Patent Grant
12037842
A portion of the disclosure of this patent document contains material that is subject to copyright protection, particularly the Figures appended hereto. The copyright owner has no objection to the reproduction by anyone of the patent document or patent disclosure as it appears in the Patent and Trademark Office, patent file or records, but otherwise reserves all copyrights whatsoever.
The present disclosure relates primarily to coverings for architectural openings. Particularly, the present disclosure is directed to embodiments of a roll-up window covering and related methods and systems.
Retractable coverings for architectural openings have assumed numerous forms over a long period of time. Originally, coverings for architectural openings such as windows, doors, archways or the like consisted principally of fabric draped across the architectural openings. Such early forms of coverings evolved into retractable roller shades, curtains, draperies, and the like wherein the covering could be extended across the architectural opening or retracted to a top or side of the opening.
An early but still popular form of covering for architectural openings is the Venetian blind wherein a plurality of vertically extending cord ladders support parallel horizontally extending slats in a manner such that the slats can be pivoted about their longitudinal axes between open and closed positions and the entire blind can be moved between an extended position wherein it extends across the architectural opening and a retracted position where the slats are accumulated in a vertical stack adjacent to the top of the architectural opening.
Vertical blinds are also available which are very similar to Venetian blinds except the slats or vanes extend vertically and are suspended from their upper ends for pivotal movement about their longitudinal vertical axes. The entire blind can be extended across the opening or retracted adjacent to one or more sides of the opening in a horizontal stack.
However, the current state of the art of Venetian blinds and similar products continue to suffer from a variety of deficiencies. Embodiments of the present disclosure provide solutions for these as well as other problems.
The purpose and advantages of the present disclosure will be set forth in, and be apparent from, the description that follows, as well as will be learned by practice of embodiments made in accordance with the disclosure. Additional advantages of the invention will be realized and attained by the methods and systems particularly pointed out in the written description and claims hereof, as well as from the appended drawings.
To achieve these and other advantages and in accordance with the purposes of the disclosure, as embodied and broadly described, in accordance with some implementations, the disclosure provides a covering for an architectural opening, which may preferably be a roll-up covering. The roll-up covering may include a roller having a first end and a second end and defining a width between the first end and the second end, but it should be understood that the roller is not an essential part of the roll-up covering. The roller preferably defines a central rotational axis. The roll-up covering includes a first outer elongate tape that in turn has a first end, a second end, and defines a length between the first end and the second end. The first outer elongate tape further defines a lateral width, a thickness and a first central longitudinal axis between the first end and second end of the first outer elongate tape, such as along a geometric center of the first outer elongate tape. The first end of the first outer elongate tape can be attached to the roller such that the first central longitudinal axis of the first outer elongate tape is oriented generally orthogonally with respect to the central rotational axis of the roller. The elongate tapes have inner faces along the lengths of the tapes that are oriented and face towards each other, and have outer faces on the opposite surface or side from the inner face of each elongate tape such that the outer faces are oriented and face away from each other.
The roll-up covering further includes a first inner elongate tape disposed proximate to the outer elongate tape. The first inner elongate tape has a first end, a second end, and defines a length between the first end and the second end. The first inner elongate tape further defines a lateral width, a thickness and a second central longitudinal axis between the first end and second end of the first inner elongate tape. The first inner elongate tape may define a plurality of collapsible hinge segments disposed along the length of the first inner elongate tape, however, these hinge segments are not essential to the roll-up covering. The collapsible hinge segments are configured to collapse in order to decrease the effective length of the first inner elongate tape when the first inner elongate tape is rolled up around the roller. The collapsible hinge segments are further configured to expand in order to increase the effective length of the first inner elongate tape when the roll-up covering is unrolled from the roller. The first end of the first inner elongate tape can be attached to the roller such that the second central longitudinal axis can be oriented generally orthogonally with respect to the central rotational axis.
The roll-up covering further includes a plurality of slats disposed between and coupled to the first outer elongate tape and the first inner elongate tape. Preferably the slats each have a first end and a second end, and have a longitudinal length between the first end and the second end. The slats each preferably further include an inner longitudinal edge and an outer longitudinal edge, which are parallel to the length of the slat and define a depth (also referred to herein as width of the slat) between the inner longitudinal edge and the outer longitudinal edge. Each slat also preferably has a thickness orthogonal to the length and orthogonal to the depth of the slat. The slats can be oriented transversely with respect to the first and central longitudinal axes of the first inner and first outer elongate tapes, such that the length of each slat preferably is parallel with and in the same direction as the width of each elongate tape. The plurality of slats, first outer elongate tape and first inner elongate tape define a subassembly that is configured to be rolled up around the roller, wherein the first inner elongate tape is located radially inwardly with respect to the first outer elongate tape when the subassembly is rolled up around the roller. The slats may also have an upper face defined by an inner longitudinal edge, an outer longitudinal edge, a first end, and a second end, along with a lower face defined by an inner longitudinal edge, an outer longitudinal edge, a first end, and a second end. The upper face and the lower face of the slats being opposite each other and oriented so that they face away from each other, the upper face facing the roller, and the lower face facing away from the roller.
The roll-up covering without the roller and the hinge segments includes a first outer elongate tape having a first end, a second end, and defining a length between the first end and the second end, the first outer elongate tape further defining a lateral width, a thickness and a first central longitudinal axis between the first end and second end of the first outer elongate tape. The roll-up covering without the roller further includes a first inner elongate tape disposed proximate to the outer elongate tape, the first inner elongate tape having a first end, a second end, and defining a length between the first end and the second end, the first inner elongate tape further defining a lateral width, a thickness and a second central longitudinal axis between the first end and second end of the first inner elongate tape, and a plurality of slats disposed between and coupled to the first outer elongate tape and the first inner elongate tape, the slats being oriented transversely with respect to the first and second central longitudinal axes when the roll-up covering is in an expanded configuration. The plurality of slats, first outer elongate tape and first inner elongate tape define a subassembly that is configured to be rolled up, and the first inner elongate tape is located radially inwardly with respect to the first outer elongate tape when the subassembly is rolled up.
The roll-up covering may additionally include a roller having a first end and a second end, a width between the first end and the second end, a diameter, a central rotational axis, and a radius of curvature.
The first inner elongate tape may define a plurality of collapsible hinge segments disposed along the length of the first inner elongate tape, the collapsible hinge segments being configured to collapse in order to decrease the effective length of the first inner elongate tape when the first inner elongate tape is rolled up, the collapsible hinge segments being further configured to expand so that the first inner elongate tape attains its length when the roll-up covering is unrolled. The hinge segments can be preformed into the first inner elongate tape.
From this exemplary embodiment, it should be understood that when referring to the roller and the hinge segments in the disclosure, these features should be considered as optional.
In accordance with a further aspect, the plurality of slats may define a length that is parallel to the lateral width of the first outer elongate tape and first inner elongate tape, the length of the slats being greater than the largest lateral width of one of the first outer elongate tape and first inner elongate tape.
The lateral width of the inner and/or outer elongate tapes can be substantially perpendicular to said length, and the thickness can be substantially perpendicular to said length and lateral width.
In accordance with a further aspect, the subassembly can be configured to reside in a collapsed configuration wherein the slats are closed when the subassembly is initially unrolled from the roller, optionally from the roller. The plurality of slats are preferably oriented parallel to the first inner elongate tape and the outer elongate tape when the subassembly is in the collapsed configuration, wherein the slats are closed or substantially closed when the subassembly is initially unrolled, optionally from the roller. The sub assembly can be deployed from the collapsed configuration into an expanded configuration wherein the slats are opened by further rotation or further rotation of the roller. The slats can be coupled to said first outer elongate tape and said first inner elongate tape, such that an upper and a lower face of the slats are transverse to said central longitudinal axis of said elongate tapes when said subassembly is in an expanded configuration and said upper and lower faces of the slats are substantially parallel to said central longitudinal axis of said elongate tapes when said subassembly is in a closed configuration.
In many implementations, the first outer elongate tape and the first inner elongate tape can be substantially parallel along their length when the subassembly is in the collapsed configuration and the expanded configuration. Moreover, the first outer elongate tape and the first inner elongate tape can be substantially parallel along their lengths while the subassembly is deployed from the collapsed configuration into the expanded configuration. Alternatively, the tapes are not always parallel during deployment.
In accordance with a further aspect, a plurality of the slats, and if desired, all of the slats can have an elongate, flexible generally planar body that has an inner edge attached to the first inner elongate tape, an outer edge attached to the first outer elongate tape, and side edges at the ends of the slats joining and extending between the inner edge and outer edge of the slats. The inner and outer edges can define a slat length, and side edges joining the inner edge and outer edge can define a slat depth. The slats can have a length in a direction transverse to said first central longitudinal axis and the second central longitudinal axis, thereby corresponding to the width of the finished covering and the slat lengths can be longer than the lateral widths of the greater one of the first outer elongate tape and the first inner elongate tape. In some implementations, at least one of an inner edge region along the inner edge of at least one slat and an outer edge region along the outer edge of the at least one slat can be stiffer than a region between the inner edge and outer edge of the at least one slat. Such flexibility can be useful in providing a versatile geometry for the roll-up covering. In some implementations, at least one of the inner edge region and the outer edge region can include at least one elongate stiffener for increasing the stiffness of the at least one slat, the at least one elongate stiffener defining a length and a central lateral axis along its length. Thus, the inner edge, outer edge, or both edges can be provided with one or more such stiffeners disposed along the length of at least one of the slats.
In accordance with further aspects, the at least one elongate stiffener can be substantially planar (e.g., flat, crowned, creased, and the like) and lie in substantially the same plane as one of the first central longitudinal axis of the first outer elongate tape and the second central longitudinal axis of the first inner elongate tape. The at least one stiffener can further define a width perpendicular to the length, and a thickness perpendicular to the width and the length. The at least one elongate stiffener can have a curved cross section in a plane perpendicular to the central lateral axis (e.g. be “crowned”) such that a first curved planar face of the at least one elongate stiffener can be convex and a second, opposite curved planar face of the at least one elongate stiffener can be concave. The concave face of the at least one stiffener preferably faces the roller when the subassembly is rolled up around the roller. The concave face of the at least one stiffener can have a radius of curvature that substantially matches a radius of curvature of the roller. The at least one stiffener has a thickness that is preferably substantially smaller than its width.
In accordance with a further aspect, the at least one slat can includes a first stiffener proximate to the inner edge region of the at least one slat and a second stiffener proximate to an outer edge region of the at least one slat, each of the first and second stiffeners having a concave face. The concave faces of the first stiffener and the second stiffener can both face in the same direction. Moreover, the concave faces of the first stiffener and the second stiffener can have a radius of curvature that substantially matches a radius of curvature of the roller to facilitate rolling up of the subassembly. The at least one slat for example can be formed from a flexible fabric material. The at least one stiffener can be formed, for example, from at least one of a rigid plastic material, a metallic material, such as aluminum, titanium, brass or steel, or the like.
In some implementations, the illustrative examples of flexible fabric material of the at least one slat can be disposed between and attached to an outwardly facing face of the first inner tape and an inwardly-facing concave face of the first stiffener along the inner edge of the at least one slat. Alternatively, the first stiffener can be disposed in a sleeve defined along an interior portion of the slat. The flexible fabric material of the at least one slat can be disposed between and attached to an inwardly facing face of the first outer tape and an outwardly-facing convex face of the second stiffener along the outer edge of the at least one slat, among other possible configurations. The flexible fabric material of the at least one slat can be attached to an inwardly facing face of the first outer tape along a two dimensional contact or bonding area that extends parallel to the first central longitudinal axis and transversely with respect to the first central longitudinal axis. For example, the contact or bonding area can be generally rectangularly-shaped, triangularly shaped, “X”-shaped, “L”-shaped, as desired. The flexible fabric material of the at least one slat can be attached to an inwardly facing face of the outer tape by one or more of (i) an adhesive, (ii) at least one fastener, (iii) stitching, (iv) three dimensional weaving and (v) ultrasonic welding. Other flexible or non-flexible materials than the flexible fabric as exemplified here may be used.
In accordance with a further aspect, at least one of the slats can include at least one transverse stiffener attached to the at least one slat in a region of the slat disposed between the first outer elongate tape and first inner elongate tape. Any desired number of slats can be provided with this feature in order to help maintain uniform spacing between the tapes when the subassembly is deployed. In one embodiment, one or more such transverse stiffeners are provided in, on or under a top slat in the subassembly to resist an inwardly compressive force arising from a combination of the weight of the subassembly acting in concert with an angulation of the inner and outer tapes proximate the roller. In one embodiment, the at least one transverse stiffener can be disposed between the first stiffener and the second stiffener to provide a slat with a particularly stable shape during deployment. When the at least one transverse stiffener is disposed on an upper slat in the subassembly, the at least one transverse stiffener is thus adapted to maintain the upper slat in a generally open condition, and causes the first outer elongate tape to be separated from the first inner elongate tape. If desired, the at least one transverse stiffener can be disposed across the slat between the first outer elongate tape and the first inner elongate tape to act as a strut to separate the tapes. Moreover the at least one transverse stiffener can be crowned for enhanced sectional modulus and column strength. Preferably, the at least one transverse stiffener can buckle or otherwise collapse and roll up around the roller when the subassembly is retracted around the roller.
In accordance with one embodiment, first and second magnetic connectors can be disposed opposing one another to control the opening of the covering for the architectural opening. For example, the first magnetic connector can be disposed and movable on an outer face of the first inner elongate tape and the second magnetic connector can be disposed and movable on an outer face of the first outer elongate tape, wherein the first and second magnetic connectors hold the first inner elongate tape and first outer elongate tape together to maintain at least a portion of the window covering in a closed condition. In some implementations, the first and second magnetic connectors have sufficient magnetic forces attracting each other such that moving one of the first and second magnetic connectors can cause coordinated movement of the other of the first and second magnetic connectors. In accordance with an exemplary embodiment of the present disclosure, the coordinated upward movement of the first and second magnetic connectors can cause the side edges of the plurality of slats to collapse against the first inner elongate tape and first outer elongate tape, and the downward movement of the first and second magnetic connectors can cause the side edges of the plurality of slats to separate from the first inner elongate tape and first outer elongate tape. In the illustrated embodiment, the first connector can be movable along the second central longitudinal axis, and second connector can be movable along the first central longitudinal axis. In another embodiment, the pair of magnetic connectors can be removable from the first outer elongate tape and the first inner elongate tape. It will be appreciated that a variety of other connectors can be used in place of or in addition to the first and second magnetic connectors, such as clips and the like to selectively hold the inner and outer elongate tapes together. In accordance a further embodiment, each pair of opposing elongate tapes, such as the third and fourth, and fifth and sixth, elongate tapes (or only some of the pairs of tapes, as desired) can be provided with pairs of magnetic connectors as described above.
In accordance with still a further aspect, the first inner elongate tape and first outer elongate tape can be aligned to roll on top of each other when the subassembly is retracted around the roller. Alternatively, the first inner elongate tape and first outer elongate tape can be laterally displaced from each other along the length of the slats such that they do not roll on top of each other when the subassembly is retracted around the roller. In accordance with a further example, the first inner elongate tape and first outer elongate tape can have different lateral widths.
In accordance with one embodiment, the first inner elongate tape and first outer elongate tape can be attached proximate to a center of the roller between the first end and the second end. If desired, the ends of the slats of this embodiment can be freely floating by virtue of using one or more stiffeners along the length of each slat.
In accordance with another embodiment of the present disclosure, a door can be provided on the body of the roller, wherein the door has a width defined by the first and second end of the roller (or other suitable width), a radial curvature that substantially matches that of the roller, an inner end, an outer end, a thickness, and a length that is defined between the inner and outer end. It can be further provided that the radial curvature of the door forms a concave inner face and a convex outer face for the door.
In a further embodiment, the door can be attached to the roller via a hinge at the inner end, wherein the hinge can be a concavely curved inner end of the door on the concave inner face hooked into a receiving cavity of the roller for the width of the roller.
In accordance with another embodiment, the door can be operable to be opened by detaching or separating from the roller on the outer end and attaching to the roller at the inner end via the hinge across the width of the door. The door can be further operable to be closed by collapsing and rolling the outer end of the door toward and around the roller.
In a further embodiment of the present disclosure, a raised ridge can be integrally provided on the concave inner face of the door along the width of the door whereby the ridge and the outer end of the door form a track across the width of the door and the ridge can have a concave raised edge along the width of the door. In accordance with one embodiment, the track can accommodate at least one elongate stiffener attached to a flexible slat of the covering. For example, the stiffener can be covered by a flexible portion of the slat such that the stiffener covered with the flexible portion of the slat can be disposed in the track across the width of the track. The slat can be attached to an inwardly facing face of the first inner elongate tape by, for example, adhesive, fastener(s), stitching, three-dimensional weaving, ultrasonic welding and the like. In accordance with another embodiment of the present disclosure, a receiving track can be integrally provided on the body of the roller wherein the receiving track has a width defined by the first and second end of the roller, a radial curvature that substantially matches the curvature of the roller, a first end, a second end, a thickness, and a length defined between the first and second end of the receiving track. In a further embodiment, the receiving track can accommodate at least one elongate stiffener whereby the stiffener is covered by a flexible slat portion such that the stiffener covered with the slat portion can be disposed in the receiving track for the width of the receiving track and the slat portion of the at least one stiffener is attached to an inwardly facing face of the first outer elongate tape by, for example, adhesive, fastener, stitching, three-dimensional weaving, ultrasonic welding and the like.
In accordance with another embodiment, when the door on the roller is in an open position it maintains the upper slat of the roll-up covering in a generally open condition such that the first outer elongate tape can be separated from the first inner elongate tape. Such an embodiment can thus be used without a transverse stiffener, as described elsewhere herein. In accordance with another embodiment, the first inner elongate tape and first outer elongate tape can be attached proximate to a first end of the slats, and the roll-up covering can further include a second outer elongate tape having a first end, a second end, and defining a length between the first end and the second end. The second outer elongate tape can further define a lateral width, a thickness and a third central longitudinal axis between the first end and second end of the second outer elongate tape. The first end of the second outer elongate tape can optionally be attached to a roller such that the third central longitudinal axis of the second outer elongate tape can be oriented generally orthogonally with respect to the central rotational axis of the roller, and be displaced laterally along the roller from the first outer elongate tape, such as at the second end of the roller, or another location. The roll-up covering can still further include a second inner elongate tape disposed proximate to the second outer elongate tape. The second inner elongate tape can have a first end, a second end, and define a length between the first end and the second end. The second inner elongate tape can further define a lateral width, a thickness and a fourth central longitudinal axis between the first end and second end of the second inner elongate tape. The second inner elongate tape can further define a plurality of collapsible hinge segments disposed along the length of the second inner elongate tape. The collapsible hinge segments are preferably configured to collapse in order to decrease the effective length of the second inner elongate tape when the second inner elongate tape is rolled up, optionally around the roller. The collapsible hinge segments are preferably further configured to expand in order to increase the effective length of the second inner elongate tape when the roll-up covering is unrolled, optionally from the roller. The first end of the second inner elongate tape can optionally be attached to the roller such that the second central longitudinal axis can be oriented generally orthogonally with respect to the central rotational axis. In a particular embodiment, the second inner elongate tape and second outer elongate tape are attached proximate to a second end of the slats. One of the first inner elongate tape and first outer elongate tapes can be spaced apart from respectively the second inner elongate tape and/or second outer elongate tape, for example by a distance of at least 6 inches, and preferably by a distance greater than eight inches.
In accordance with still another embodiment the roll-up covering can further include a third outer elongate tape having a first end, a second end, and defining a length between the first end and the second end. The third outer elongate tape can further define a lateral width, a thickness and a fifth central longitudinal axis between the first end and second end of the third outer elongate tape. The first end of the third outer elongate tape can optionally be attached to a roller such that the fifth central longitudinal axis of the third outer elongate tape can be oriented generally orthogonally with respect to the central rotational axis of the roller. The roll-up window covering can still further include a third inner elongate tape disposed proximate to the third outer elongate tape. The third inner elongate tape has a first end, a second end, and defines a length between the first end and the second end. The third inner elongate tape can further define a lateral width, a thickness and a sixth central longitudinal axis between the first end and second end of the third inner elongate tape. The third inner elongate tape can further define a plurality of collapsible hinge segments disposed along the length of the third inner elongate tape. The hinge segments can be configured to collapse in order to decrease the effective length of the third inner elongate tape when the third inner elongate tape is rolled up, optionally around the roller. The hinge segments can further be configured to expand in order to increase the effective length of the third inner elongate tape when the roll-up covering is unrolled, optionally from the roller. The first end of the third inner elongate tape can be attached to the optional roller such that the sixth central longitudinal axis can be oriented generally orthogonally with respect to the central rotational axis. If desired, the third inner elongate tape and third outer elongate tape can be attached to the roller proximate a center of the roller, between the first and second sets of tapes.
In accordance with still further aspects of the disclosure, the roll-up covering can further include a weight proximate to the second ends of the first, second, and/or third inner elongate tapes. The weight is preferably configured to maintain tension on the first inner elongate tape.
In accordance with still further aspects, each of the aforementioned plurality of collapsible hinge segments can be disposed proximate to a slat in the subassembly. In some implementations, each hinge segment can be defined by a plurality of spaced apart transverse crease lines defined in the first inner elongate tape. In some implementations, the hinge segment(s) can fold downward onto an exterior face of the first inner elongate tape when the subassembly is rolled onto the roller. In some embodiments, a lower crease line defining the hinge segment can be disposed proximate to an inner or outer edge of one of the slats. If desired, the lower crease line can be disposed immediately above a region where the first inner elongate tape is attached to the inner edge of the slat.
In some embodiments, the tapes can be made from a flexible material. If desired, the crease lines can be crush formed into the flexible material. For example, the flexible material can be selected from the group including films and textiles. If desired, the textile can be selected from the group consisting of knits, wovens and non-wovens. The flexible material used for the tapes preferably have a thickness between about 1-30 mils, 1.5-25 mils, 2-25 mils, 3-20 mils, 4-18 mils, 6-16 mils, 8-14 mils, and about 10-12 mils.
In some embodiments, the tapes and slats can be made from a woven material such as a Roc-Lon® blackout drapery liner material, manufactured by Rockland Industries, Inc. (1601 Edison Hwy Baltimore, MD 21213, (410) 522-2505). In some implementations, the stiffeners can be polymeric or aluminum crowned blind slats that are about 0.008 inches thick and 16 mm wide. Preferably, such materials are provided free from any waxes or other materials or treatments that inhibit adhesion with an adhesive. In further implementations, the surface of an aluminum crowned blind slat can be provided that is surface treatment, such as via anodization, oxidation, plasma treatment, and the like. In alternative embodiments, the width of the stiffeners can vary from about 3/16 of an inch to about ⅝ inch or up to about one inch. A larger stiffener width can be appropriate, particularly for slats of larger depth (e.g., 4, 4.5, 5, 5.5 or 6 inches).
A purpose of the invention is that both the length and the width of the roll-up covering are readily customizable because the length is readily controllable by selecting the desired number of slats, and the width is readily controllable by selecting the desired slat length (the slat is cut from a continuous roll of slat material) to match the desired roll-up covering width. The roll-up covering length is further customizable because the slat spacing need not be determined by ladders or any other pre-existing elements of the roll-up covering. Instead, the slats may be placed at any desired points along the tapes (or other support elements) to achieve the desired roll-up covering length and slat spacing.
In accordance with further aspects of the disclosure, slats, which may be subsequent slats, can be separated by a substantially uniform distance along the first outer elongate tape and the first inner elongate tape. If desired, such a distance can be a standard distance (e.g., 60 mm, 72 mm), or the spacing can be customized to any desired length, as subsequent slats can be overlapped to any desired extent, such as about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50% or any increment therebetween of 1%. Thus, a custom roll-up covering may be provided wherein the spacing between adjacent slats is determined by dividing a total intended custom length (also referred to herein as height) of the subassembly by a number of desired slats. The custom height is directly related to the dimensions of the architectural opening or feature the subassembly or covering is intended to be installed in or on. Thus, it is possible to provide a custom subassembly of custom height with a custom, uniform distance between the slats. As a result, when in an open configuration, the bottom-most slat or bottom-most feature (for example, a weighted bar, a slat, a bottom rail, or bottom weight) of the subassembly is separated from the next slat by the same distance separating other adjacent slats, and the subassembly is of a height that can fully extend without interference in or on the architectural opening. Any roll-up covering disclosed herein can also be made to a custom width for any width opening, and the placement of the elongate tapes along the length of the slats can similarly be a custom spacing.
In another embodiment, subsequent slats can be separated by a non-uniform distance along at least one of the first outer elongate tape and the first inner elongate tape. Preferably, this is accomplished by having the segment of the outer elongate tapes between adjacent slats being shorter or longer than the inner elongate tapes between those slats, as desired. If desired, the spacing between subsequent slats can be selected to cause the slats to open at different rates, for example, such that light will be permitted to pass through a first portion of the roll-up covering before passing through a second portion of the roll-up covering. It should be appreciated that this selection of spacing between subsequent slats can also be applied to other types of blinds, such as a conventional Venetian blind. If desired, at least one of the outer elongate tapes and/or at least one of the inner elongate tapes is longer than another of the outer elongate tapes and the inner elongate tapes between subsequent slats after at least one pair of adjacent slats. If desired, at least one of the outer elongate tapes and/or at least one of the inner elongate tapes is longer than the other of at least one of the outer elongate tapes and at least one of the inner elongate tapes between a pair of adjacent slats a different distance than between subsequent slats after said pair of a slats.
In further accordance with the disclosure, a ladder tape is provided. Such a ladder tape can be configured to be biased to close, and to roll up onto itself. For example, such a ladder tape can include a first elongate tape having a first end, a second end, and defining a length between the first end and the second end, the first elongate tape further defining a lateral width, a thickness and a first central longitudinal axis between the first end and second end of the first outer elongate tape, the first end of the first elongate tape being configured to be attached to a roller. The ladder tape can further include a second elongate tape disposed parallel to the first elongate tape. The elongate tapes have inner faces along the lengths of the tapes that are oriented and face towards each other, and have outer faces on the surface of each tape opposite from the inner faces such that the outer faces are oriented and face away from each other. The second elongate tape has a first end, a second end, and defines a length between the first end and the second end. The second elongate tape further defines a lateral width, a thickness and a second central longitudinal axis between the first end and second end of the second elongate tape. The second elongate tape further defines a plurality of collapsible hinge segments disposed along the length of the second elongate tape. The collapsible hinge segments can be configured to collapse in order to decrease the effective length of the second elongate tape when the second elongate tape is rolled up around a roller radially inwardly of the first elongate tape. The collapsible hinge segments can further be configured to expand in order to increase the effective length of the second elongate tape when the inner and outer tapes are unrolled from the roller. The ladder tape can further include a plurality of connectors disposed between and coupled to the first elongate tape and the second elongate tape along the length of the tapes, the tapes and connectors cooperating to form a ladder tape suitable for receiving (e.g., rigid) slats in the saddle area of the tapes to make a blind. If desired, at least one of the connectors can include a flexible fabric body having a first end, a second end, a first planar face and a second planar face. The first planar face can be attached to an inwardly facing face of the first elongate tape at the first end, and the second planar face can be attached to an inwardly facing face of the second elongate tape at the second end. The ladder tape can be biased to fold into a planar configuration. If desired, the connectors can assume a “Z” or “S” shape when the ladder tape is deployed.
The disclosure further provides a roll-up covering material for a covering for an architectural opening, configured to be rolled up, optionally around a roller of a roll-up covering for an architectural opening. The material includes a first outer elongate tape having a first end, a second end, and defining a length between the first end and the second end, the first outer elongate tape further defining a lateral width, a thickness and a first central longitudinal axis between the first end and second end of the first outer elongate tape. The material further includes a first inner elongate tape disposed proximate to the outer elongate tape, the first inner elongate tape having a first end, a second end, and defining a length between the first end and the second end, the first inner elongate tape further defining a lateral width, a thickness and a second central longitudinal axis between the first end and second end of the first inner elongate tape. The material further includes a plurality of flexible slats disposed between and attached to the first outer elongate tape and the first inner elongate tape, the slats being oriented transversely with respect to the first and central longitudinal axes, at least one of the slats in the plurality of slats can be a transversely stiffened slat including stiffened longitudinal edges (also referred to herein as inner and outer edges) connected by a flexible body portion, wherein the transversely stiffened slat is attached to the first outer elongate tape and first inner elongate tape at the location of the stiffened longitudinal edges of the transversely stiffened slat, wherein the plurality of slats, first outer elongate tape and first inner elongate tape define a roll-up covering material that is configured to be rolled up, optionally around a roller.
The disclosure still further provides a roll-up covering for an architectural opening, including a roller having a first end and a second end and defining a width between the first end and the second end, the roller defining a central rotational axis, and the aforementioned roll-up covering material. The first end of the first outer elongate tape is preferably attached to the roller such that the first central longitudinal axis of the first outer elongate tape is oriented generally orthogonally with respect to the central rotational axis of the roller. Further, the first inner elongate tape is preferably located radially inwardly with respect to the first outer elongate tape when the subassembly is rolled up around the roller, and further wherein the first inner elongate tape is configured to collapse upon itself as the roll-up covering is rolled around the roller. the first inner elongate tape can be configured to collapse upon itself as an edge of one of the plurality of slats approaches the roller while the roll-up covering is rolled around the roller. The disclosure further provides a roll of the aforementioned roll-up covering material for making roll-up coverings.
In some embodiments of the roll-up covering and/or roll-up covering material, the first inner elongate tape can be longer than the first outer elongate tape between adjacent slats. For example, the first inner elongate tape can be between about 0.5% and about 25% longer than the first outer elongate tape between at least one pair of adjacent slats in the roll-up covering material, in any desired increment therebetween of about 0.5%. In some implementations, the roll-up covering and/or roll-up covering material can include a plurality of inner elongate tapes and a plurality of outer elongate tapes. For example, the roll-up covering material and/or roll-up covering can include a plurality of inner elongate tapes along a first face of the slats and a plurality of outer elongate tapes along a second face of the slats. In any implementation, if desired, the roll-up covering and/or roll-up covering material can be provided in a form wherein the at least two of the tapes are of different widths. For example, at least one of the inner and/or outer elongate tapes is of a different width than another elongate tape. Moreover, placement of the tapes along the length of the slats can be varied in different embodiments. For example, the plurality of inner elongate tapes can lay over the plurality of outer elongate tapes such that they partially or completely overlap when the roll-up covering and/or roll-up covering material is collapsed on a flat surface. In other embodiments, at least one of the inner elongate may not lay over any of the plurality of outer elongate tapes when the roll-up covering and/or roll-up covering material is collapsed on a flat surface. In various embodiments, at least one of the inner and/or outer elongate tapes can be disposed along a first and/or second edge of the plurality of slats. In some embodiments, different slats within the roll-up covering material and/or roll-up coverings herein can be made from different materials to achieve different functional and design effects.
The disclosure also provides a flexible slat material for forming a roll-up covering for an architectural opening. The slat material includes an elongate flexible planar body having a first end and a second end joined by a plurality of longitudinal edges, wherein at least one of the longitudinal edges is a stiffened edge that is stiffened along the length of the slat material along a first direction orthogonal to the stiffened edge, and further wherein the stiffened edge is substantially less stiff along a second direction orthogonal to the stiffened edge. Thus, the stiffened edge can be predisposed to resist a larger bending force along one direction orthogonal to the longitudinal edge of the flexible slat material than a second direction orthogonal to the longitudinal edge of the flexible slat material.
The slat material can typically include two opposed longitudinal edges, wherein each of the longitudinal edges is stiffened. The stiffened edge(s) can include a stiffened planar region along the stiffened edge. If desired, the stiffened edge(s) can include a generally planar stiffener attached to the elongate flexible planar body. In some implementations, the stiffened edge(s) can include a stiffener attached to the elongate flexible planar body substantially along its entire length, or between ten and one hundred percent of its length in increments of one percent. In some implementations, the stiffened edge(s) can be continuously attached to the elongate flexible planar body substantially along its entire length, or between ten and one hundred percent of its length in increments of one percent. In other implementations, the stiffened edge(s) can be continuously attached to the elongate flexible planar body along its entire length. In some implementations, the stiffened edge(s) can be intermittently attached to the elongate flexible planar body substantially along its entire length, or between ten and one hundred percent of its length in increments of one percent. In still other implementations, the stiffened edge(s) can be intermittently attached to the elongate flexible planar body along its entire length.
In some implementations, the generally planar stiffener(s) can include a crown along its length. For example, the slat material can include a generally planar stiffener having a crown along its length attached to the elongate flexible planar body proximate each of two opposing longitudinal edges of the elongate flexible planar body. If so configured, the crowns of each of the generally planar stiffeners can be oriented in the same or opposite directions when the elongate flexible planar body is laid flat on a flat surface. Depending on preference, the generally planar stiffener(s) can be visible, or covered by fabric, such as by the fabric of the elongate flexible planar body. The disclosure further provides a roll of flexible slat material including the flexible slat material described herein, wherein the roll is formed by winding the flexible slat material about a core such that the plurality of longitudinal edges form side edges of the roll. The disclosure further provides a slat formed from the flexible slat material described herein.
The disclosure still further provides a roll-up covering and/or roll-up covering material for an architectural opening including a plurality of slats made from the flexible slat materials disclosed herein, overlapped and joined along longitudinal edges of the slats, resulting in a continuous roll-up covering material. Such a design creates a continuous sheet-like roll-up architectural covering (e.g., without tapes) that permits construction of a roll-up covering of a custom width due to the continuous roll-up covering material being able to be cut to any desired (custom) length corresponding to the width of the covering when the slats are assembled into a covering, although it will be appreciated that any embodiment of a roll-up covering herein can be provided in a custom width. In some embodiments, the plurality of slats can be joined to each other along their longitudinal edges at a plurality of discrete locations. This can be advantageous as it can prevent the material of the stiffeners from yielding unnecessarily. If desired, the roll-up covering material can be rolled up into a roll, wherein the longitudinal edges of the flexible slat material are parallel to a central axis defined by the roll. This can facilitate making roll-up coverings of any desired custom length.
The disclosure further provides a roll-up covering including the immediately preceding roll-up covering material, wherein the plurality of slats form an elongate planar body defining a first edge along one of the plurality of slats, wherein the roll-up covering further includes a roller attached to the elongate planar body proximate the first edge of the elongate planar body. If desired, at least one pair of adjacent slats can include elongate flexible planar bodies formed from different materials, such as opaque and translucent materials, materials of different colors, and/or materials of different patterns. If desired, the roll-up covering material can be provided with registration markings and printed with discrete segments of an image or design, wherein the design is formed when the roll-up covering material is assembled by attaching subsequent slat segments. If desired, at least one pair of adjacent slats can be of different widths. For example, two, three or more of the slats making up the roll-up covering and/or roll-up covering material can be of different widths.
The disclosure still further provides a method of forming a flexible slat material for forming a roll-up covering for an architectural opening. The slat material includes an elongate flexible planar body having a first end and a second end joined by a plurality of longitudinal edges, wherein at least one of the longitudinal edges is a stiffened edge that is stiffened along the length of the slat material along a first direction orthogonal to the stiffened edge. The method includes attaching an elongate stiffener along a face of the elongate flexible planar body.
If desired, in some embodiments, the stiffened edge(s) can include a generally planar elongate stiffener attached along the elongate flexible planar body. If desired, in some embodiments, the stiffened edge(s) can include a stiffener attached to the elongate flexible planar body substantially along its entire length, or between ten and one hundred percent of its length in increments of one percent. If desired, the stiffener(s) can be continuously attached to the elongate flexible planar body substantially along its entire length, or between ten and one hundred percent of its length in increments of one percent. If desired, the stiffener(s) can be continuously attached to the elongate flexible planar body along its entire length. If desired, the stiffener(s) can be intermittently attached to the elongate flexible planar body substantially along its entire length, or between ten and one hundred percent of its length in increments of one percent. If desired, the stiffener(s) can be intermittently attached to the elongate flexible planar body along its entire length. If desired, the generally planar stiffener(s) can include a crown along its length.
If desired, the method can further include attaching a generally planar stiffener having a crown along its length to the elongate flexible planar body proximate each of two opposing longitudinal edges of the elongate flexible planar body. The crowns of each of the generally planar stiffeners can be oriented in the same or opposite directions when the elongate flexible planar body is laid flat on a flat surface. If desired, the generally planar stiffeners can be visible, or can be covered by fabric, such as the fabric of the elongate flexible planar body. The generally planar stiffeners can include plastic and/or metallic material, such as aluminum. The aluminum material can be surface treated to promote adhesion with an adhesive material. For example, the aluminum material can be treated with a plasma or can be anodized or oxidized.
In another embodiment, a method of forming a flexible slat material for forming a roll-up covering for an architectural opening is provided, the slat material including an elongate flexible planar body having a first end and a second end joined by a plurality of longitudinal edges, wherein at least one of the longitudinal edges is a stiffened edge that is stiffened along the length of the slat material along a first direction orthogonal to the stiffened edge. The method includes impregnating the elongate flexible planar body with a stiffening material along the at least one stiffened edge to create the stiffened edge. In various embodiments, the stiffened edge of the slats/slat material is substantially less stiff along a second direction orthogonal to the stiffened edge.
The disclosure still further provides a method of forming a roll-up covering material configured to be rolled up, optionally around a roller of a roll-up covering for an architectural opening. The method includes providing a first elongate tape having a first end, a second end, and defining a length between the first end and the second end, the first outer elongate tape further defining a lateral width, a thickness and a first central longitudinal axis between the first end and second end of the first outer elongate tape. The method further includes attaching at least one flexible slat to the first elongate tape, the at least one flexible slat being oriented transversely with respect to the first central longitudinal axis, the at least one flexible slat being a transversely stiffened slat including stiffened longitudinal edges connected by a flexible body portion, wherein the transversely stiffened slat is attached to the first elongate tape proximate a first stiffened longitudinal edges of the transversely stiffened slat. The method preferably further includes providing a second elongate tape distinct from the first elongate tape. The method still further includes attaching the second elongate tape to a second edge of the transversely stiffened slat. The second elongate tape has a first end, a second end, and defines a length between the first end and the second end. The second elongate tape further defines a lateral width, a thickness and a second central longitudinal axis between the first end and second end of the second elongate tape. The at least one flexible slat, first elongate tape and second elongate tape can define a roll-up covering material that is configured to be rolled up around a roller.
A method of forming a roll-up covering for an architectural opening is similarly provided that includes providing a roller having a first end and a second end and defining a width between the first end and the second end, the roller defining a central rotational axis, and attaching the previously discussed roll-up covering material to the roller. In so doing, the first end of the first elongate tape can be attached to the roller such that the first central longitudinal axis of the first outer elongate tape is oriented generally orthogonally with respect to the central rotational axis of the roller. Moreover, the second elongate tape can be located radially inwardly with respect to the first outer elongate tape when the subassembly is rolled up around the roller. The second elongate tape can be configured to collapse upon itself as the roll-up covering is rolled around the roller. If desired, the second elongate tape can be between about 0.5% and about 25% longer than the first elongate tape between at least one pair of adjacent slats in the roll-up covering material, in any desired increment therebetween of about 0.5%.
In some embodiments, the roll-up covering and/or roll-up covering material can include a plurality of first elongate tapes and a plurality of second elongate tapes. The plurality of first elongate tapes can be attached to a portion of a first face of the at least one flexible slat, and the plurality of second elongate tapes can be attached to a portion of a second face of the at least one flexible slat. If desired, at least two of the tapes can be of different widths. For example, at least two of the plurality of first and/or second elongate tapes can be of different widths.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and are intended to provide further explanation of the embodiments disclosed herein.
Reference will now be made in detail to the present preferred embodiments of the disclosure, examples of which are illustrated in the accompanying figures.
The embodiments of roll-up coverings herein can be used for covering any desired architectural opening such as windows, sliding doors, French doors and the like. Ladder tapes as presented herein can be used with any desirable slat configuration to achieve a desired aesthetic appearance for a window covering. Roll-up coverings as set forth herein represent a significant improvement over existing technology. To Applicant's knowledge, no window coverings have existed before that provide all of the advantages, benefits, simplicity and aesthetic appeal of the disclosed embodiments.
For purpose of illustration and not limitation, a first embodiment of the device made in accordance with the present invention is illustrated in
The roll-up covering 10 includes a first outer elongate tape 30 that in turn has a first end 32, a second end 34, and defines a length between the first end and the second end. The first outer elongate tape 30 further defines a lateral width, a thickness and a first central longitudinal axis “X1” between the first end 32 and second end 34 of the first outer elongate tape 30, such as along a geometric center of the first outer elongate tape 30. The first end 32 of the first outer elongate tape 30 can be attached to the roller such that the first central longitudinal axis of the first outer elongate tape is oriented generally orthogonally with respect to the central rotational axis “R” of the roller 20.
The roll-up covering 10 further includes a first inner elongate tape 40 disposed proximate to the outer elongate tape 30. The first inner elongate tape 40 has a first end 42, a second end 44, and defines a length between the first end 42 and the second end 44. The first inner elongate tape 40 further defines a lateral width, a thickness and a second central longitudinal axis “X2” between the first end 42 and second end 44 of the first inner elongate tape 40. The first inner elongate tape 40 further defines a plurality of collapsible hinge segments 50 (
As further illustrated in the Figures, the roll-up covering further includes a plurality of slats 60 disposed between and coupled to the first outer elongate tape 30 and the first inner elongate tape 40. The slats 60 can be oriented transversely with respect to the first and central longitudinal axes (X1, X2). The plurality of slats 60, first outer elongate tape 30 and first inner elongate tape 40 define a subassembly 70 that is configured to be rolled up, such as around the roller 20, wherein the first inner elongate tape 40 is located radially inwardly with respect to the first outer elongate tape 30 when the subassembly is rolled up around the roller. Locating tape 40 radially inwardly from tape 30 results in tape 40 needing to have a shorter effective length than tape 30 when rolled up. The collapsible hinge segments 50 facilitate this. Each collapsible hinge segment includes a displaceable body portion 52 that is bounded by a lower hinge 54 and an upper hinge 56. As illustrated in the figures, when the subassembly 70 is rolled around the roller, the inner tape 40 buckles outwardly from the second central longitudinal axis X2, and forces the body portion 52 to be displaced and bent over the lower hinge 54 such that the inner tape effectively folds upon itself at each hinge point in order to shorten its effective length when rolled up, and permit the subassembly to roll up neatly around the roller. For purposes of clarification, not limitation, it will be appreciated that the width of the subassembly corresponds to the length of the slats, and generally corresponds to the substantially horizontal width of the architectural opening to be covered by the subassembly.
In accordance with a further aspect, the subassembly 70 can be configured to reside in a collapsed configuration (
In accordance with a further aspect, as illustrated in
While a stiffener 80 is generally depicted herein as including a crowned slat material, the stiffener can be located along some or all of the expanse of the slat. For example,
As will be appreciated, the cross section of the stiffener 80 is generally vertically oriented, and provides a substantial sectional modulus and rigidity to the slats 60. As illustrated, the stiffeners can be substantially planar (e.g., flat, crowned, creased, and the like) and lay in substantially the same plane as one of the first central longitudinal axis X1 of the first outer elongate tape 30 and the second central longitudinal axis X2 of the first inner elongate tape. The at least one stiffener 80 can further define a width perpendicular to the length, and a thickness perpendicular to the width and the length, as clearly evident from the Figures. The stiffener 80 can have a curved cross section in a plane perpendicular to the central lateral axis (e.g. be “crowned”) such that a first curved planar face of the at least one elongate stiffener can be convex and a second, opposite curved planar face of the at least one elongate stiffener can be concave. The concave face of the at least one stiffener preferably faces the roller 20 when the subassembly 70 is rolled up around the roller. The concave face of the stiffener 80 can have a radius of curvature “r” that substantially matches a radius of curvature of the roller 20. As illustrated, the at least one stiffener 80 has a thickness that is substantially smaller than its width.
As illustrated, each of the slats 60 includes stiffeners along each longitudinal edge, and the concave faces of the stiffeners face the same way and are configured to face and engage with a curved surface defined by the roller 20 when the subassembly 70 is retracted around the roller 20.
As illustrated in
In accordance with a further aspect, at least one of the slats can include at least one transverse stiffener 90 attached to the at least one slat (
As depicted in the figures, the transverse stiffener is further positioned between the longitudinal stiffeners along the side edges of the top slat 60, thus ensuring that the top slat 60 can maintain its shape during and after deployment. When the transverse stiffener 90 is disposed on an upper slat in the subassembly, the at least one transverse stiffener is thus adapted to maintain the upper slat in a generally open condition, and causes the first outer elongate tape 30 to be separated from the first inner elongate tape 40. If desired, and as presented in the Figures, the transverse stiffener 90 can be disposed across the slat 60 between the first outer elongate tape 30 and the first inner elongate tape 40 to act as a strut to separate the tapes 30, 40. Moreover the transverse stiffener 90 can be crowned similar to the stiffeners 80 for enhanced sectional modulus and column strength. Preferably, and as illustrated, the transverse stiffener 90 is a crowned member that can buckle or otherwise collapse and roll-up around the roller when the subassembly is retracted around the roller.
As illustrated in the Figures, the first inner elongate tape and first outer elongate tape are aligned behind each other such that they roll on top of each other when the subassembly 70 is retracted around the roller 20. In an alternative embodiment (not shown) the first inner elongate tape 40 and first outer elongate tape 30 can be laterally displaced from each other along the length of the slats such that they are not behind each other, and do not roll on top of each other when the subassembly is retracted around the roller. In accordance with a further example, the first inner elongate tape and first outer elongate tape can have different lateral widths (not shown), such as from about 5 mm to about 100 mm in increments of 1 mm. Furthermore, a different number of tapes can be provided along the outer edges of the slats as compared to the inner edges. For example, two outer tapes can be provided along the outer edges of the subassembly, and a single inner tape can be provided along the center of the inner edges of the subassembly 70. Alternatively, more tapes can be provided along the inner edges of the subassembly, and fewer tapes can be provided along the outer edges of the subassembly.
In accordance with one embodiment, and as illustrated in
In accordance with another embodiment, and as illustrated in
As further illustrated in
As further illustrated in the Figures, the roll-up covering can further include a weight 95 proximate to the second ends of the first, second, and/or third inner elongate tapes 34, 44, 134, 144, 234, 244. The weight is preferably configured to maintain tension on the first inner elongate tape. The weight can be of any shape, but for purposes of simplicity it can be a weighted bar that spans the width of the roll-up covering.
In accordance with still further aspects, each of the aforementioned plurality of collapsible hinge segments 50, 150, 250 can be disposed proximate to a slat 60 in the subassembly 70. In some implementations, each hinge segment 50, 250, 350 can be defined by a plurality of spaced apart transverse crease lines 54, 56, 154, 156, 254, 256 defined in the applicable tape 40, 140, 240 inner elongate tape. In some implementations, the hinge segment(s) can fold downward onto an exterior face 40b, 140b, 240b of the inner elongate tape(s) when the subassembly 70 is rolled onto the roller. In some embodiments, a lower crease line 54, 154, 254 defining the hinge segment can be disposed proximate to an inner transverse edge 64 of one or more of the slats 60. If desired, the lower crease line(s) can be disposed immediately above a region where the first inner elongate tape is attached to the transverse edge of the slat.
In accordance with a further aspect, the slats are preferably formed from a flexible fabric material. The stiffeners 80, 90 can be formed, for example, from at least one of a rigid plastic material, a metallic material, such as aluminum, titanium, brass or steel, ceramic, rigid foam, or the like. Alternatively, the stiffeners can be formed and shaped like wires.
The tapes 30, 40, 130, 140, 230, 240 are preferably made from a flexible material. If desired, the crease lines 54, 56, 154, 156, 254, 256 can be crush formed into the flexible material. For example, the flexible material can be selected from the group including films and textiles. If desired, the textile can be selected from the group consisting of knits, wovens and non-wovens. The flexible material used for the tapes 30, 40, 130, 140, 230, 240 preferably have a thickness between about 1-30 mils, 1.5-25 mils, 2-25 mils, 3-20 mils, 4-18 mils, 6-16 mils, 8-14 mils, and about 10-12 mils. It will be appreciated however that crush formation is not required, and the material of the tapes can be sufficiently flexible to permit the hinge segments to be formed each time the covering is rolled up. Specifically, the inner elongate tape will collapse upon itself as the edge of the slat including the stiffening member 80 approaches the roller, by virtue of the fact that the hinge is being “squeezed” into shape as illustrated, for example, in
Hinge formation during roll up can be facilitated by making the inner elongate tape (e.g., 40) between subsequent slats slightly longer than the outer elongate tape (e.g., 30) between the same subsequent slats. Specifically, having a comparatively longer inner tape segment makes that tape segment longer than the outer tape, providing additional material to encourage the hinge to form and collapse during roll-up of the roll-up covering 10. For example, the inner tape segment between adjacent slats can be about 0.5%, about 1.0%, about 1.5%, about 2.0%, about 2.5%, about 3.0%, about 3.5%, about 4.0%, about 4.5%, about 5.0%, about 5.5%, about 6.0%, about 6.5%, about 7.0%, about 7.5%, about 8.0%, about 8.5%, about 9.0%, about 9.5%, or about 10.0% longer (or greater than 10% in any desired increment of about 0.5% up to about 25%) than its corresponding outer tape segment. It will be further appreciated that the distance between a first pair of slats along the inner and outer tapes can be different than the distance between a second pair of slats along the inner and outer tapes. For example, the length of the inner tape(s) can be a first percentage longer than the outer tape(s) between a first pair of slats, and the length of the inner tape(s) can be a second percentage longer than the outer tape(s) between a second pair of slats. Moreover, the length of the inner tape(s) can be a third percentage longer than the outer tape(s) between a third pair of slats. Accordingly, completely custom spacing of the slats along the inner and outer tapes can be achieved, as well as custom widths to fit a desired opening.
In some embodiments, the tapes 30, 40, 130, 140, 230, 240 and slats 60 can be made from a woven material such as a Roc-Lon® blackout drapery liner material, manufactured by Rockland Industries, Inc. (1601 Edison Hwy, Baltimore, MD 21213, (410) 522-2505). In some implementations, the stiffeners 80, 90 can be polymeric or aluminum crowned blind slats that are about 0.008 inches thick and 16 mm wide. In alternative embodiments, the width of the stiffeners 80, 90 can vary from about 3/16 of an inch to about ⅝ inch or up to about one inch. A larger stiffener width can be appropriate, particularly for slats of larger depth (e.g., 4, 4.5, 5, 5.5 or 6 inches).
In accordance with further aspects of the disclosure, subsequent slats 60 can be separated by a substantially uniform distance along the first outer elongate tape 30 and the first inner elongate tape 40. If desired, such a distance can be a standard distance (e.g., 60 mm, 72 mm), or the spacing can be customized to any desired length, as subsequent slats can be overlapped to any desired extent, such as about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50% or any increment therebetween of 1%. Thus, a custom roll-up covering 10 may be provided wherein the spacing between adjacent slats is determined by taking the dimensions of the architectural opening or structure the covering is intended to be installed within or on (e.g., the total height of the sub assembly) and dividing such total custom height of the subassembly by a number of desired slats. Thus, it is possible to provide a custom subassembly of custom height with a custom, uniform distance between the slats, such that the subassembly has a slat or other feature (e.g., a weighted bar, a bottom rail, a bottom weight) at the second end of the elongate tapes and such bottom-most slat or other feature (e.g., a weighted bar, a bottom rail, a bottom weight) is separated from the next adjacent slat by the same distance separating other adjacent slats. In other words, a roll-up covering may be formed with slats that are uniformly spaced across the total length (also referred to herein as height) of the roll-up covering or subassembly, in contrast with other types of window coverings with horizontal elements that are spaced apart at predetermined distances and therefore cannot always be sized so that the horizontal element is spaced the same distance as the slat above it as the distance and spacing of other adjacent slats. In other types of window coverings the spacing between adjacent slats is uniform, predetermined, and fixed (such as because spacing is dependent on other elements of the covering, such as support elements for the slats), and the height is selected without changing the spacing of the horizontal elements, rather than as in embodiments of the present covering and subassembly where the height is selected first and the spacing of the horizontal elements is changed based on the total height of the covering or subassembly. And, in contrast with other types of slatted shades which have predetermined spacings between the slats (e.g., venetian blinds with the spacing of adjacent slats dictated by the rungs of the ladder tapes supporting the slats), the slats 60 of the disclosed roll-up coverings may be coupled to the first outer elongate 30 and the first inner elongate tape 40 at any desired location along their length such that the spacing between the slat 60 is fully customizable, and may be varied according to the desired custom height of the roll-up covering. It will be appreciated that the length of a customizable roll-up covering formed in accordance with the above may be set by the lengths of the inner elongate tape and the outer elongate tape (or any other support element to be used to support the slats), and coupling the slats to such support element or elements. The spacing of the slats along the support elements may be determined such as by the width of the slats (the dimension substantially transverse to the width of the roll-up covering and the length of the slats along the width of the roll-up covering), and/or the desired spacing between slats such as when the roll-up covering is in a closed configuration so that the slats are close enough to one another to shade against light passing through the architectural opening to be covered by the roll-up covering. The overall spacing between the slats may be uniform or non-uniform, as desired, but, is customizable, such as based on the overall final custom length of the roll-up covering. The number of slats preferably is selected to provide sufficient slats along the length of the roll-up shade (determined, e.g., by the length of the support elements) so that the slats will provide the desired shading effect (e.g., light blockage) when the roll-up covering is in the closed configuration.
In accordance with a further aspect, and as illustrated in
In another embodiment of the present disclosure, the first connector 1201 has at least one metallic or magnetic contact surface, i.e., 1201A or 1201C, which is attracted to at least one metallic or magnetic contact surface of the second connector 1202. In the preferred embodiment of the present disclosure, the magnetic attraction between the at least one metallic or magnetic contact surface, i.e., 1201A or 1201C, of the first connector 1201 and the at least one metallic or magnetic contact surface of the second connector 1202 maintains the first inner elongate tape 40 and the first outer elongate tape 30 collapsed together. In another embodiment of the present disclosure, the first and second connectors 1201 and 1202 have sufficient magnetic forces attracting one and another such that moving one of the pair of magnetic connectors 1201 and 1202 can cause coordinated move of the other one of the pair of magnetic connectors 1201 and 1202. It will be appreciated that the illustrated magnets are permanent magnets. Any suitable permanent magnets can be used, such as those including rare earth elements and the like. If desired, one of the magnets can be replaced with a piece of steel, preferably one that has been plated or lightly coated with a corrosion resistant layer.
In accordance with an exemplary embodiment, the coordinated upward movement of the first and second connectors 1201 and 1202 can cause the side edges 68 of the plurality of slats 60 to collapse against the first inner elongate tape 40 and first outer elongate tape 30, thus causing the plurality of slats 60 to be in a closed position. The downward movement of the first and second connectors 1201 and 1202 can cause the side edges 68 of the plurality of slats 60 to separate from the first inner elongate tape 40 and first outer elongate tape 30, thus causing the plurality of slats 60 to be in an open position. In the illustrated embodiment, the first connector 1201 can be movable along the second central longitudinal axis X2, and second connector 1202 can be movable along the first central longitudinal axis X1. In another embodiment of the present disclosure, the pair of magnetic connectors 1201 and 1202 can be removable from the first outer elongate tape 30 and the first inner elongate tape 40. Selective placement of the magnets can provide for any desired combination of privacy (below the magnets) and shading (above the magnets). It will be further appreciated that any of the disclosed roll-up coverings can have slats that extend outwardly beyond the tapes that have freely floating ends. For example, the embodiments of
It will be further appreciated that some or all of the pairs of elongate tapes can be provided with pairs of magnets to selectively hold the tapes together. Thus, a roll-up covering with two pairs of tapes would have four magnets, a covering with three pairs of tapes would have six magnets, and so on. It will be further appreciated that a clip or other suitable sliding fastener can be positioned over the tapes rather than magnets (or a magnet and opposing steel disc) if the tapes are at the edge of the roll-up covering.
In accordance with a further embodiment of the present disclosure, for purposes of illustration, a second pair of magnetic connectors can be disposed opposite of one another such that a third connector 1203 of the second pair of magnetic connectors 1203 and 1204 can be disposed and movable on an outer face of the second inner elongate tape 140 and a second connector 1204 of the second pair of magnetic connectors 1203 and 1204 can be disposed and movable on an outer face of the second outer elongate tape 130 in response to and coordinated with the movement of the third connector 1203. In an exemplary embodiment of the present disclosure, the third connector 1203 and the fourth connector 1204 are magnetic discs of the same dimension, each with a circular surface, e.g., 1203A, corresponding to another circular surface, e.g., 1203C, connected by a transverse circular rim surface 1203B. In a preferred embodiment of the present disclosure, circular surfaces 1203A and 1203C of the third connector 1203 and fourth connector 1204 can be of the same radius dimension, e.g., 1203R. In another embodiment of the present disclosure, the third connector 1203 has at least one metallic or magnetic contact surface, i.e., 1203A or 1203C, which is attracted to at least one metallic or magnetic contact surface of the fourth connector 1204. In the preferred embodiment of the present disclosure, the magnetic attraction between the at least one metallic or magnetic contact surface, i.e., 1203A or 1203C, of the third connector 1203 and the at least one metallic or magnetic contact surface of the fourth connector 1204 maintains the third connector 1203 and the fourth connector 1204 collapsed together. In another embodiment of the present disclosure, the third and fourth connectors 1203 and 1204 have sufficient magnetic forces attracting one and another such that moving one of the pair of magnetic connectors 1203 and 1204 can cause coordinated move of the other one of the pair of magnetic connectors 1203 and 1204.
In accordance with an exemplary embodiment, the coordinated upward movement of the third and fourth connectors 1203 and 1204 can cause the side edges 68 of the plurality of slats 60 to collapse against the second inner elongate tape 140 and second outer elongate tape 130, thus causing the plurality of slats 60 to be in a closed position. The downward movement of the third and fourth connectors 1203 and 1204 can cause the side edges 68 of the plurality of slats 60 to separate from the second inner elongate tape 140 and second outer elongate tape 130, thus causing the plurality of slats 60 to be in an open position. In the illustrated embodiment, the third connector 1203 can be movable along the fourth central longitudinal axis X4, and fourth connector 1204 can be movable along the third central longitudinal axis X3. In another embodiment of the present disclosure, the pair of magnetic connectors 1203 and 1204 can be removable from the second outer elongate tape 130 and the second inner elongate tape 140.
In accordance with another embodiment, door 1300 can be operable to be opened by detaching or separating from the roller 20 on the outer end 1302 along the width of door 1300 and remain attached to the roller at the inner end 1301 via latch element 1305. The door 1300 can be further operable to be closed by collapsing and rolling the outer end 1302 of the door 1300 toward and around the roller 20 along the width of the door 1300.
In a further embodiment of the present disclosure, as shown in
In accordance with another embodiment of the present disclosure, as illustrated in
As illustrated in details in
In a further embodiment, as illustrated in
As further illustrated in
In an illustrated embodiment of the present disclosure, shown in
In a further illustrated embodiment of the present disclosure, as show in
In further embodiments, it will be appreciated that the disclosed coverings can be oriented in any desired manner with respect to the architectural opening that it is covering. For example, in some implementations, it can be desirable for the outer face of the inner elongate tape(s) to face the architectural opening when the covering is unrolled from the roller (e.g., window or door). In other implementations, the outer face of the outer elongate tape(s) can face the architectural opening.
For purposes of illustration, and not limitation,
The disclosure further provides a roll-up covering material configured to be rolled up around a roller of a roll-up covering for an architectural opening, as it will be appreciated that the subassembly that may attach to the roller of the embodiment of
In any implementation, if desired, the roll-up covering material can be provided in a form wherein the at least two of the tapes are of different widths. For example, as illustrated in the embodiment of
The disclosure also provides a flexible slat material for forming a roll-up covering for an architectural opening. The slat material includes an elongate flexible planar body having a first end and a second end joined by a plurality of longitudinal edges, wherein at least one of the longitudinal edges is a stiffened edge that is stiffened along the length of the slat material along a first direction orthogonal to the stiffened edge, and further wherein the stiffened edge is substantially less stiff along a second direction orthogonal to the stiffened edge.
For purposes of illustration, and not limitation, a simplified schematic of a method and system for making rolls of slat material is presented in
In some implementations, the stiffeners or stiffening strips 2124, 2126 can be continuously attached to the elongate flexible planar body 2122 substantially along its entire length. In other implementations, the stiffener material 2124, 2126 can be continuously attached to the elongate flexible planar body 2122 along its entire length. In some implementations, the stiffener material 2124, 2126 can be intermittently attached to the elongate flexible planar body 2122 substantially along its entire length. In still other implementations, the stiffener material 2124, 2126 can be intermittently attached to the elongate flexible planar body 2122 along its entire length.
In some implementations, the generally planar stiffener(s) can include a crown along its length, such as by using aluminum or plastic slat material, as described herein. The crowns of each of the generally planar stiffeners can be oriented in the same (or opposite directions) when the elongate flexible planar body is laid flat on a flat surface, as illustrated in
The disclosure still further provides a roll-up covering material for an architectural opening including a plurality of slats made from the flexible slat materials disclosed herein, overlapped and joined along longitudinal edges of the slats.
For purposes of illustration, and not limitation, as embodied herein, an exemplary roll-up covering made by stacking slat material is presented in
If desired, adjacent slat panel portions of the embodiment of
The disclosure still further provides a method of forming a roll-up covering material configured to be rolled up around a roller of a roll-up covering for an architectural opening. In accordance with at least one aspect of the method, at least one of and preferably both the length and width of the covering are readily customizable. The length of the covering preferably is readily controllable or customizable by selecting the desired number of slats used to form the covering. The width of the covering preferably is readily controllable or customizable by selecting the desired slat length to match the desired shade width. For instance, the slat may be cut from a continuous roll of slat material to any desired length which is to extend along the width of the covering. The shade length is further customizable because the slat spacing preferably may be selected as desired and need not be predetermined (such as by ladders or any other pre-existing shade elements). For instance, the slats may be placed at any desired locations along the tapes (or other support elements) to achieve the desired shade length and slat spacing.
The disclosure additionally provides a method for assembling a custom-length and optionally a custom width covering for an architectural opening. The method includes the step of selecting a desired custom length (also referred to as height) of the covering. The method may also include the step of providing a first outer elongate tape having a first end and a second end opposite the first end, a length along a first central longitudinal axis extending between the first end and the second end that is selected to correspond to the selected custom length of the covering, a lateral width substantially perpendicular to the length of the first outer elongate tape, and a thickness substantially perpendicular to the length and width of the first outer elongate tape. The method may further include providing a first inner elongate tape having a first end and a second end opposite the first end, a length along a second central longitudinal axis extending between the first end and the second end that is selected to correspond to the selected custom length of the covering, a lateral width substantially perpendicular to the length of the first inner elongate tape, and a thickness substantially perpendicular to the length and width of the first inner elongate tape. The method of assembly may further include the step of selecting a desired custom width for the covering which may include the step of providing a plurality of flexible slats having a first end and a second end, an inner longitudinal edge and an outer longitudinal edge between the first end and the second end and defining a length of the slat corresponding to and preferably substantially the same size as the custom width of the covering. The method of assembly may further include the step of providing a slat having a depth between its inner longitudinal edge and the outer longitudinal edge. The method may include the step of coupling the slats between and preferably transverse to the first outer elongate tape and the first inner elongate tape, the slats preferably having an upper face coupled to the first inner elongate tape and a lower face coupled to the first outer elongate tape. The slats may be coupled to the elongate tapes by bonding and may be fed into a machine to bond the slats at any desired custom position along the length of the elongate tapes.
The method of assembly preferably results in the first outer elongate tape, the first inner elongate tape, and the slats joined and assembled to define a subassembly configured to be rolled up, where the slats are coupled to the first outer elongate tape and the first inner elongate tape at any desired location along the lengths of the first outer elongate tape and the first inner elongate tape such that the plurality of flexible slats are spaced apart to achieve a desired spacing of the slats along the elongate inner and outer tapes, thereby providing a custom subassembly of custom length, and/or custom width such that the custom subassembly is configured to fit any desired architectural opening and preferably provide a desired shading effect. The method can also include the step of spacing the slats a custom uniform distance apart from adjacent slats along the length of the first outer and first inner elongate tapes. Preferably the custom uniform distance is determined by at least one of the width of the slats, a desired number of slats, and a desired spacing between the slats. The method may also include selecting a desired custom width of the covering, wherein the length of the slats is determined by the selected custom width of the covering. Alternatively, instead of including the step of uniformly spacing the slats, the method may include the step of spacing at least one slat a custom non-uniform distance apart from at least one adjacent slat.
For purposes of illustration, and not limitation, as embodied herein,
The frame and other supporting structure of the machine 2600 are not specifically illustrated to provide more clarity as to the interrelation of the components to describe how the system works. As will be appreciated, a plurality of rolls of starting materials, including continuous rolls of elongate tape material 2602, 2604, 2608, 2610 are provided, wherein rolls 2602, and 2608 provide outer elongate tapes 40, 140 respectively, while rolls 2604, and 2610 provide inner elongate tapes 30, 130 respectively. Flexible slat material with stiffener(s) along the edge(s) is provided from roll 2130, which in turn is preferably made using a machine and method as described with reference to
Motor(s) 2614 are operatively connected to one or more controllers 2650, which can include a central computer system and one or more programmable logic controllers (not shown) for sequentially advancing tape material and slat material. The inner and outer elongate tapes are kept sufficiently separated to permit slat material to be advanced between them by the system. After the slat material is inserted and cut to length by the cutting station 2620, it is advanced by a push plate (not shown) in synchronization with the elongate tapes through nip rollers to compress the components of the subassembly with adhesive to form an integral unit.
Gluing and cutting station 2620 is provided to deposit predetermined amounts of adhesive onto the top and bottom of the slat material as it is being advanced between the inner and outer tapes. As soon as the slat material has been metered out to the correct length, it is cut by station 2620, and the inner and outer elongate tapes are attached to the slat material by the adhesive, typically a hot melt adhesive. The outer elongate tape(s) are preferably each attached to each slat at one location near the stiffener at an edge of the slat. As each slat is installed, the elongate tapes 30, 130, 40, 140 are advanced to accept the next length of slat, which is adhered and pressed into adhesion with the elongate tapes. Once the subassembly has been formed, the elongate tapes are advanced and cut at cutting station 2630 to remove the subassembly from the machine. At this point, the elongate tapes can optionally be attached to a roller, and the roll-up covering can be completed. It will be appreciated that the embodiment 2600 and the order of the process can be modified in many ways to achieve the same or slightly different functionality.
It will be appreciated that the controller 2650 can be programmed to utilize slat material of any desired length or width, and to provide any desired placement of the slats along the elongate tapes 30, 130, 40, 140 to provide for a roll-up covering of any desired slat length, or slat spacing. It will be further appreciated that the inner elongate tapes 30, 130 can be made longer than the outer elongate tapes on the subassembly between at least one pair of adjacent slats by advancing more tape material using the motorized feed rollers drawing material from rolls 2604, 2610 than from rolls 2602, 2608. Spacing between subsequent slats can be varied along the subassembly, and can be configured to make some slats open before others, as discussed elsewhere herein. It will be further appreciated that system 2600 can be provided with feed rolls of slat material of different widths and material types.
Moreover, using the system of
Similarly, such a roll-up covering can be made any desired custom height, such as a height between one foot and fifty feet, in any increment, for example of about one tenth of an inch. Moreover, the placement of the elongate tapes can be any desired suitable location along the front or back of the slats 60, as the case may be. For instance, the total height of the covering may be selected based on the dimensions of the architectural opening to be covered by the window covering, and the spacing of the slats may be calculated to permit the desired spacing between the slats to achieve the desired appearance, such as by assuring that the bottom-most slat or feature of the subassembly (e.g., a weighted bar, a bottom rail, a bottom bar) is at the bottom of the covering and spaced a distance from the slat above that is substantially the same distance that spaces apart other adjacent slats. In contrast with other window coverings that have preset spacings of their horizontal elements such that selection of that window covering and sizing it to a total height based on the architectural opening to be covered does not always result in the horizontal element being at the bottom of the window covering and spaced the same distance from its adjacent slat as the distance separating other adjacent horizontal slats (e.g., elements) in that window covering. The front and back elongate tapes can be aligned, or be out of mutual alignment. The spacing between tapes across the length of the slats can be programmed into the system 2600, and the lateral location of rolls of elongate tape material can be adjusted to custom spacing. Moreover, it will be appreciated that system 2600 can produce custom width roll-up coverings with minimal scrap material.
The devices and methods of the present disclosure, as described above and shown in the drawings, provide for roll-up window coverings and ladder tapes with superior attributes vis-à-vis the prior art. It will be apparent to those skilled in the art that various modifications and variations can be made in the devices and methods of the present disclosure without departing from the spirit or scope of the disclosure. Thus, it is intended that the present disclosure include modifications and variations that are within the scope of the subject disclosure and equivalents.
This patent application is a continuation application of U.S. patent application Ser. No. 15/510,181 filed on Mar. 9, 2017, is related to and claims priority to International Patent Application PCT/US15/49444 filed on Sep. 10, 2015 and is related to and claims priority to U.S. Provisional Patent Application Ser. No. 62/048,516 filed on Sep. 10, 2014. This patent application is related to International Patent Application No. PCT/US2014/026756, filed Mar. 13, 2014 and is a continuation-in-part of U.S. patent application Ser. No. 14/210,257, filed Mar. 13, 2014, each of which claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 61/801,058, filed Mar. 15, 2013. Each of the aforementioned patent applications is incorporated by reference herein in its entirety for any purpose whatsoever.
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| Child | 17468079 | US |
