Patent Application
20200378125
Aspects of the embodiments generally relate to roller shades, and more particularly to systems, methods, and modes for a skylight roller shade.
Motorized roller shades provide a convenient one-touch control solution for screening windows, doors, or the like, to achieve privacy and thermal effects. A motorized roller shade typically includes a rectangular shade material attached at one end to a cylindrical rotating tube, called a roller tube, and at an opposite end to a hem bar. The shade material is wrapped around the roller tube. An electric motor, either mounted inside the roller tube or externally coupled to the roller tube, rotates the roller tube to unravel the shade material to cover a window.
In typical roller shades, the bottom end of the fabric is free hanging and will roll up and down perpendicular to the floor. To install a roller shade in a skylight or in a window that angles towards or out of a room, it is desirable to have the fabric hang and travel parallel to the window such that the fabric is sloped at the same angle as the window. It is also desirable to have the fabric not to sag, but be taught at all times—across the width and the roll-out length of the fabric—for any slope at which the skylight shade is attached. This is commonly achieved by tensioning the fabric with springs and pulley cables to guide it and having the fabric ride in side channels.
Typical skylight shades are difficult to assemble and install as they contain many parts, need to be customized to the window size, need to be perfectly aligned to a window, and need to be properly tensioned. While there are skylight shades available that are self-contained and pre-tensioned in a single frame, it becomes difficult to install such skylight shades in large skylight windows due to their size and weight. Typically more than one person is required to lift, align, and secure such a shade.
Therefore, a need has arisen for systems, methods, and modes for a skylight roller shade that can be easily customized to size, assembled, installed, and tensioned.
It is an object of the embodiments to substantially solve at least the problems and/or disadvantages discussed above, and to provide at least one or more of the advantages described below.
It is therefore a general aspect of the embodiments to provide systems, methods, and modes for a skylight roller shade that can be easily customized to size, assembled, installed, and tensioned.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
Further features and advantages of the aspects of the embodiments, as well as the structure and operation of the various embodiments, are described in detail below with reference to the accompanying drawings. It is noted that the aspects of the embodiments are not limited to the specific embodiments described herein. Such embodiments are presented herein for illustrative purposes only. Additional embodiments will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein.
According to one aspect of the embodiments, a roller shade adapted to adjustably cover a structural opening is provided. The roller shade comprises a roller tube assembly having a roller tube, a shade material attached to the roller tube, and a pair of cables adapted to be wound about opposite ends of the roller tube. The roller shade further comprises a pair of longitudinal side panel assemblies adapted to be attached at opposite sides of the structural opening and retain the roller tube assembly therebetween, wherein each side panel assembly comprises a tensioning assembly adapted to tension the shade material. Each tensioning assembly comprises: a fixed pulley bracket comprising a first and second pulleys, floating pulley bracket comprising a third pulley, a tension assist bracket removably attached to and between the fixed pulley bracket and the floating pulley bracket, and a spring attached at one end to the floating pulley bracket. The tension assist bracket is adapted to keep the floating pulley bracket fixed during installation and is adapted to be removed after the side panel assemblies are attached at the structural opening and the pair of cables are looped through the first, second, and third pulleys of respective tensioning assemblies and attached to a free end of the shade material.
According to an embodiment, each tensioning assembly is adapted to be tensioned after removal of the tension assist bracket. According to an embodiment, the roller tube assembly further comprises a shade drive unit adapted to rotate the roller tube to unroll or roll the shade material to adjustably cover or uncover the structural opening. The shade drive unit may comprise a motor.
According to an embodiment, each side panel assembly comprises a longitudinal channel containing the tensioning assembly. Each tensioning assembly may further comprise: a traveler tension bracket attached to an opposite end of the spring; an anchor tension bracket attached to the longitudinal channel; and a threaded bolt adjustably attached to and between the traveler tension bracket and the anchor tension bracket, wherein the bolt is adapted to be tightened or loosened to bring the traveler tension bracket closer or farther from the anchor tension bracket to adjust tension in the spring. According to an embodiment, each tensioning assembly is adapted to be tensioned by adjusting the threaded bolt after removal of the tension assist bracket. According to another embodiment, the longitudinal channel comprises at least one longitudinal track, wherein the traveler tension bracket contains at least one arm adapted to be slidably received by the track allowing the traveler tension bracket to longitudinally translate with respect to the longitudinal channel. According to an embodiment, wherein the track is adapted to slidably receive a plurality of back plates, wherein the fixed pulley bracket and the anchor tension bracket are adapted to be attached to the plurality of back plates at desired locations along the longitudinal channel. According to an embodiment, the longitudinal channel is adapted to be cut to correspond to a size of the structural opening.
According to an embodiment, the roller tube assembly further comprises a hem bar attached to the free end of the shade material, and wherein the pair of cables are attached to the hem bar. According to an embodiment, the hem bar comprises wheels extending from opposite ends of the hem bar, wherein each side panel assembly comprises a longitudinal hem bar channel adapted to receive at least one of the wheels to guide the hem bar along the side panel assembly. Each hem bar channel may comprise a longitudinal lateral wall upon which the at least one wheel rolls. According to an embodiment, the roller tube assembly further comprises a pair of cable cones at each end of the roller tube, wherein each cable cone comprises a helical groove, wherein each cable is adapted to wound on the helical groove of a respective cable cone.
According to another aspect of the embodiments, a roller shade adapted to adjustably cover a structural opening is provided. The roller shade comprises a roller tube assembly comprising: a roller tube; a hem bar; a shade material attached to and extending between the roller tube and the hem bar; a shade drive unit adapted to rotate the roller tube to unroll or roll the shade material to adjustably cover or uncover the structural opening; and a pair of cables adapted to be wound about opposite ends of the roller tube. The roller shade further comprises a pair of side panel assemblies each comprising a longitudinal channel containing a tensioning assembly adapted to tension the shade material. Each tensioning assembly comprises: a fixed pulley bracket attached to the longitudinal channel and comprising a first and second pulleys; a floating pulley bracket comprising a third pulley; a tension assist bracket removably attached to and between the fixed pulley bracket and the floating pulley bracket; and a spring attached at one end to the floating pulley bracket. The tension assist bracket is adapted to keep the floating pulley bracket fixed during installation and is adapted to be removed after the pair of side panel assemblies are attached at opposite sides of the structural opening, the roller tube assembly is attached between the side panel assemblies, and the cables are looped through the first, second, and third pulleys of respective tensioning assemblies and attached to the hem bar.
According to an embodiment, each tensioning assembly is adapted to be tensioned via the spring after removal of the tension assist bracket. Each tensioning assembly further comprises: a traveler tension bracket attached to an opposite end of the spring; an anchor tension bracket attached to the longitudinal channel; and a threaded bolt adjustably attached to and between the traveler tension bracket and the anchor tension bracket, wherein the bolt is adapted to be tightened or loosened to bring the traveler tension bracket closer or farther from the anchor tension bracket to adjust tension in the spring. According to an embodiment, the longitudinal channel comprises at least one longitudinal track, wherein the traveler tension bracket contains at least one arm adapted to be slidably received by the track allowing the traveler tension bracket to longitudinally translate with respect to the longitudinal channel.
According to another aspect of the embodiments, a method of installing a roller shade to adjustably cover a structural opening is provided. The method comprises the step of attaching a pair of side panel assemblies at opposite sides of the structural opening, wherein each side panel assembly comprises a tensioning assembly. Each tensioning assembly comprises a fixed pulley bracket comprising a first and second pulleys; a floating pulley bracket comprising a third pulley; a tension assist bracket removably attached to and between the fixed pulley bracket and the floating pulley bracket; and a spring attached at one end to the floating pulley bracket. The method also comprises the step of attaching a roller tube assembly to and between the pair of side panel assemblies, wherein the roller tube assembly comprises a roller tube, a shade material attached to the roller tube, and a pair of cables adapted to be wound about opposite ends of the roller tube. The method further comprise the steps of looping the pair of cables through the first, second, and third pulleys of respective tensioning assemblies; attaching the pair of cables to the free end of the shade material; and removing the tension assist bracket. The method may further comprise the step of tensioning each tensioning assembly after removal of the tension assist bracket.
The above and other objects and features of the embodiments will become apparent and more readily appreciated from the following description of the embodiments with reference to the following figures. Different aspects of the embodiments are illustrated in reference figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered to be illustrative rather than limiting. The components in the drawings are not necessarily drawn to scale, emphasis instead being placed upon clearly illustrating the principles of the aspects of the embodiments. In the drawings, like reference numerals designate corresponding parts throughout the several views.
The embodiments are described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the inventive concept are shown. In the drawings, the size and relative sizes of layers and regions may be exaggerated for clarity. Like numbers refer to like elements throughout. The embodiments may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the inventive concept to those skilled in the art. The scope of the embodiments is therefore defined by the appended claims.
Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the embodiments. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
The following is a list of the major elements in the drawings in numerical order.
For 40 years Crestron Electronics, Inc. has been the world's leading manufacturer of advanced control and automation systems, innovating technology to simplify and enhance modern lifestyles and businesses. Crestron designs, manufactures, and offers for sale integrated solutions to control audio, video, computer, and environmental systems. In addition, the devices and systems offered by Crestron streamlines technology, improving the quality of life in commercial buildings, universities, hotels, hospitals, and homes, among other locations. Accordingly, the systems, methods, and modes of the aspects of the embodiments described herein can be manufactured by Crestron Electronics, Inc., located in Rockleigh, N.J.
The different aspects of the embodiments described herein pertain to the context of a skylight roller shade, but is not limited thereto, except as may be set forth expressly in the appended claims. While the roller shade is described herein for covering a skylight, the roller shade may be used to cover other types of windows, as well as doors, wall openings, or the like. The embodiments described herein may further be adapted in other types of window or door coverings, such as inverted rollers, Roman shades, Austrian shades, pleated shades, blinds, shutters, skylight shades, garage doors, or the like.
Disclosed herein are systems, methods, and modes for a skylight roller shade that can be easily customized to size, assembled, installed, and tensioned. Beneficially, the skylight roller shade of the present embodiments can be easily customized to fit any sized window frame by using components that can be cut and assembled to size as described in more detail below. The design of the skylight roller shade of the present embodiments also allows it to be easily installed and tensioned in the field by a single installer.
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The first end 115a of the roller tube 111 receives the motor drive unit 112, and the second end 115b receives the idler 113. The idler 113 may comprise an idler pin 119 rotatably connected about an idler body 118. The idler body 118 is inserted into the roller tube 111 and is operably connected to the roller tube 111 such that rotation of the roller tube 111 also rotates the idler body 118. The idler body 118 comprises a flange 116 to prevent the idler body 118 from sliding entirely into the roller tube 111. The idler body 118 may comprise ball bearings therein (not shown) allowing the idler body 118, and thereby the roller tube 111, rotate with respect to the idler pin 119.
The motor drive unit 112 may comprise a motor head 121, a crown adapter wheel 122, a motor housing 120 containing a motor control module 128 and motor 125 therein, and a drive wheel 123. The motor head 121 is adapted to be connected to a motor latch bracket 160. The crown adapter wheel 122 and drive wheel 123 are generally cylindrical in shape and are inserted into and operably connected to roller tube 111 at its first end 115a. Crown adapter wheel 122 and drive wheel 123 may comprise a plurality of channels extending circumferentially about their external surfaces that mate with complementary projections radially extending from an inner surface of roller tube 111 such that crown adapter wheel 122, drive wheel 123, and roller tube 111 rotate together during operation. Crown adapter wheel 122 can further comprise a flange 124 radially extending therefrom to prevent the crown adapter wheel 122 from sliding entirely into the roller tube 111 and maintain the motor head 121 exterior to the roller tube 111. The crown adapter wheel 122 may be rotatably attached to a first end of the motor housing 120 via ball bearings therein (not shown). The crown adapter wheel 122 is adapted to removably and releasably couple the motor drive unit 112 to the roller tube 111. The drive wheel 123 is operably connected to the output shaft of the motor 125 such that rotation of the motor output shaft also rotates the drive wheel 123. The motor 125 may comprise a brushless direct current (BLDC) electric motor. In another embodiment, the motor 125 comprises a brushed DC motor, or any other motor known in the art. The motor drive unit 112 may comprise similar configuration to the CSM-QMTDC-163-1 series motors, available from Crestron Electronics, Inc. of Rockleigh, N.J. The Crestron® CSM-QMTDC-163-1 series motors utilizes the quiet, precision-controlled Quiet Motor Technology to control the movement of the shade, keep track of the shade's position, and adjust the shade to the user's desired preset positions.
In operation, the shade material 106 is rolled and unrolled from the roller tube 111 via the roller shade drive unit 112 to open or close the window. Particularly, the motor 125 drives the drive wheel 123, which in turn engages and rotates the roller tube 111. The roller tube 111, in turn, engages and rotates the crown adapter wheel 122 and idler body 118 with respect to the motor 125, while the motor housing 120, including the motor 125 and motor control module 128, remain stationary. As a result, the shade material 106 may be unrolled from an opened position, when substantially the entire shade material 106 is wrapped about the roller tube 111, to a closed position, when the shade material 106 is substantially unraveled, and vice versa.
The motor control module 128 operates to control the motor 125, directing the operation of the motor 125, including its direction, speed, and position. The motor control module 128 may comprise fully integrated electronics. It can comprise a controller, a memory, and a wired or wireless communication interface. The motor controller can comprise a processor adapted to execute an operating system, run various applications, and/or provide processing, for example to process various commands and perform operations, such as controlling the direction, position, and speed of the motor 125. The communication interface is configured for receiving control commands from an external control point.
The motor drive unit 112 can further comprise a local user interface 129, such as a three-button interface, configured for enabling configuration of the motor drive unit 112 as well as receiving control commands directly from a user. Furthermore, the motor control module 112 may comprise a light indicator (not shown), such as a multicolor light emitting diode (LED), to provide feedback as to the status of the roller shade 100. Control commands received by the motor control module 128 may be a direct user input from the user interface 129 or a wired or wireless signal from an external control point. For example, the controller may receive a control command from a wall-mounted button panel or a touch-panel in response to a button actuation or similar action by the user. Control commands may also originate from a signal generator such as a timer or a sensor.
Power can be supplied to the motor drive unit 112 through a power cord 126 by connecting a terminal block 127 to a dedicated power supply (not shown), such as the CSA-PWS40 or CSA-PWS10SHUB-ENET power supplies, available from Crestron Electronics, Inc. of Rockleigh, N.J. In another embodiment, the motor drive unit 112 may be battery operated and as such may be connected to an internal or external power supply in a form of batteries. In yet another embodiment, the motor drive unit 112 may be powered via solar panels placed in proximity to the window to aggregate solar energy.
Referring to
During assembly of the roller tube assembly 105, the design of each cable cone 140 allows the cone 140 to be indexed into a correct position with respect to the roller tube 111. One terminal end of the shade material 106 is first attached to the longitudinal channel 146 and the other terminal end of the shade material 106 is attached to the hem bar 107. Then the shade material 106 is wrapped about the roller tube 111 until it reaches an opened position where the shade material 106 is substantially fully rolled onto the roller tube 111 as shown in
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Shade 100 may be ordered by a consumer by providing measurements of the window frame 110 to the manufacturer. The manufacturer can use the measurements to cut the roller tube 111, the side channels 130a-b, the base channel 130c, the head panel 103, as well as the side fascia sections 158a-b, base fascia section 158c, and head fascia section 159 to correspond to the size of the measured window frame 110. The manufacturer will then assemble the roller tube assembly 105 as well as the side and bottom panel assemblies 101, 102 and 104 and ship the assemblies along with the head panel 103, the fascia sections 158a-c and 159 to the consumer. During installation, the first and second side panel assemblies 101 and 102 may be secured to the sides of the window frame 110, for example via screws. The screws may be left not fully tightened such that the height of the side panel assemblies 101 and 102 with respect to each other and the window frame 110 may be adjusted.
The roller tube assembly 105 is then mounted between the side panel assemblies 101 and 102. The roller tube assembly 105 may be first mounted to the second side panel assembly 102 by inserting the pin tip of the idler pin 119 into a keyhole 178 (
According to one embodiment, shade 100 may be configured as a single skylight with a single roller tube assembly 105 as shown in
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To solve the aforementioned problems, the aspects of the embodiments are directed toward systems, methods, and modes for a skylight roller shade that can be easily customized to size, assembled, installed, and tensioned. It should be understood that this description is not intended to limit the embodiments. On the contrary, the embodiments are intended to cover alternatives, modifications, and equivalents, which are included in the spirit and scope of the embodiments as defined by the appended claims. Further, in the detailed description of the embodiments, numerous specific details are set forth to provide a comprehensive understanding of the claimed embodiments. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.
Although the features and elements of aspects of the embodiments are described being in particular combinations, each feature or element can be used alone, without the other features and elements of the embodiments, or in various combinations with or without other features and elements disclosed herein.
This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.
The above-described embodiments are intended to be illustrative in all respects, rather than restrictive, of the embodiments. Thus the embodiments are capable of many variations in detailed implementation that can be derived from the description contained herein by a person skilled in the art. No element, act, or instruction used in the description of the present application should be construed as critical or essential to the embodiments unless explicitly described as such. Also, as used herein, the article “a” is intended to include one or more items.
All United States patents and applications, foreign patents, and publications discussed above are hereby incorporated herein by reference in their entireties.
Alternate embodiments may be devised without departing from the spirit or the scope of the different aspects of the embodiments. The embodiments described herein may be used for covering windows as well as doors, wall openings, or the like. The embodiments described herein may further be adapted in other types of window or door coverings, such as inverted rollers, Roman shades, Austrian shades, pleated shades, blinds, shutters, garage doors, or the like.
