Abstract:
A shade cutter for trimming rotating window shades includes a larger opening to accommodate larger diameter shades, one blade for cutting both the slat and the shade, a mechanism to remove the shade pin, a protective cover for the blade, and a motor contained in the shade cutting machine base.

Description:
REFERENCE TO RELATED APPLICATION  
       [0001]     The application claims priority to U.S. Provisional Application entitled “Shade Cutter,” Ser. No. 60/808,741, filed May 26, 2006, which is incorporated herein by reference in its entirety. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention is directed to a machine for trimming rotating window shades.  
       DESCRIPTION OF THE PRIOR ART  
       [0003]     Shade cutters have been around for many years. The primary purpose of a shade cutter is to cut a window shade to a precise dimension. In this manner, a standard length window shade can be formed in the factory and then sent to the customer or customer&#39;s shop for measurement and trimming if necessary.  
         [0004]     There are some issues with the prior art shade cutters though. For example, the shade cutter opening is typically too small. Newer shades are made with different materials and/or insulated which increases the diameter and makes the older shade cutter models inoperable. Further, the prior art machines have a guillotine type cutting blade to cut the slat, which is a safety problem. Further still, the shade pieces, i.e., the cast offs, which are coming off of the machine after the shade has been cut, can fly off in a variety of directions and create a safety problem. In addition, the cutting blade is readily accessible to the operator, creating a safety problem during the cutting operation.  
       SUMMARY OF THE INVENTION  
       [0005]     The present invention overcomes these and other issues associated with prior art shade cutters with a new, useful and unobvious device as described and claimed in the following paragraphs.  
         [0006]     Referring now to the drawings, the present invention is directed to a shade cutter assembly device  10  for trimming a rotating window shade  200  (illustrated in  FIG. 10 ) to a precise dimension. Referring to  FIG. 1 , the shade cutter assembly device  10  comprises a shade support measuring rail  12  having a first end  14  and a second end  16  and which is supported on a base  18  by supports  19 .  
         [0007]     As illustrated in  FIG. 1   a , the rail  12  is an extruded rail in the shape of a “V” with a “T” base  15  on its dorsal side for positioning the rail  12  on the base  18  by means of the shade support brackets  19 . A shallow slot  13  runs the length of the rail  12  for placement of an adhesive measuring tape (not illustrated) if desired.  
         [0008]     Further illustrated in  FIG. 1  is a shade support bracket  20  slidably affixed to the rail  12  by means of glides  21 , which slidably interact with the V-shaped conformation of the rail  12 . The shade support bracket  20  comprises a universal inner bearing brace  22  that mates with the shade  200  having both the pin-type and tab-type shade roller ends, therefore minimizing vibrations that were seen in previous designs. The shade support bracket  20  further includes a shade support tightening handle  24  to allow flexibility in the placement of the bracket  20  along the rail  12 . A spring loaded pin plunger  26  allows the shade pin  203  ( FIG. 9 ) to be reinserted without having to move the shade support bracket  20 .  
         [0009]     Further illustrated in  FIG. 1  is an optional vibration dampener  30 , which is designed to stabilize the shade  200  oscillation during the cutting process. The vibration dampener  30  is mounted along the rail  12  approximately equidistant between the shade support bracket  20  and the cutting machine  40  and is adjustable for different size shades  200 . The vibration dampener  30  includes counter-rotating wheels  32 ,  34  to maintain a pressure against the shade  200  as the shade  200  is cut, keeping the shade  200  collinear.  
         [0010]      FIGS. 2-6  illustrate the shade cutting machine  40 , which comprises a shade cutting machine base  42  and a roller shade slat support  44  for allowing both the shade  200  and the slat  202  (illustrated in  FIGS. 9 and 10 ) to be cut in the same operation, ensuring both are the same length. The shade cutting machine  40  includes a mechanism for pulling the shade pin  203  from a shade  200  which includes a shade rest  48 , a pin puller handle  50  which is activated in a 180-degree fashion in order to pull the pin (not illustrated) from the end of the shade  200 , and a collet  49  within the opening  46 . The collet  49  is a 4-jawed tapered device to clamp the shade pin  203  of the shade  200  on the core spindle and allow removal. The mechanism is a rack and pinion design activated by the handle  50 . A thumb knob or tightener  51  tightens down the collet  49  onto the shade pin  203  on the shade  200 .  
         [0011]     The cutting machine  40  also includes a drive motor  60  which is fully enclosed in the shade cutting machine base  42  of the machine  40 . The motor  60  is supported on both ends to reduce vibrations in the machine  40 . One end of the motor  60  is securely fastened to the shade cutting machine base  42  with locknuts or the like. The other end of the motor  60  is secured with a removable closure cap  62  that slides over the end of the motor  60  with a press fit. The motor  60  is activated by a standard power source  61 .  
         [0012]     Referring to  FIGS. 4 and 5 , the machine  40  further includes a bearing assembly  70  surrounding the shade clamp assembly  71 . The bearing assembly  70  comprises an insert ring  72 , surrounded by a molded plastic bearing casing  74 . The bearing assembly  70  further includes a slot  78  ( FIG. 5 ) for mounting the timing belt tensioner  80 . This slot  78  ensures proper belt tension at all times. A timing belt  82  and drive gear  83  are placed on the bearing casing  74  to rotate the shade clamp assembly  71 . The timing belt  82  is connected to a smaller sprocket  86  on the motor  60  to rotate the bearing assembly  70 .  
         [0013]     Referring to  FIGS. 6 and 7 , the machine  40  includes a shade clamping assembly  71  comprising a clamping device  90  with a threadable centering clamp  92  having four centering surfaces  92   a ,  92   b ,  92   c , and  92   d  such that the shade  200  is clamped in the central portion of the orifice  94 . Therefore, the shade  200  is always clamped at the four centering surfaces  92   a ,  92   b ,  92   c , and  92   d.    
         [0014]     The machine  40  further comprises a cutting blade  100  supported by a cutting blade handle  101 , comprising a stationary steel blade wherein the blade is a single bevel blade. The cutting blade  100  can be rotated at intervals using the spring clip  110  to always have a sharpened portion of the blade  100 . The cutting blade  100  includes a circular row of eight rectangular blade notches  109  spaced out over half the blade  100 . These notches  109  are used in conjunction with a spring steel clip  110  to prevent blade  100  rotation during cutting and allow for quick and easy blade indexing. The spring steel clip  110  attaches directly between the cutting blade handle  101  and the blade  100  using a bolt  112  (illustrated in  FIG. 8 ). The clip  110  penetrates the blade notch  109  in the blade  100 . One side of the clip  110  is perpendicular to the blade notch  109 , allowing the blade  100  to stay in a fixed position while cutting the shade  200 . The other side of the clip  110  has been designed with a taper (not illustrated). This allows the operator, using a supplied tool  116  attached to the machine  40  by a flexible tether  118  ( FIG. 2 ), to advance the blade  100  rotationally to the next slotted position. This exposes a new sharp cutting surface area of the circular blade  100 . The blade notches  109  only cover half of the blade  100  because the other half of the blade  100  is used for cutting of the slats  202 , and may be dull from that operation. Once the user reaches the end of the blade notches  109 , it is time to replace the blade  100 .  
         [0015]     A cutting blade handle  101  is provided for shade  200  cutting as well as slat  202  cutting. The handle  101  is used in conjunction with a safety tab  120  connecting the blade cutting arm  101  to the shade cutting machine base  42  and designed to prevent the handle  101  from lifting past the center line  122  of the shade  200  as illustrated in  FIGS. 7 and 8 . The tab  120  will allow the handle  101  to raise just enough to cut the shade  200 , but no further.  
         [0016]     The machine  40  further comprises a protective cutting blade guard  102 , preferably made of clear plastic, which includes a spring and safety switch (not illustrated) hidden in shade cutting machine base  42  to protect the user, a stationary cutting blade base  124  affixed to the shade cutting machine base  42 , and a rotating cutting blade safety cover  126 . Preferably the guard  102  is clear plastic to allow the user to witness the slat cutting operation, a protective measure. The guard  102  further includes a tapered cone  128  that, when closed, forms an enclosed circle to protect the user from the cutting blade  100 . The guard  102  is used in conjunction with a shut down mechanism comprising a plunger  130  that, when closed, activates a switch (not illustrated) hidden inside the shade cutting machine base  42  of the machine  40 . To operate, the user must pull the plunger  130  out with one hand while lowering the safety cover  126  of the guard  102  with the other hand. If the plunger  130  is not pulled out, the safety cover  126  can not be fully depressed and the machine  40  will not be activated. A switch (not illustrated) is enclosed within the machine  40  to prevent accidental activation or intentional bypass of the safety cover  126 . A spring (not illustrated) from the shade cutting machine base  42  to the safety cover  126  is designed to allow the operator to lower the safety cover  126  onto the shade cutting machine base. This ensures immediate machine shutdown if the safety cover  126  is released for any reason.  
         [0017]     The present invention is also directed to a method for cutting a shade  200 , comprising placing an uncut shade  200  in the pin puller  46  (illustrated in  FIG. 9 ) to remove the pin  203  from the shade  200 . Next, the shade support bracket  20  is adjusted to the final length of the shade  200 . The shade support bracket  20  can be placed at different positions depending on whether the shade  200  will be an inside mount shade  200  or an outside mount shade  200 . The slat  202  is then pulled from the shade  200  and positioned on the slat cutter mechanism  23 . The shade  200  is then inserted and clamped at the clamping device  90 . The cutting blade cover  126  is then lowered. Prior to completely lowering the cutting blade cover  126 , a safety pin must be pulled to allow the cutting blade cover  126  to be placed in the appropriate position, which will activate the rotating motor  60 . The cutting blade cover  126  must be continued to be physically held down in order to activate the motor  60 . This is a safety feature. Once the motor  60  is activated, the shade  200  is then rotated within the bearing assembly  70 . The handle  101  is then lifted to cut the rotating shade  200 . After the shade  200  has been cut, the cover  126  is lifted to deactivate the rotating motor  60 . The handle  101  is then depressed to cut the slat  202 . The shade  200  and slat  202  are then removed from the device  10  and reassembled. The shade  200  may then be placed in the pin puller mechanism  46  to reinstall the shade pin  203 .  
         [0018]     The shade cutter of the present invention overcomes many prior art problems. Of greatest importance, the present invention includes several safety features. Specific advantages of the present invention include that fact that the slat cutter is covered. Therefore, there is no risk of injury to fingers. Further, the opening is larger to accommodate larger diameter shades. Further still, there is only one blade, not two, for cutting both the slat and the shade. The pin puller handle operates at a 180-degree motion, which is an advantage over prior art models which requires nearly a full circular motion. The prior art models must be placed at the edge of a table or bench, which creates safety hazards.  
         [0019]     The shade cutter device of the present invention is designed for use by retail customers in “self-service” or other types of retail establishments selling window shades. In this manner, customers can cut custom sized window shades from stock shades having a set width.  
         [0020]     The objects and advantages of the invention will appear more fully from the following detailed description of the preferred embodiment of the invention made in conjunction with the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0021]      FIG. 1  is a perspective view of the shade cutter assembly  10  of the present invention.  
         [0022]      FIG. 1   a  is a cross-sectional view of the rail  12  assembly taken along lines  1   a - 1   a  of  FIG. 1 .  
         [0023]      FIG. 2  is a perspective view of the shade cutter machine  40  within the shade cutter assembly  10 .  
         [0024]      FIG. 3  is a side elevated view of the shade cutter machine  40 .  
         [0025]      FIG. 4  is a partially exploded perspective view of the shade cutter machine  40 .  
         [0026]      FIG. 5  is a partial perspective view of the shade cutter machine  40  of  FIG. 4  focusing on the bearing assembly  70 .  
         [0027]      FIG. 6  is a second side elevated view of the shade cutter machine  40  with the cover  126  missing.  
         [0028]      FIG. 7  is a partial perspective view of the shade cutter machine  40  of  FIG. 6  focusing on the clamping device  90 .  
         [0029]      FIG. 8  is a side elevated view of the shade cutter machine  40  of  FIG. 5  with the cover  126  intact.  
         [0030]      FIG. 9  is a perspective view of the shade cutter assembly  10  of the present invention illustrating the placement of a shade  200  on the pin puller mechanism  46 .  
         [0031]      FIG. 10  is a perspective view of the shade cutter assembly  10  of the present invention illustrating the placement of the shade  200  and the shade slat  202  within the cutting machine  40 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0032]     Reference is now made to the figures for the following detailed description of the invention as described in the Summary.  
         [0033]     As previously noted, and referring to  FIG. 1 , the shade cutter assembly device  10  comprises a shade support measuring rail  12  having a first end  14  and a second end  16 . The shade cutter assembly device  10  is generally supported on a base  18  by supports  19 .  
         [0034]     Referring now to  FIG. 1   a , the rail  12  is configured in a V shape with a T-shaped base  15  on its dorsal side for positioning the rail  12  on the base  18  by means of shade support brackets  19 . The base  18  can be made of any of a number of materials, including wood, plywood, plastic, metal or other types of extruded board material. It is also within the scope of the present invention to position the shade cutter assembly device  10  directly on an existing bench or table.  
         [0035]     As illustrated in  FIG. 1   a , a shallow slot  13  extends the length of the rail  12 . The slot is ideally suited for the option placement of a measuring tape, such as an adhesive measuring tape (not illustrated), if desired. In this manner, the rail  12  is slotted for precise measuring tape alignment. The measuring tape is printed the length of the slot  13  to measure the shade  200  in order to find the correct spot to cut the shade  200 . While the measuring rail  12  can be made of a number of materials, it is preferably made of a lightweight extruded aluminum. The T-shaped base is of a more rigid design allowing for the secure mounting to the shade cutting machine base  42  of the cutting machine  40  as well as to the rail supports  19 .  
         [0036]     As further illustrated in  FIG. 1 , the shade support bracket  20  is slidably affixed to the rail  12  by means of glides  21  which slidably interact with the V-shaped confirmation of the rail  12 . The shade support bracket  20  comprises a universal inner bearing brace  22  that mates with the shade  200  having both the pin-type and tab-type shade roller ends, therefore minimizing vibrations in the design. The shade support bracket  20  further includes a shade support tightening handle  24  to allow flexibility in the placement of the bracket  20  along with the rail  12 . A spring-loaded pin plunger  26  allows the shade pin  201  (illustrated in  FIG. 8 ) to be reinserted without having to move the shade support bracket  20 . Thus, the shade support bracket  20  is configured as a one-piece clamping device, which allows easier operation of a shade support as opposed to the prior two-piece clamping designs.  
         [0037]     As further illustrated in  FIG. 1 , an optional vibration dampener  30  is designed to stabilize the shade  200  oscillation during the cutting process. The vibration dampener  30  is adjustable for different size shades  200 . The vibration dampener  30  includes counter-rotating wheels  32 ,  34  to maintain a pressure against the shade  200  as the shade  200  is cut, thereby maintaining the shade  200  in the correct fixed position for cutting. Because the wheels  32 ,  34  rotate freely on ball bearings (not illustrated), there is no marring or damaging to the shade  200  as the wheels  32 ,  34  rotate. This results in a cleaner, more controlled cut on the shade  200 .  
         [0038]     Turning now to  FIGS. 2-6 , the shade cutting machine  40  has a shade cutting machine base  42 , which is designed to be secured to the base  18 . It also includes a roller shade slat support  44  for allowing both the shade  200  and the slat  202  to be cut in the same operation, ensuring that both the shade  200  and the slat  202  are of the same length.  
         [0039]     The shade cutting machine  40  also advantageously includes a mechanism for pulling the extension pin from a shade  200 . This mechanism includes a shade rest  48 , a pin puller handle  50  which is activated in a 180-degree fashion in order to pull the pin (not illustrated) from the end of the shade  200 , and a collet  49  within the opening  52 . As best illustrated in  FIG. 3 , the collet  49  is a four-jawed tapered device to clamp the pin of the shade  200  and allow removal. The mechanism is typically of a rack and pinion design and activated by the handle  50 . A thumb knob or tightener  51  activates the collet  49  to tighten down on the shade pin  203  on the shade  200 .  
         [0040]     As illustrated in  FIG. 2  and  FIG. 6 , the cutting machine  40  also includes a drive motor  60 , which is fully enclosed within the shade cutting machine base  42  of the cutting machine  40 . The motor  60  is supported on both ends to reduce vibrations in the machine  40 . One end of the motor  60  is securely fastened to the shade cutting machine base  42  with lock nuts or the like. The other end of the motor  60  is secured with a removable closure cap  62  ( FIG. 2 ) that slides over the end of the motor  60  with a press fit. It is within the scope of the present invention to utilize any of a number of motors produced to activate a machine such as the cutting machine  40 . One such motor is a DC motor produced by Dumore (Mauston, Wis.).  
         [0041]     Referring now to  FIG. 5 , the cutting machine  40  further includes a bearing assembly  70  surrounding the shade clamp assembly  71 . The bearing assembly  70  comprises an insert ring  72 . Preferably, the insert ring  72  is made from a machined brass ring surrounded by a molded plastic bearing casing  74 . Other materials for making the insert ring  72 , such as steel, are contemplated. An opening  76  is provided through the top of the casing  74  to allow future oiling of the shade clamp assembly  71 , should this be required. The bearing assembly  70  further includes a slot  78  for mounting the timing tensioner  80 . This slot  78  ensures proper belt tension at all times. A timing belt  82  and a drive gear  83  are placed on the bearing casing  74  to rotate the shade clamp assembly  71 . The timing belt  82  is connected to a smaller sprocket  86 , which in turn is rotatably connected to the motor  60  in order to rotate the bearing assembly  70 . As illustrated,  FIG. 4  is an exploded view of the machine  40  in which a portion of the casing  41  has been removed.  
         [0042]     Referring now to  FIGS. 6 and 7 , the cutting machine  40  further comprises a shade clamp assembly  71  comprising a clamping device  90  which consists of a threadable centering clamp  92  having four centering surfaces  92   a ,  92   b ,  92   c  and  92   d  such that the shade  200  is clamped in the central portion of the orifice  94 . Therefore, the shade  200  is always clamped at four centering surfaces  92   a ,  92   b ,  92   c  and  92   d . The centering clamp  92  automatically centers the shade  200  to be cut, thereby minimizing vibrations during the rotation of the shade  200  during the cut. A counterweight  96  ( FIG. 7 ) prevents the clamping assembly  71  from vibrating excessively during rotation. Advantageously, the shade clamp assembly  71  of the present invention is adjustably designed to fit a variety of shade diameters. The shade is clamped with an easy-to-use, attached thumb screw  108 , allowing the shade to be fully secured without over tightening that could cause damage to the shade  200  or clamping device  90 .  
         [0043]     A clamping base  98  ( FIG. 5 ) is made from a machined, preferably brass, ring surrounded by molded plastic and allows for a machined precision fit with the bearing support while dampening vibrations with the molded plastic.  
         [0044]     Referring now to  FIG. 6  and  FIG. 8 , the cutting machine  40  further comprises a cutting blade  100  supported by a cutting blade handle  101 , comprising a stationary steel blade wherein the blade is preferably a single beveled blade. A protective cutting blade cover  102  ( FIG. 2 ) also includes a spring and safety switch to protect the user. The cutting blade  100  can be rotated at intervals using a spring clip  110  and blade notches  109  on the blade  100 , to always have a sharpened portion of the blade  100 , available for cutting the shade  200 . The cutting blade  100  preferably includes a circular row of eight blade notches  109  spaced out over half the blade  100 . It is within the scope of the present invention to include more or less notches  109  as desired. These notches  109  are used in conjunction with a spring steel clip  110  to prevent blade  100  rotation during cutting and allow for quick and easy blade indexing. The spring steel clip  110  attaches directly between the cutting blade handle  101  and the blade  100  using a bolt  112  ( FIG. 8 ). The point of the clip  110  penetrates the blade notch  109  in the blade  100 . One side of the clip  110  is perpendicular to the blade notch  109 , allowing the blade  100  to stay in a fixed position while cutting the shade  200 . The other side of the clip point has been designed with a taper  114  (not illustrated). This allows the operator, using a supplied tool  116  attached to the machine  40  by a flexible tether  118 , to advance the blade  100  rotationally to the next slotted position. This exposes a new sharp cutting surface area of the circular blade  100 . The notches  109  only cover half of the blade  100 . The other half of the blade  100  is used for cutting the slats  202 , and may be dull from that operation. Once the user reaches the end of the blade notches  109 , it is time to replace the blade  100 .  
         [0045]     The cutting blade handle  101  is provided for shade cutting as well as slat cutting. The handle  101  is used in conjunction with a safety tab  120  connecting the blade handle  101  to the shade cutting machine base  42  and designed to prevent the handle  101  from lifting past the centerline  122  of the shade  200  as illustrated in  FIG. 8 . The tab  120  will allow the handle  101  to raise just enough to cut the shade  200 , but no further, making the operation as efficient as possible.  
         [0046]     The cutting machine  40  further comprises a protective cutting blade guard  102 , preferably of a clear plastic or polycarbonate material, which includes a stationary cutting blade base  124  affixed to the shade cutting machine base  42 , and a rotating cutting blade cover  126 . Preferably, the guard  102  is clear plastic to allow the user to witness the slat cutting operation, a protective measure. The guard  102  further includes a tapered cone  128  that, when closed, forms an enclosed circle to protect the user from the cutting blade  100 . The guard  102  is used in conjunction with a shutdown mechanism comprising a plunger  130  that, when closed, activates a switch (not illustrated) hidden inside the shade cutting machine base  42  of the machine  40 . To operate, the user must pull the plunger  130  out with one hand while lowering the safety cover  126  with the other hand. If the plunger  130  is not pulled out, the safety cover  126  cannot be fully depressed and the machine  40  will not be activated. A switch (not illustrated) is enclosed within the machine  40  to prevent accidental activation or intentional bypass of the safety cover  126 . A spring  132  ( FIG. 2 ) from the shade cutting machine base  42  to the safety cover  126  is designed to allow the operator to lower the cover  126  onto the stationary cutting blade base  124 . This ensures immediate machine shutdown if the safety cover  126  is released for any reason.  
         [0047]     Unless otherwise specified, all of the materials making the shade cutter assembly device can be of plastic or other composite material. Preferably, materials include glass-filled nylon. Other materials include polycarbonates. It is within the scope of the invention to have all of the materials be of some kind of metal or other material if necessary.  
         [0048]     Reference is now made to  FIGS. 9 and 10  for a description of the operation of the shade cutter assembly device  10 . Referring now to  FIG. 9 , an uncut shade  200  is placed in the pin puller mechanism  46  to remove the pin from the shade  200 . Next, the shade support bracket  20  is adjusted to the final length of the shade  200  utilizing the measuring tape within the rail  12 . The shade support bracket  20  can be placed at different positions along the rail  12 , depending on whether the shade  200  will be an inside mount shade or an outside mount shade. The slat  202  is then pulled from the shade  200  and positioned within the roller shade slat support  44  of the shade cutting machine  40 . The shade  200  is then inserted into the orifice  94  as illustrated in  FIG. 10  and affixed to the clamping device  90  ( FIG. 7 ). The cutting blade cover  126  is then lowered. Prior to completely lowering the cutting blade cover  126 , the plunger pin  130  must be pulled to allow the cutting blade cover  126  to be placed in the appropriate position, which will then activate the motor  60 . The cutting blade cover  126  must be continued to be physically held down with the plunger pin  130  in the pulled position in order to activate the motor  60 . This is a safety feature. Once the motor  60  is activated, the shade is then rotated within the bearing assembly  70 . The operator then lifts the handle  101 , which places the stationary blade  100  against the rotating shade  200  thereby slicing the unwanted length from the shade  200 . After the shade  200  has been cut, the cover  126  is lifted to deactivate the rotating motor  60 . The handle  101  is then depressed to cut the slat  202  within the roller shade slat support  44 . The shade  200  and the slat  202 , now both having the same length, are then removed from the cutting machine  40  and the shade cutter assembly  10 . The slat  202  is reassembled within the shade  200 . The shade  200  is then placed in the pin puller mechanism  26  to reinstall the pin by reversing the operation of the pin puller mechanism  46 .  
         [0049]     It is understood that the invention is not confined to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof that fall literally or equivalently within the scope of the following claims.