCRIPTION OF A SPECIFIC EMBODIMENT
As mentioned above the invention relates to blinds in which the head rail supports blind slats, and in which the head rail is made of plastics material and is reinforced to carry the weight of the blind slats. Typically the blinds are “Venetian” blinds with a plurality of horizontal blind slats. However the invention does not exclude to possibility of its use with vertical blinds, in which the blind slats hang vertically down from the head rail.
Thus, purely for purpose of explanation and without limitation
FIG. 1
illustrates a typical “venetian” blind
10
. It has a head rail
12
, and blind elements, in this case slats
14
, attached on ladder tapes
16
. A tilt control rod
18
, and raise cords
20
provide means by which the blind slats can be tilted open or closed, or raised or lowered, in known manner. In many cases it may also have a bottom rail, also of extruded plastic material. The blind controls
18
and
20
are all mounted in the head rail. The head rail
12
in this embodiment, is shown in the form a three sided U-shaped channel, with the open side facing upwardly. As has been explained there is a demand for more economical blinds, in which the blind elements or slats are made of extruded plastic and are relatively thick and heavy. In these lower cost blinds it is desirable to make both the head rail and the blind slats from extruded plastic. This renders the blind easier to trim to length at a point of sale using an in store trim cutting apparatus However it is found that where the blind slats are heavy, because for example they are made of relatively thick extruded solid plastic material, or even of wood in some cases, the plastic head rail will bend and sag in the middle. This will be unsightly and cause malfunction of the blind controls located in the head rail.
While blind slats are illustrated it will be understood that the invention is not solely limited to blinds having blind slats. The term blind elements as used herein is intended to include both blind slats and other forms of blind designs, whether having slats, fabric, or any other type of window covering.
Accordingly the invention makes provision for the reinforcement of the plastic head rail so as to give it increased strength and enable it to resist bending stresses.
One embodiment of the invention is illustrated in
FIGS. 2
, and
3
.
A head rail
30
is illustrated, formed of plastic material, such as polyvinyl chloride extruded, in this embodiment, in a channel shape of a head rail. It defines side walls
32
-
32
, and a web
34
. The upper side is open upwardly. Blind controls, consisting of tape drums
36
, and a raise cord lock
38
and a tilt control
40
are located in head rail
30
. A transmission rod
42
extends through the tilt control
40
and drums
36
.
All of this is well known in the art and requires no description.
As shown in
FIG. 3
the head rail is formed on its interior with upper and lower ridges
44
, which extend parallel to side walls
32
but are spaced inwardly.
Upper arcuate ribs
46
are formed along the upper edges of side walls
32
, and face inwardly partially closing the open upper side of the channel of head rail
30
.
In order to reinforce the head rail, in this embodiment, two planar reinforcement strips
48
are secured within the head rail
30
. Strips
48
are secured in place by sliding between ridges
44
and side wails
32
(FIG.
3
). The reinforcement strips
48
may typically be formed of a suitable metal. However the invention does not exclude the use of non-metallic reinforcement strips, such as might be made of some more rigid form of plastic material, for example fibre reinforced resin materials or the like.
Where the reinforcement is of a material, or a metal, which is suitable for in store trim cutting for example by saw cutting trim apparatus, for example, aluminum, then the reinforcement strips can extend from end to end of the head rail. When trimming the head rail down to size, at the point of sale, in the retail store, the sales clerk will simply place one end of the head rail, and the blind slats and the bottom rail (if provided) in a saw cut down machine (not shown) and make a cut, and then reverse the blind and make a similar trim cut at the other end of the components, using the saw for example. Such a saw will easily cut through both the plastic head rail and the softer metal reinforcement, as well as through the bind slats and bottom rail.
However, in some cases the metallic strip or strips will be of harder metal such as steel. In these cases also, it is necessary to permit a sales clerk to trim the ends of the head rail, as well as the blind slats and bottom rail, in this embodiment of the invention the harder metallic strips
48
will extend only over a median portion of the length of the head rail
30
, as shown in phantom in FIG.
4
.
The features of the plastic head rail
30
are the same as those in
FIGS. 2 and 3
, and have the same reference numbers.
However, as explained above the metal reinforcement strips
48
will be shorter than the length of the head rail
30
, in this embodiment, so as to permit trimming at each end, and will terminate short of each end of the head rail
30
.
In this case, additional stiffness at each end of head rail
30
is provided in this embodiment by stiffening plugs
50
(FIGS.
5
and
6
).
Stiffening plugs
50
are formed of plastic material, and in this case may be in the shape of an inverted channel, although any other shape providing extra strength and stiffness will be suitable.
Side walls
52
and web
54
, are integral, and define a width and height such that they make a sliding fit into the ends of head rail
32
. To hold plug
50
secure, upper and lower lips
56
and
58
are arranged to interfit with ridges
44
on head rail
32
. When slid into place at each end of head rail
32
the plugs
50
add stiffness to the ends of the head rail and at the same time permit trimming of the head rail, in these ends regions, by a variety of different cutting media, of which the saw cutter is one example, at the same time as trimming the blind slats and bottom rail.
Another embodiment of reinforcement is shown in head rail
60
in
FIGS. 7 and 8
.
In this case the head rail
60
is of substantially regular channel-shaped cross-section, having side walls
62
and a web
64
. Rolled edges
66
are formed on the upper free edges of side walls
62
. The entire head rail
60
, in some cases, or as in this illustration, only a median portion of head rail
60
, is reinforced with a metallic three sided channel
68
. Channel
68
is dimensioned to make a snug sliding fit within head rail
60
. However, as in the
FIG. 4
embodiment the reinforcement terminates short of each end of the head rail so as to leave portions at each end of the head rail, which are not reinforced, and are therefor suitable for trimming. Plugs
70
, generally similar to plugs
50
, will be inserted in each end of head rail
60
, where the reinforcement member is absent, so as to permit trimming of each end by a saw. However, if the channel
68
was made of a softer metal, or a non-metal, then it could extend to full length of head rail
60
, and in this case the plugs
70
would not be required.
A further embodiment is shown in FIG.
9
.
In this case, a head rail
80
is formed of extruded plastic material, having a shape in section generally similar to head rail
60
, having side walls
82
and a web
84
defining a rectangular U-shaped channel, with rolled edges
86
.
However, within side walls
82
there are formed inner passage walls
88
spaced inwardly from side walls
82
, which define slim vertical passages
90
.
Reinforcement strips
92
of suitable metallic reinforcement material are received in passages
90
. In this way the reinforcement strips
92
can be held in position and resist bending stresses imposed on the head rail
80
by the weight of the blind slats. As before the metallic reinforcement, strips may be of softer metal, in which case they can extend the full length of head rail
80
, or they may be of harder metal, in which case they would terminate short of each end. In this case some form of additional stiffness (not shown), such as plugs
50
or
70
, would be inserted at the ends of the head rail.
A further embodiment is shown in FIG.
10
.
In this case, a head rail
100
, has side walls
102
and a web
104
, formed of plastic material, and define a rectangular U-shaped channel. In this embodiment reinforcement is provided by a plurality of reinforcement strips or rods
106
. Rods
106
would be co-extruded with the plastic material, and would be integrally embedded in the side walls and web as illustrated. The rods could be made of any suitable metal, or of non-metallic material adequate to provide reinforcement for the head rail
100
.
In this case, provided the reinforcement material is suitable, the rods could be continued to the ends of the head rail
100
. There would then be no need for a plastic plug at each end. The ends could simply be trimmed with a saw, which would cut both the plastic material and the reinforcement rods
106
.
For the sake of completeness, an embodiment of the invention having a metallic reinforcement channel
68
extending from end to end of the head rail is illustrated in FIG.
11
.
It will be understood that with suitable selection of reinforcement materials, especially softer metals, or non-metals, any of the embodiments of
FIGS. 1
to
9
could all be made with reinforcement extending from end to end, as shown in
FIG. 11
, provided that the reinforcements were suitable for cutting, by what ever cutting system was available in the store.
A still further embodiment is shown in FIG.
12
. In this case the head rail
110
is extruded from thermoplastic material, with side walls
112
and a bottom wall
114
.
On the outer sides or side walls
112
upper and lower retaining lips
116
and
118
are formed, defining retention grooves
120
. Exterior reinforcement strips
122
are slid into grooves
120
, to provide extra bending resistance to the head rail
110
.
Strips
122
may be of non-metallic materials, or of metals, either of which being softer, and suitable for cutting in an end trimming apparatus. In this embodiment such reinforcement strips
122
will preferably extend the full length of head rail
110
since the reinforcement strip on at least one side of the head rail
110
will be visible at all times and will in fact present the finished exterior appearance of the head rail
110
. In this embodiment this factor may well be an advantage. The exterior facing or finish of the head rail
110
will be the appearance of the reinforcement strip
122
.
Since this can be made in a variety of finishes and materials and colours, this embodiment offers great flexibility for stores and for customers.
In all the examples described above, the head rail has been described as a three sided channel. This is in fact the commonest form of such head rail, and is in wide use, both in metal structures as well as in extruded plastics. However it will be understood, that in certain cases, where the head rail is supported with a suitable reinforcement it may be possible to dispense altogether with one of the two channel side walls, of the extruded plastic channel. Thus the plastic head rail would become in effect an L-shaped extrusion with a front wall and a bottom wall, but with no back wall.
Such an embodiment is shown in FIG.
13
. The head rail extrusion consists of front wall
130
and bottom wall
132
, formed of extruded plastic material.
A reinforcement channel
134
is secured within walls
130
and
132
. It may be of softer metal or non metal and extend from end to end, or it may be formed of steel in which case it will terminate short of each end. In this cases some further end members such as plugs
52
of
FIGS. 2 and 3
can be used at each end, so as to permit trimming of each end in store end trim machines.
This may not be suitable for every form of blind, and may not be acceptable to all customers. However for those customers looking for economy and low price, it might have a certain appeal.
The foregoing is a description of a preferred embodiment of the invention which is given here by way of example only. The invention is not to be taken as limited to any of the specific features as described, but comprehends all such variations thereof as come within the scope of the appended claims.
Claims
- 1. An extruded plastic head rail for a blind having a plurality of blind elements suspended from a head rail, said head rail being reinforced to prevent sagging of said head rail under the load of said plurality of blind elements, and being suitable for trimming to length by an in store point of sale trim cutting apparatus, said head rail comprising:(a) a head rail extrusion extruded from plastic material for forming said head rail and defining at least a front wall and a bottom wall, said head rail being of a predetermined length; and (b) a reinforcement member in said head rail, said reinforcement member being the same length as said head rail, wherein said reinforcement member is formed of a material adapted to be cut by the in store point of sale trim cutting apparatus, said reinforcement member being adapted to support said head rail and said plurality of blind elements, and to prevent bending of said head rail under the load of said plurality of blind elements.
- 2. An extruded plastic head rail for a blind as claimed in claim 1 wherein said head rail defines a front side wall and a rear side wall and a bottom wall.
- 3. An extruded plastic head rail for a blind as claimed in claim 2 wherein saidreinforcement member comprises a three sided channel of reinforcement material.
- 4. An extruded plastic head rail for a blind as claimed in claim 3 wherein said reinforcement material is metallic.
- 5. An extruded plastic head rail for a blind as claimed in claim 1 wherein said head rail is of generally L-shape in section and defines a front wall and a bottom wall, and wherein said reinforcement member is a generally three sided channel fitting within said front wall and said bottom wall.
- 6. An extruded plastic head rail for a blind as claimed in claim 2 wherein said head rail is formed with upper retention flanges in said side walls, and wherein said reinforcement member is received in said flanges.
- 7. An extruded plastic head rail for a blind as claimed in claim 6 wherein said head rail further defines lower retention flanges on said side walls, and wherein said reinforcement member is in the form of two planar reinforcement strips, each said strip being received in respective upper and lower flanges.
- 8. An extruded plastic head rail for a blind as claimed in claim 7 wherein said retention flanges are located on the inwardly facing sides of said side walls.
- 9. An extruded plastic head rail for a blind as claimed in claim 7 wherein said retention flanges are formed on the outwardly facing sides of said side walls.
- 10. An extruded plastic head rail for a blind having a plurality of blind elements suspended from a head rail, said head rail being reinforced to prevent sagging of said head rail under the load of said plurality of blind elements, and being suitable for trimming to length by a point of sale trim cutting apparatus, said head rail comprising:(a) a head rail extrusion extruded from plastic material for forming said head rail and defining at least a front wall, a side wall and a bottom wall; (b) a reinforcement member in said head rail, said reinforcement member extending along at least a median portion of said head rail, said reinforcement member being adapted to support said head rail and said plurality of blind elements and to prevent bending of said head rail under the load of said plurality of blind elements, said reinforcement member having at least one planar strip of metallic material; (c) said head rail being formed with at least one partition wall along said side wall, defining at least one elongated passage therein; and wherein at least one metallic strip being received within said at least one passage.
- 11. An extruded plastic head rail for a blind as claimed in claim 10, wherein said reinforcement member is shorter than said head rail and terminates short of each end of said head rail.
- 12. An extruded plastic head rail for a blind as claimed in claim 11 and including reinforcement plug members located in each end of said head rail and wherein said plug members are formed of a material softer than said reinforcement member whereby said head rail may be cut at each end in the region of said plug members.
- 13. An extruded plastic head rail for a blind as claimed in claim 4, wherein said head rail is formed with two partition walls along said side wall defining two elongated passages therein, and wherein each of said passages receive a metallic strip therein.
- 14. An extruded plastic head rail for a blind as claimed in claim 10, wherein said reinforcement member is the same length as said head rail and extends from end to end thereof, and wherein said reinforcement member is formed of a material adapted to be cut by the point of sale trim cutting apparatus.
- 15. An extruded plastic head rail for a blind as claimed in claim 10, wherein said reinforcement member has at least one rigid strip of plastic material.
- 16. An extruded plastic head rail for a blind as claimed in claim 15, wherein said plastic material is received within at least one elongated passages.
- 17. An extruded plastic head rail for a blind having a plurality of blind elements suspended from a head rail, said head rail being reinforced to prevent sagging of said head rail under the load of said plurality of blind elements and being suitable for trimming to length by a point of sale trim cutting apparatus, said head rail comprising:(a) a head rail extrusion extruded from plastic material for forming said head rail and defining at least a front wall and a bottom wall; (b) a reinforcement member in said head rail, said reinforcement member extending along at least a median portion of said head rail, said reinforcement member being adapted to support said head rail and said plurality of blind elements, and to prevent bending of said head rail under the load of said plurality of blind elements; and (c) said reinforcement member having a plurality of reinforcement rods embedded in said head rail.
- 18. An extruded plastic head rail for a blind as claimed in claim 17, wherein said reinforcement member is the same length as said head rail and extends from end to end of said head rail, and wherein said reinforcement member is formed of a material adapted to be cut by a point of sale trimming apparatus.
- 19. An extruded plastic head rail for a blind having a plurality of blind elements suspended from a head rail, said head rail being reinforced to prevent sagging of said head rail under the load of said plurality of blind elements, and being suitable for trimming to a reduced length at a point of sale establishment by a trim apparatus, said head rail comprising:(a) a head rail extrusion extruded from plastic material for forming said head rail and defining at least one side wall and a bottom wall, said head rail having two ends spaced at a predetermined length; (b) said head rail being formed with at least one partition wall along at least one said side wall defining at least one elongated passage therein; (c) a reinforcement member in said head rail having at least one planar strip of metallic material, wherein said strip is received within said at least one passage of said head rail; (d) said reinforcement member being of a length shorter than said predetermined length of said head rail and extending along a median portion of said head rail and terminating short of said ends of said head rail; and (e) plug members located in each end of said head rail in which said reinforcement member is absent, wherein said plug members are formed of a material softer than said reinforcement member, whereby said head rail may be cut at each end in the region of said plug members.
- 20. An extruded plastic head rail for a blind having a plurality of blind elements suspended from a head rail, said head rail being reinforced to prevent sagging of said head rail under the load of said plurality of blind elements, and being suitable for trimming to a reduced length at a point of sale establishment by a trim cutting apparatus, said head rail comprising:(a) a head rail extrusion extruded from plastic material for forming said head rail and defining at least a front wall, a bottom wall, and two ends separated by a predetermined length; (b) a reinforcement member of a material stiffer than said head rail and located in said head rail, said reinforcement member being the same length as said head rail and extending from end to end of said head rail, for supporting said head rail and said plurality of blind elements, and to prevent bending of said head rail under the load of said plurality of blind elements; and (c) said reinforcement member being formed of a material having characteristics adapting it to be trimmed by the trim cutting apparatus.
US Referenced Citations (9)