Patent Application
20080236766
The present disclosure relates generally to window coverings, and more particularly, to multi-panel window coverings.
Window coverings are typically used within windows to block light, allow light, or to provide privacy to a room of a dwelling. The coverings may be drapes, curtains, blinds, or panels, etc. In the case of a vertical paneled window covering, there may be narrow vertical panels that are pivotally mounted to a head rail. When a user desires to have outside light enter a room, the vertical panels are rotated to allow the light through. Otherwise, the vertical panels may be rotated to overlap to block light entry. These vertical panels may be made of fabric, plastic, metal, or wood, among other materials. However, knitted fabrics provide some aesthetic advantages and also allow for panels that have opaque sections as well as translucent sections that connect the panels.
Knitted fabrics are made on a machine that produces variable pitch in the loops and catches that may be called “stitches” in a knit. This may depend in part on the variations in the yarn paths that produce the patterns typical of knits, and in particular, knit laces. The pitch is affected by yarn type, yarn size, tension, lubrication, and finishing. One finishing technique is often referred to as “blocking.” When a knit fabric is blocked, predetermined dimensions are given to a fabric after the knitting operation, but before finishing. In general, blocking is a general term that can be used by numerous methods to expand or contract the size of the knit or material, as well as provide a function of normalizing the size due to variations in manufacturing. Thus, the blocking techniques may be used to change the size or dimensions of the knitted textile after the knitting operation is complete. In addition to dimensional changes, blocking may also be used to clean up the edges of knitted fabrics to provide a crisp, finished edge.
Typically, blocking machines are used to take knitted textiles and by applying heat, steam, or other methods, the knit is formed to a particular size and density, as is desired for window treatments. However, blocking is a highly variable process such that the finished knit is blocked to a size having a significant variation from each blocking, and in particular, from run to run. Knitted and blocked fabrics, and in particular knit laces, have variable pitch in the loops and catches of the knit. The variation in pitch leads to an inconsistent dimensional pattern that is not tolerated for manufacturing of window treatments, especially those with registered, periodic patterns. Thus, while the knitted fabrics are desirable for use with drapery panels, the difficulty and expense of manufacturing has prevented their consistent use.
Despite prior efforts to provide hanging systems for knit drapery panels, these systems exhibit shortcomings. For example, the prior efforts require that uniform periodicity exist in the knit fabric panels. This is because hangers must be attached to each of the hinged panels and must be located precisely with respect to the supported panel so that all panels hang evenly and cooperate together in producing the light-control function of the completed window covering. However, the knit fabrics do not exhibit consistent tolerances for dimensions and periodicity.
Thus, a need exists for improved knit drapery panel elements and methods of making them. Such an improved knit drapery panel would allow for simplified manufacturing of drapery panels having variations in periodicity of the panels. Moreover, the improved knit drapery panel would also allow for variation in the widths of the opaque sections and translucent sections.
The features and inventive aspects of the present invention will become more apparent upon reading the following detailed description, claims, and drawings, of which the following is a brief description:
Referring now to the drawings, illustrative embodiments are shown in detail. Although the drawings represent the embodiments, the drawings are not necessarily to scale and certain features may be exaggerated to better illustrate and explain an innovative aspect of an embodiment. Further, the embodiments described herein are not intended to be exhaustive or otherwise limit or restrict the invention to the precise form and configuration shown in the drawings and disclosed in the following detailed description.
The embodiments disclosed herein generally concern multi-panel window coverings. The window covering is a single piece of textile material, e.g. a single drapery panel, which acts as a multi-panel light control system. To achieve the multi-panel effect, the textile material has periodically spaced relatively opaque or translucent sections that define the panels, or sections. Hanger elements are attached directly to panel sections that correlate with the periodic opaque sections. Disclosed herein are methods and apparatuses for attaching hangers to single sheet window covering material. The methods and apparatuses adapt to any non-uniformity of textile material in the spacing of the opaque and translucent panel sections. These variations are typically produced in the manufacture of the textile material. However, the methods and apparatuses described herein compensate for other variations in textile material. In addition to the adaptation to non-uniformity in the textile material, the methods and apparatuses described herein also stabilize the free, cut edge, of the textile material in a similar manner as the attachment of the hangers.
The textile material for a vertical drapery panel typically includes a pattern of a first louver portion connected to a second louver portion by a hinge forming a double-thickness vertical panel, also known as a louver. The vertical panels are typically substantially opaque or translucent depending upon the design or requirements of a user. Multiple vertical panels are connected by sheer panels forming the window covering. When the window covering is in an open position, a user may see through the window covering because the vertical panels are rotated to expose the view through the sheer connecting panels. When the window covering is in a closed position, the substantially opaque and/or translucent panels overlap one another and hide and/or prevent viewing through the sheer connecting panels, providing for reduced light transmission through the window covering as well as privacy to the user. An example of a textile material suitable for use with the embodiments herein includes a woven fabric that includes alternating opaque and translucent sections as are illustrated in U.S. patent application Ser. No. 10/960,272, filed on Oct. 7, 2004, U.S. patent application Ser. No. 10/960,533, filed on Oct. 7, 2004, U.S. patent application Ser. No. 11/099,921, filed on Apr. 6, 2005, U.S. patent application Ser. No. 11/100,280, filed on Apr. 6, 2005, U.S. patent application Ser. No. 11/345,912, filed on Feb. 2, 2006, each claiming priority to U.S. Provisional Application No. 60/562,333, filed Apr. 14, 2004, the contents of all of which are included by reference herein.
A vertical panel window covering may be made of a single-piece textile knit fabric. The knit fabric has opaque portions that act as light control panels. The opaque portions are connected to each other by translucent sections of knit material, all of the same piece. The opaque portions form light-control louvers, connected by sheer connecting panels. When rotated to an open position, the light-control louvers may allow light through the window covering (through the sheer connecting panels). When rotated to a closed position, light and view through the window covering is substantially reduced or blocked.
Hangers are positioned at the top of each opaque portion of the knit fabric for attachment to rotatable clips of a standard vertical blind top-track system. The hangers are manually aligned with (i.e., located to) each opaque portion of the knit fabric due to inconsistencies of the single-piece textile. Except for at the ends, two panels are folded to face each other to create a double-thickness, light-control vane. The standard top-track system allows for the coordinated rotation of each vane, such that the vanes cooperate in a system to allow an open or closed set of vanes. Moreover, the top-track system allows for the sliding and rotating of the panels. When open, the vanes are substantially perpendicular to the window, allowing light to flow through the window covering at the translucent portions. When closed, the vanes are substantially parallel with the window, and each vane slightly overlaps the two adjacent vanes to block light flow and view through the window covering.
To accomplish alignment of inconsistent locations of translucent or opaque panel sections of knit fabric, hangers are centered at each panel section before being attached. Once the hangers are fixed to the fabric, each two (2) panels are folded together to achieve facing contact and the hangers attach to one another to form a double-thickness light-control vane. To accomplish the alignment, the single-piece textile knit fabric is laid out on a table. The table includes fixtures for holding the hangers, where the fixtures are moveable to align the hangers with the panel sections. Once aligned, the knit fabric is bonded to the hangers. One example of this is heat staking. The hangers must be permanently attached to their respective panels of the knit fabric. Moreover, the hangers must be precisely located with respect to the panel so that all panels in the window treatment system hang evenly and cooperate together when rotated to enable the light-controlling function of the completed window covering.
In general, the single-piece textile knit fabric is a panel of periodic design. The hangers are located in a precise relationship to opaque portions of the single-piece textile knit fabric, and the hangers are permanently affixed to the single-piece textile knit fabric at that location. An aperture on the hanger allows for attachment to rotatable clips of a standard vertical blind top track system.
Sheer connecting panels 112a, 112b are translucent because the knit of the material is not tight and dense. Vertical panel portions 110a, 110b are relatively opaque because they are more tightly knitted and dense. The blocking operation also allows for the adjustability of the density of both sheer connecting panels 112a, 112b and vertical panel portions 110a, 110b. Alternatively, vertical panel portions 110a, 110b may be configured to be more translucent than opaque if the function is merely to control the amount of light through the multi-panel window covering, but not block the light entirely.
Sheer connecting panels 112a, 112b are integral with vertical panel portions 110a, 110b, as they are a part of a single-piece textile knit fabric. However, sheer connecting panels 112a, 112b must also be flexible enough to allow for the rotation of vertical panel portions 110a, 110b with minimal effort. During manufacturing of a single-piece textile knit fabric, sheer connecting panels 112a, 112b are defined from vertical panel portions 110a, 110b by the basic knitting operation. However, the blocking operation is at least partly responsible for creating inconsistency in each single-piece textile knit fabric because the blocking operation may cause variation in the overall size of the single-piece textile knit fabric. Thus, each hanger 114a, 114b, 114c must be aligned with each vertical panel portion 110a, 110b for every single-piece textile knit fabric that is used to manufacture window covering 100.
Hangers 114a, 114b, 114c also include a bonding portion 120a, 120b, 120c that overlaps with the top end of each respective vertical panel portion 110a, 110b. Bonding portion 120A (120B and 120C not shown in
When assembled (as shown in
In addition to holding vertical panel portion 110, aperture 116 allows attachment to a head rail (e.g., a top-track system). The head rail attachment at aperture 116 is typically a non-permanent attachment allowing for replacement or cleaning of the blinds when removed from the window. Moreover, bonding portion 120 provides a stabilizing area for vertical panel portion 110, which may have a cut fabric or knit end. By bonding vertical panel portion 110 at the cut edge onto bonding portion 120, the fabric or knit end is stabilized from fraying or unraveling.
To facilitate a heat welding process, hangers 200a, 200b, 200c, 200d are made of a thermoplastic material with a melting point of around fifty degrees Fahrenheit (50° F.) below that of the fabric fibers of window covering 100. The melting point of the thermoplastic is below that of the fabric fibers of window covering 100 so that pressing the fibers of window covering 100 causes an impression of the fibers into the softened thermoplastic material of hangers 200a, 200b, 200c, 200d to effect a permanent bond when the thermoplastic material is cooled. Although the melting point is discussed herein as fifty degrees Fahrenheit (50° F.) below the fabric fibers of window covering 100, the melting point may change depending upon the choice of material for window covering 100 and/or hanger 200. Thus, the temperatures provided are a guide.
In addition to bonding window covering 100 with hanger 350, top edge 610 allows an inspector to visually determine whether complete bonding has taken place between window covering 100 with hanger 350, as evidenced by heat welding pattern 520. Moreover, an inspector could test the bond by applying force to top edge 610 (e.g. by tugging or another suitable force). Such a testing method allows for the test of the bond without damaging any of the visible portions of window covering 100.
At step 815, the user loads a sheet of window covering 100 onto table 702. The user may be required to cut the sheet from a bulk source, or the sheets of window covering 100 may be pre-cut to the appropriate size. When the user loads window covering 100 onto table 702, the sheet should be laid flat and any folds or inconsistencies determined by inspection. Control then proceeds to step 820.
At step 820, the user aligns cut edge 510 of window covering 100 with the bonding portion 120 of each hanger 200 (see
At step 825, the user aligns each movable fixture 722 (including hanger 200) to align the centers of movable fixture 722 with substantially panel portions 410 (see
At step 830, the user inspects the alignment of each moveable fixture 722 and hanger 200 with respect to substantially panel portions 410 and knitted-in hinge 420. If each element is not in the proper position, control proceeds to step 825. Otherwise, if the registration of each moveable fixture 722 and hanger 200 is proper, control proceeds to step 835.
At step 835, moveable fixtures 722 are locked into position such that movable fixture 722 and hanger 200 are not inadvertently moved during the rest of the process. Control then proceeds to step 840.
At step 840, a final check of alignment is performed. If alignment is proper, control proceeds to step 845. Otherwise, if alignment is improper, then the offending movable fixtures 722 are unlocked and control proceeds to step 825.
At step 845, heat bar 710 is lowered for attaching window covering 100 to each hanger 200. The time, temperature, and pressure of heat bar are adjusted such that the appropriate melting of hanger 200 is achieved without damaging the knit material of window covering 100. Moreover, the pressure applied by heat bar 710 is adjusted such that sufficient force is applied to push the fibers of window covering 100 into the soft thermoplastic material of hanger 200, but without deforming hanger 200. Control then proceeds to step 850.
At step 850, heat bar 710 is raised away from window covering 100 and a cooling period is performed. Control then proceeds to step 855.
At step 855, the completed window covering 100 is removed from table 702 and each hanger 200 may be mated with its adjacent hanger 200. The process then ends.
As discussed above with respect to
When the final positioning is verified, locking mechanism 912 is rotated to engage locks that hold movable fixtures 722 in place. Locking mechanism 912 prevents movement of moveable fixtures 722 during manufacturing and/or the heat fusion stage. If spaces 960, 962, 964, 966 (or any other gaps) remain open during the heat fusion process (described above in
Stiffener 1310 is assembled by sliding stiffener end 1320, wit latch 1330, upwardly through stiffener receiver 1230. Latch 1330 extends outwardly from the surface of stiffener 1310 via hinge portion 1340. When assembling stiffener 1310 to right band hanger 1210 and left hand hanger 1250, each stiffener receiver 1230 forms a bounded slot that receives stiffener 1310. Because latch 1330 extends via hinge portion 1340, when pushing stiffener 1310 through stiffener receiver 1230, latch 1330 will yield and flex inwardly toward stiffener 1310 until pushed all the way through stiffener receiver 1230. Once latch 1330 is pushed past stiffener receiver 1230, latch 1330 will extend outwardly past stiffener receiver 1230 and will be retained from moving downwardly. Moreover, because latch 1330 is moveable, stiffener 1310 may be removed from hangers 1210, 1250 by pressing latch 1330 inwardly and sliding stiffener 1310 through stiffener receiver 1230.
The curvature of stiffener 1310 provides flexural and torsional stability to panel portions 410a, 410b when turned. Thus, a bottom portion 1420 of panel portions 410a, 410b will turn substantially in unison with hangers 1210, 1250. Otherwise, depending upon the rigidity of panel portions 410a, 410b, bottom portion 1420 may not move in unison or may lag when hangers 1210, 1250 are turned. Additionally, when hangers 1210, 1250 come to rest, bottom portion 1420 may sag or droop and may not be angularly aligned with hangers 1210, 1250.
By providing stiffener 1310, the performance of panel portions 410a, 410b is greatly improved at bottom portion 1420. When a rotational input is provided to panel portions 410a, 410b at hangers 1210, 1250, bottom portion 1420 is impelled to rotate in unison, or substantially in unison, with hangers 1210, 1250. With reference to
The present invention has been particularly shown and described with reference to the foregoing embodiments, which are merely illustrative of the best modes for carrying out the invention. It should be understood by those skilled in the art that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention without departing from the spirit and scope of the invention as defined in the following claims. The embodiments should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non-obvious combination of these elements. Moreover, the foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application.
With regard to the processes, methods, heuristics, etc. described herein, it should be understood that although the steps of such processes, etc. have been described as occurring according to a certain ordered sequence, such processes could be practiced with the described steps performed in an order other than the order described herein. It further should be understood that certain steps could be performed simultaneously, that other steps could be added, or that certain steps described herein could be omitted. In other words, the descriptions of processes described herein are provided for illustrating certain embodiments and should in no way be construed to limit the claimed invention.
Accordingly, it is to be understood that the above description is intended to be illustrative and not restrictive. Many embodiments and applications other than the examples provided would be apparent to those of skill in the art upon reading the above description. The scope of the invention should be determined, not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. It is anticipated and intended that future developments will occur in the arts discussed herein, and that the disclosed systems and methods will be incorporated into such future embodiments. In sum, it should be understood that the invention is capable of modification and variation and is limited only by the following claims.
All terms used in the claims are intended to be given their broadest reasonable constructions and their ordinary meanings as understood by those skilled in the art unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.
