Patent Application
20130105095
The invention relates to a wirelessly operated motorized shade. Specifically, the invention relates to a wirelessly operated motorized shade having an improved antenna arrangement and/or antenna cable connection.
A roller shade is a rectangular panel of fabric, or other material, that is attached to a cylindrical, rotating tube. The shade tube is mounted near the header of a window such that the shade rolls up upon itself as the shade tube rotates in one direction, and rolls down to cover a desired portion of the window when the shade tube is rotated in the opposite direction.
Rotation of the roller shade is accomplished with an electric motor that is directly coupled to the shade tube. Recently-developed battery-powered roller shades provide installation flexibility by removing the requirement to connect the motor and control electronics to facility power. The batteries for these roller shades are typically mounted within, above, or adjacent to the shade mounting bracket, headrail or fascia. The motor may be located inside or outside the shade tube, is fixed to the roller shade support and is connected to a simple switch, or, in more sophisticated applications, to a radio frequency (RF) based system that controls the activation of the motor and the rotation of the shade tube. These RF based systems typically need an antenna to transmit and receive RF signals and associated cabling to connect the antenna to a controller. Unfortunately, these RF based systems suffer from many drawbacks, including, for example, poor performance, need for a large area for an antenna, increased costs, increased complexity, and/or the like for the antenna and cabling.
Aspects of the invention advantageously provide a motorized roller shade that includes a shade tube, including an outer surface upon which a shade is attached, an inner surface defining an inner cavity and two end portions, a motor/controller unit, disposed within the shade tube inner cavity and mechanically coupled to the shade tube inner surface, including a support shaft configured to attach to a mounting bracket, a DC motor having an output shaft coupled to the support shaft such that the output shaft and the support shaft do not rotate when the support shaft is attached to the mounting bracket, a power supply unit, electrically coupled to the motor/controller unit, disposed within the shade tube inner cavity and mechanically coupled to the shade tube inner surface, including a support shaft attachable to a mounting bracket, a wireless receiver coupled to the motor/controller unit to receive wireless signals, and an antenna arranged on or in at least one of the two end portions.
Additional aspects of the invention advantageously provide a motorized roller shade that includes a shade tube including an outer surface upon which a shade is attached, an inner surface defining an inner cavity and two end portions, a motor/controller unit including a support shaft configured to attach to a mounting bracket, a DC motor having an output shaft coupled to the support shaft, a power supply unit, electrically coupled to the motor/controller unit, disposed within the shade tube inner cavity and mechanically coupled to the shade tube inner surface, including a support shaft attachable to a mounting bracket, a wireless receiver coupled to the motor/controller unit to receive wireless signals, and an antenna arranged on or in the motorized roller shade and a coupling that couples the antenna to said wireless receiver.
There has thus been outlined, rather broadly, certain aspects of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional aspects of the invention that will be described below and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of aspects in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the invention.
The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. The term “shade” as used herein describes any flexible material, such as a shade, a curtain, a screen, etc., that can be deployed from, and retrieved onto, a storage tube or similar structure.
Aspects of the invention provide a remote controlled motorized roller shade in which the batteries, DC gear motor, control circuitry may be entirely contained within a shade tube that may be supported by bearings. Two support shafts may be attached to respective mounting brackets, and the bearings rotatably couple the shade tube to each support shaft. The output shaft of the DC gear motor may be fixed to one of the support shafts, while the DC gear motor housing is mechanically coupled to the shade tube. Accordingly, operation of the DC gear motor causes the motor housing to rotate about the fixed DC gear motor output shaft, which causes the shade tube to rotate about the fixed DC gear motor output shaft as well. The control circuitry is operated by the user using a radio frequency remote control. Control signals from the remote control are received by the control circuitry through an antenna.
The antenna is arranged on the remote controlled motorized roller shade. In one aspect, the antenna may be arranged on an end of the roller shaft. In a further aspect, the antenna may be a fractal antenna. In another aspect, the antenna may be connected to the control circuitry with a coaxial cable through a connector. The antenna configuration and/or coaxial cable configuration improves performance, reduces the size of the components, reduces costs, reduces complexity, and/or the like.
The motorized roller shade assembly 1 may be supported by shafts 6 that may be positioned and retained by openings 5 in the mounting brackets 3. The upper or first end of the shade material is secured to the storage roll 8 by means known in the art. In some aspects, all of the components necessary to power and control the operation of the motorized roller shade assembly 1 may be advantageously located on or within motorized tube assembly 8 (Shown in
The motorized roller shade assembly 1 also includes an antenna 4 so that control signals may be received in the motorized roller shade assembly 1 and/or transmitted from the motorized roller shade assembly 1. The antenna 4 may be arranged anywhere on or in the motorized roller shade assembly 1. In particular, the antenna 4 may be arranged on an outside surface of the motorized roller shade assembly 1 to improve reception and/or transmission performance. Furthermore, the antenna 4 may be arranged on an outside end surface of the motorized roller shade assembly 1 to further improve reception and/or transmission performance. Additionally, the antenna may be arranged on a Printed Circuit Board (PCB) or wafer 14. Arranging the antenna 4 on a PCB 14 makes manufacturing less complex and less expensive.
The end cap 7 closest to the motor may include the PCB 14 or similar mounting structure. The PCB 14 may include a substantially flat surface for the antenna 4. The antenna 4 may be located a distance from the receiver and motor control 11. However, the antenna 4 may be arranged on any surface of the motorized roller shade assembly 1.
The RF signals received by the antenna 4 from a user transmitter (not shown) or transmitted from the antenna 4 are carried by wiring to the receiver and motor control 11. The wiring may be a coaxial cable 9.
Regarding the connection, the coaxial cable 9 may be configured so that an outer insulator 17 is stripped away or removed at an end of the coaxial cable 9 adjacent to the PCB 14. Further, a braid 18 of the coaxial cable 9 may be trimmed to expose a center insulator 19 at the end of the coaxial cable 9 adjacent to the PCB 14. The center insulator 19 then may be trimmed to slightly less than the thickness of the PCB 14.
The coaxial cable 9 with this construction may be inserted into a hole 23 in the PCB 14 that is centered between two pads 15 and 21 (one on the top layer and one on the bottom layer). The two pads 15 and 21 may not be plated through the hole 23 in the PCB 14. The braid 18 may be soldered to pad 15 so as to form a solder connection 16 between the pad 15 and the braid 18. The solder 16 may make an electrical connection between the pad 15 and the braid 18. The solder connection 16 may also serve as a mechanical fastener for fastening the cable 9 to the PCB board 14.
The construction of the solder connection 16 to the pad 15 relieves strain associated with the fragile center conductor 20 and reduces the chance of damage. The PCB hole 23 may be sized to only allow the center insulator 19 inside the PCB board 14.
It should be noted that in this aspect, the size of the common hole is critical to the performance of this construction/method. The braid 18 (outer conductor) should not be allowed to enter into the hole 23. Additionally, the center insulator 19 may be trimmed so as to not protrude beyond the bottom layer 21. However, other configurations are contemplated.
The center conductor 20 may be soldered to the bottom layer 21 and trimmed. Note the insulator 19 can be trimmed to expose the center conductor 20 below the surface near the bottom layer 21. In this alternate fashion, the center conductor 20 may be soldered 16 to the bottom layer 21 and then trimmed very flush to the bottom layer 21.
The connection of the antenna coaxial cable 9 to the PCB 14 can be formed onto or incorporated into a printed circuit board (PCB) 14 placed in the end cap 7 of the storage roll 8. This configuration eliminates the need for a more costly coaxial connector on the cable and costly coaxial socket on the PCB 14. Additionally, the invention reduces the size of the attachment to nearly the diameter of the incident coaxial cable. The invention relieves strain associated with the cable directly at the PCB 14, allowing flexing immediately above the PCB 14 surface. With a connector of the invention, the strain relief occurs at the back of the connector, thus not allowing the cable to flex at the PCB itself.
The motorized roller shade assembly 1 may include other components such as an electrical power connector that includes a terminal that couples to a power supply unit, and power cables that may connect to the circuit board(s) located within the circuit board housing.
Two circuit boards may be mounted within the circuit board housing in an orthogonal relationship. Circuit boards generally include all of the supporting circuitry and electronic components necessary to sense and control the operation of the motor, manage and/or condition the power provided by the power supply unit, etc., including, for example, a controller or microcontroller, memory, a wireless receiver, etc. In one embodiment, the microcontroller is a Microchip 8-bit microcontroller, such as the PIC18F25K20, while the wireless receiver is a Micrel QwikRadio® receiver, such as the MICRF219. The microcontroller may be coupled to the wireless receiver using a local processor bus, a serial bus, a serial peripheral interface, etc. In another embodiment, the wireless receiver and microcontroller may be integrated into a single chip, such as, for example, the Zensys ZW0201 Z-Wave Single Chip, etc.
In another embodiment, a wireless transmitter is also provided, and information relating to the status, performance, etc., of the motorized roller shade may be transmitted periodically to a wireless diagnostic device, or, preferably, in response to a specific query from the wireless diagnostic device. In one embodiment, the wireless transmitter is a Micrel QwikRadio® transmitter, such as the MICRF102. A wireless transceiver, in which the wireless transmitter and receiver are combined into a single component, may also be included, and in one embodiment, the wireless transceiver is a Micrel RadioWire® transceiver, such as the MICRF506. In another embodiment, the wireless transceiver and microcontroller may be integrated into a single module, such as, for example, the Zensys ZM3102 Z-Wave Module, etc. The functionality of the microcontroller, as it relates to the operation of the motorized roller shade 320, is discussed in more detail below.
The many features and advantages of the invention are apparent from the detailed specification, and, thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and, accordingly, all suitable modifications and equivalents may be resorted to that fall within the scope of the invention.
