Abstract:
In a shade system with a bracket supporting a shade storage roll, an anti-reversible power spring apparatus includes a biasing member and a housing with a receiver end and a connector end where the housing encloses the biasing member and the receiver end and the connector end contain the biasing member within the housing. A connector device is connected with the housing and a receiver device is connected with the housing where the connector is connectable with a receiver and where the receiver is connectable with a connector.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation in Part of U.S. patent application Ser. No. 12/799,879 filed May 4, 2010 entitled “Anti-Reversible Power Spring Apparatus and Method”. The Applicants hereby claim the benefit of the non-provisional application under 35 U.S.C. §120. The entire content of the non-provisional application is incorporated herein by this reference. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to shade systems and mechanisms and methods for assisting in the movement of the shade system. In particular, in accordance with one embodiment, the invention relates, in a shade system with a bracket supporting a shade storage roll, to a modular anti-reversible power spring apparatus including a biasing member and a housing with a receiver end and a connector end where the housing encloses the biasing member and the receiver end and the connector end contain the biasing member within the housing. A connector device is connected with the housing and a receiver device is connected with the housing where the connector is connectable with a receiver and where the receiver is connectable with a connector. 
     BACKGROUND OF THE INVENTION 
     A difficulty arises with the operation of shades for windows, doors and the like. In particular, shade systems include shade rolls to which the shade is attached. The shade is rolled onto the shade roll and dispensed from the roll and taken up by the roll as required. A major difficulty is caused by the requirements to keep the shade system small enough to not be obtrusive and to fit in the window or door space while still enabling the easy operation and movement of the shade. Motors are utilized to assist the movement of the shade but the weight of the shade can require very large, noisy and expensive motors. 
     Prior art devices abound that provide assistance to motors and to the operation of shade systems. In particular, roll type shades, curtains, and doors can be counterbalanced as has been known in the art. In Erpenbeck, U.S. Pat. No. 4,009,745, a window shade support roller having an improved spring motor construction and method of manufacture includes a spring retaining structure which holds a driving spring and a spear structure having an integral spear. The spear structure and the spring retaining structure cooperate together, and with a ball, to form a ball clutch mechanism. The spring retaining structure has ball-receiving recesses with canting floors which simplify assembly. Assembly steps include inserting balls into the spring retaining structure, inserting the spear structure into the spring retaining structure, inserting a dowel into the spear structure, positioning a spring around the dowel, and inserting one end of such spring between portions of the spring retaining structure, which uniquely capture and retain the end without other securement, for torsional winding of the spring. However this device must be mounted horizontally so gravity can move the balls in the channel of the ratchet surface arrangement. If the device is mounted vertically, such that there is no force from gravity the balls will not move in the channel. 
     In U.S. Pat. Nos. 6,283,192 and 6,957,683 to Toti, a spring drive system for window covers is disclosed which includes a so-called flat spring drive and the combination whose elements are selected from a group which includes (1) a band transmission which provides varying ratio power transfer as the cover is opened and closed; (2) a gear system selected from various gear sets which provide frictional holding force and fixed power transfer ratios; and (3) a gear transmission which provides fixed ratio power transfer as the cover is opened or closed. The combination permits the spring drive force at the cover to be tailored to the weight and/or compression characteristics of the window cover such as a horizontal slat or pleated or box blind as the cover is opened and closed. This art discusses the use of multiple drums with flat type springs but does not address the issue of possible back winding the spring. 
     In U.S. Pat. No. 6,648,050 to Toti, a spring drive system useful for window covers is disclosed, which comprises one or more coil spring drives or flat spring drives and the combination whose elements are selected from one or more of a group which includes (1) a band or cord transmission which provides varying ratio power transfer as the cover is opened and closed; (2) gear means comprising various gear sets which provide frictional holding force and fixed power transfer ratios; (3) a gear transmission which provides fixed ratio power transfer as the cover is opened or closed; (4) crank mechanisms; (5) brake mechanisms; and (6) recoiler mechanisms. The combination permits the spring drive force to be tailored to the weight and/or compression characteristics of an associated window cover such as a horizontal slat or pleated or box blind as the cover is opened and closed. 
     In U.S. Pat. No. 6,659,156 to Wen et al., a screw transmission mechanism for a motor-driven blind is constructed to include a driving unit, and at least one cord roll-up unit controlled by the driving unit to lift/lower or tilt the slats of the motor-driven Venetian blind. Each cord roll-up unit includes an amplitude modulation set controlled by the driving unit to lift/lower the slats and bottom rail of the Venetian blind, a frequency modulation set for rotation with the amplitude modulation set to tilt the slats of the Venetian blind, and a linkage adapted to control connection between the frequency modulation set and the amplitude modulation set. 
     In U.S. Pat. No. 6,854,503 to Cross et al., the invention includes an unbalanced horizontal blind with a spring means to provide a lifting or retraction force for the slats of the blinds. A brake means prevents undesired movement of the slats that would otherwise result from the continuous retraction force of the spring means when the slats are set in a desired position. Controls for the release of the brake means and tilting are also provided in an embodiment of a blind of the invention. An embodiment of the invention permits the blind to be operated by a single wand that can be used to either raise the slats or tilt the slats. This eliminates the need for a loose cord or bead chain that would traditionally be used as the user interface for controlling the movement of the slats of the blind. 
     Despite these efforts, the art is still missing a counter balancing system that is easily adjustable such that counter balances may be added or deleted as the circumstances require and as they change. That is, all the prior art of which Applicants are aware are fixed systems or complex adjustable systems that are bulky and hard to manipulate. At best prior art systems can accommodate small adjustments but major changes in the weight of the shade to be moved require total replacement of existing counter balances. 
     Another missing element in the prior art is a simple system for the prevention of back winding of the counter balance springs. For example, if some element of a prior art system was changed, like a battery or batteries, and then the shade was rehung partially deployed, this can result in a reverse wind of the counter balance spring when the motor moves the shade up to the fully open position. This is not desirable since it can, and often does, damage the counter balance systems in the prior art. 
     The cross referenced application goes a long way to eliminating the prior art problems but others still remain. It has been determined that the cross referenced housing limits the number of biasing members by its own dimensions. That is, while the housing may contain multiple biasing members only a certain definite number may be contained in any one preconstructed housing. 
     Further, in order to add or delete biasing members, the entire group of biasing members and the entire housing must be removed, the housing opened, the biasing member(s) added or removed, and then the housing resealed and reinserted for operational use. 
     Further, there is no way provided by the prior art to add additional housings within the system and, at the same time, ensure that the additions are secure with each other and within the system. 
     Thus, it is an object of this invention to provide a counter balance system and method that is modular and that is easy to install and adjust. Further it is an objective of the invention to provide a counter balance system that does not back wind and can not back wind during operation of a shade system. 
     SUMMARY OF THE INVENTION 
     Accordingly, according to one embodiment in a shade system with a bracket supporting a shade storage roll, a modular anti-reversible power spring apparatus includes a biasing member and a housing with a receiver end and a connector end where the housing encloses the biasing member and together the housing, the receiver end and the connector end contain the biasing member within the housing. A connector is connected with the housing and a receiver is connected with the housing where the connector is connectable with a receiver and where the receiver is connectable with a connector. 
     Terms used herein are given their common and ordinary meaning as known by those of ordinary skill in the art. “Modular” is used to describe a device that includes identical or nearly identical attributes such as form and dimension, for example only, such that one may be added to and removed from another, for example only, in a simple, predicable manner. “Connector” and “receiver” describe structures that cooperate together to hold two items together. Likewise “female connector” and “male connector” describe structures designed to cooperate with each other to secure one to the other. Further, “biasing member” describes a device that can exert pressure in a system to move it or resist movement, for example only, such as a spring, for example only and not by way of limitation. 
     In one aspect of the invention, a second housing enclosing a second biasing member is provided and a connector on one housing connects with a receiver on the other housing such that the two housings are locked together. 
     In another aspect, the invention further includes a support connected with the bracket, such that the support does not move. The support is also connected with the biasing member within the housing. A first end cap and a second end cap are provided where one end cap is connected to the shade storage roll at each end of the shade storage roll and also to the support such that the first end cap and the second end cap are held stationary along with the support but the shade storage roll is free to rotate about the end caps. Further, a connector is connected with the first end cap and a receiver is connected with the second end cap where, again, the connector is connectable with a receiver and the receiver is connectable with a connector. 
     As used herein, the term “connectable” means “capable of being connected” and describes a structure or combination of structures that provide the ability, when combined, to result in joining together, at least temporarily, two or more separate structures. 
     In one aspect, the biasing member further includes a first end and a second end where the first end of the biasing member is connected with the housing and where the second end of the biasing member is connected with the support. In a further aspect, the support has a length and the housing has a length and the support is conformed in length to approximately the length of the housing. 
     In one aspect of the invention, the shade storage roll includes a female connector and the housing includes a male connector and the male connector is conformed to connect with the female connector and to lock the housing with the shade storage roll. 
     In another aspect, the connection of the second end of the biasing member with the support is such that the biasing member is held in place when the housing rotates in one direction and is released when the housing rotates in an opposite direction. In a further aspect, the support includes a groove that accepts the second end and holds the second end against movement when the storage roll is rotated in one direction but which allows passage of the second end past the groove when the storage roll is rotated in the opposite direction. 
     In another aspect, the biasing member is selected from a group consisting of: a spring and a coiled flat spring. 
     According to another embodiment of the invention, in a shade system with a bracket supporting a shade storage roll, a modular anti-reversible power spring apparatus includes a biasing member and a housing with a receiver end and a connector end where the housing encloses the biasing member and the receiver end and the connector end contain the biasing member within the housing. A connector is provided that is connected with the receiver end and a receiver is provided that is connected with the connector end where the connector is connectable with a receiver and where the receiver is connectable with a connector. A support is connected with the bracket, such that the support does not move, and where the support is also connected with the biasing member within the housing. A first end cap and a second end cap are provided where one end cap is connected to the shade storage roll at each end of the shade storage roll and to the support such that the first end cap and the second end cap are held stationary with the support and the shade storage roll is free to rotate about the end caps. And a connector is connected with the first end cap and a receiver is connected with the second end cap where the first end cap connector is conformed to connect with the connector end receiver and the second end cap receiver is conformed to connect with the receiver end connector. 
     In one aspect of this invention, it further includes more than one housing with a biasing member where each housing is conformed to connect with at least one additional housing. 
     In another aspect, the biasing member further includes a first end and a second end where the first end of the biasing member is connected with the housing and where the second end of the biasing member is connected with the support. In one aspect, the support has a length and the housing has a length and the support is conformed in length to approximately the length of the housing. In a further aspect, the shade storage roll includes a female connector and the housing includes a male connector and the male connector is conformed to connect with the female connector and to lock the housing with the shade storage roll. 
     In a further aspect, the connection of the second end of the biasing member with the support is such that the biasing member is held in place when the housing rotates in one direction and is released when the housing rotates in an opposite direction. In another aspect, the support includes a groove that accepts the second end and holds the second end against movement when the storage roll is rotated in one direction but which allows passage of the second end past the groove when the storage roll is rotated in the opposite direction. 
     According to another embodiment of the invention, in a shade system with a bracket supporting a shade storage roll, a modular anti-reversible power spring method includes the steps of: 
     a. providing a biasing member; a housing with a receiver end and a connector end where the housing encloses the biasing member and the receiver end and the connector end contain the biasing member within the housing; a connector connected with the housing; and a receiver connected with the housing where the connector is connectable with a receiver and where the receiver is connectable with a connector; and 
     b. connecting the housing with the shade storage roll. 
     In another aspect of this invention the method includes the steps of” 
     a. providing a support connected with the bracket, such that the support does not move, and also connected with the biasing member within the housing; a first end cap and a second end cap where one end cap is connected to the shade storage roll at each end of the shade storage roll and to the support such that the first end cap and the second end cap are held stationary with the support and the shade storage roll is free to rotate about the end caps; and a connector connected with the first end cap and a receiver connected with the second end cap where the first end cap connector is conformed to connect with a receiver and the second end cap receiver is conformed to connect with a connector; and 
     b. connecting an end cap with a housing. 
     In one aspect, the biasing member further includes a first end and a second end where the first end of the biasing member is connected with the housing and where the second end of the biasing member is connected with the support such that the biasing member is held in place when the housing rotates in one direction and is released when the housing rotates in an opposite direction. 
     In another aspect, the method includes the steps of: 
     a. providing more than one housing with a biasing member where each housing is conformed to connect with at least one additional housing; and 
     b. connecting each housing with at least one additional housing. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       Other objects, features and advantages of the present invention will become more fully apparent from the following detailed description of the preferred embodiment, the appended claims and the accompanying drawings in which: 
         FIG. 1  is a perspective view of a shade roll and bracket assembly for the modular anti-reversible power spring apparatus of the present invention according to one embodiment; 
         FIG. 2  is an exploded perspective view of the invention of  FIG. 1  showing three separate housings each including one biasing member; 
         FIG. 3  is a close up, exploded perspective view of the invention of  FIGS. 1 and 2 ; 
         FIG. 4  is a close up, exploded perspective view of one end cap and one housing with one biasing member; 
         FIG. 5  is a close up, exploded perspective view of  FIG. 4  from the opposite view from  FIG. 4 ; 
         FIG. 6  is an end section view of the invention; 
         FIG. 7  is a side perspective view of the invention showing three housings and a support approximately the same length as the total length of the three separate housings; 
         FIG. 8  is a side perspective view of the invention showing two housings and a support approximately the same length as the total length of the two separate housings; and 
         FIG. 9  is a side perspective view of the invention showing one housing and a support approximately the same length as the total length of the one housing. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The preferred embodiment of the present invention is illustrated by way of example in  FIGS. 1-9 . With specific reference to  FIG. 1 , the preferred embodiment of the modular anti-reversible power spring apparatus  10  of the present invention includes an associated roll shade assembly  12  consisting of a shade material  14 , mounting bracket  16 , a shade storage roll  18  and at least one arbor shaft or support  20 . The shade material  14  is attached to the storage roll  18  as is known in the art. As used herein, the term “shade material” is used in its common manner to indicate a substance used to provide shade. It thus includes fabric and plastic, for example only and not by way of limitation, and any other flexible material now known or hereafter developed capable of being rolled onto and off of a storage roll. 
     Referring now to  FIGS. 2 and 3 , the inside of the storage roll  18 , according to a preferred embodiment is hollow. It thus is capable of including within the hollow interior  22  many mechanisms such as, for example only, a motor assembly  24 , including a motor and gearbox (not shown) for example, and a power supply  26 , including batteries (not shown) for example only. The motor assembly  24  and the power supply  26  have one or more male connectors  28 , such as a spline or ridge as shown for example only, that mate with an internal longitudinal groove(s) or female connector  30  in the interior surface of the hollow interior  22  of storage roll  18 . The figures show one or two longitudinal female connectors  30  but there may be more. The effect of inserting motor assembly  24  and power supply  26  within the hollow interior  22  of storage roll  18 , by aligning the male connector  28  with the female connectors  30 , is to lock the elements together such that the motor assembly  24  and the power supply  26 , and any and all other elements connected in such a manner with storage roll  18  as will be discussed more fully hereafter, turn with the storage roll  18 . 
     Still referring to  FIGS. 2 and 3 , in a preferred embodiment, a first end cap  32  and a second end cap  34  are provided. First end cap  32  is connected with support  20  and storage roll  18  on one end of storage roll  18  and second end cap  34  is connected with support  20  and storage roll  18  on the other end of storage roll  18  as illustrated. The connection of support  20  with mounting bracket  16  is fixed. That is, support  20  does not move with relation to bracket  16  once it is secured thereto. Likewise, support  20  is connected with first end cap  32  and second end cap  34  in a fixed relation such that once secured in place, the end caps  32  and  34  do not move either. Storage roll  18 , however, although it is supported between and by the two end caps  32  and  34  is free to move in relation to the end caps  32  and  34 . This movement may be facilitated by the use of bearings  36  at end caps  32  and  34 , for example only. In this manner, output from motor assembly  24  which is connected with storage roll  18  as described above, turns shade roll  18  about end caps  32  and  34  when power from power supply  26  is applied. 
     Finally,  FIGS. 2 and 3  illustrate housing  38  with a receiver end  40  and a connector end  42 . Preferably, housing  38  is cylindrically shaped and similar in dimension to the inside diameter of storage roll  18 . Together, housing  38  and receiver end  40  and connector end  42  enclose biasing member  44  (see  FIGS. 4 and 5 ) and retain biasing member  44  inside housing  38 . Here it should be noted that housing  38  encloses only a single biasing member  44  as will be described more fully hereafter. The figures also show that, preferably, housing  38  includes male connectors  28  that cooperate with female connectors  30  to secure housings  38  in place within storage roll  18 , as discussed above with regard to the motor assembly  24  and the power supply  26 . And, the figures show that preferably, support  20  is connected with each housing  38  as will be described more fully hereafter. 
     Referring now to  FIG. 3 , this close up view further illustrates some of the features of the present invention such as receiver end  40  connected with housing  38 . Connector end  42  is not shown (see  FIG. 4 ) but is opposite from receiver end  40  and connected with housing  38  as well. 
     Further, it can be seen that support  20  is conformed, according to a preferred embodiment, to pass through first end cap  34  and housings  38  and to connect with power out put shaft  46 . Again, because support  20  is fixed and does not move, and because motor assembly  24  is connected with storage roll  18 , which is allowed to move, when operated power out put shaft  46  turns storage roll  18 . 
     Importantly,  FIG. 3  also clearly illustrates receiver  48 . Receiver  48  preferably consists of one or more keyed slots as illustrated.  FIG. 4  shows connector  50 . Connector  50  preferably consists of one or more extended keys as illustrated. Connector  50  cooperates with receiver  48  to lock two separate housings together, as will be discussed more fully hereafter. 
     Referring now to  FIGS. 4 and 5 , many of the above features are more clearly illustrated along with a clear view of the biasing member  44 . Preferably, biasing member  44  is a spring, such as a coiled, flat spring as shown. Biasing member  44  has a first end  52  and a second end  54 . The first end  52  is connected with housing  38 . Preferably, first end  52  fits within slot  56  in housing  38  and is held in that position after installation. 
     Second end  54  fits within groove  58  on support  20 . Importantly, second end  54  and groove  58  cooperate together to prevent movement between them when housing  38  rotates with storage roll  18  in one direction. However, second end  54  is released from groove  58  when rotated in the opposite direction as is more clearly seen from  FIG. 6  and as will be discussed more fully hereafter. 
     Another important feature of the present invention is shown in  FIGS. 4 and 5  in which second end cap  34  includes connectors  50  as described above. As a result, connectors  50  on second end cap  34  cooperate with receivers  48  on connector end  42  of housing  38  to secure housing  38  to the end cap  34 . First end cap  32  (not shown) may also include connectors  50  for the same purpose. Obviously, it is not essential to the invention which element has the connectors  50  and which has the receivers  48  but only that they are positioned so as to function as described. Nonetheless, this feature of the invention ensures that housings  38  inserted within storage roll  18  do not travel or move along the hollow interior  22  after insertion. This is a decided advantage over the prior art in that is reduces noise and vibration as Applicants have determined by testing. 
       FIG. 5  clearly shows connector end  42  of housing  38  with receivers  48 . 
     Referring now to  FIG. 6  a cross section view shows storage roll  18  with female connectors  30  and housing  38  with male connectors  28  connected within female connectors  30 . Four female connectors  30  are shown in the cross section and only two male connectors  28 , which is acceptable for the purposes of the invention. 
     Slot  56  in housing  38  is clearly shown as is first end  52  of biasing member  44 . Also shown are second end  54  of biasing member  44  formed, for example into a rounded end and set within groove  58  of support  20 . In this position, when rotated in the direction of direction arrow  60  the second end  54  is held against movement by groove  58  in stationary support  20  and the biasing member  44  is wound up. When rotated in the direction of direction arrow  62 , the opposite direction from arrow  60 , the second end  54  ramps over the top of groove  58  and unwinds. This feature of the invention prevents reverse or back winding of the biasing member  44 . 
     Referring now to  FIGS. 7 ,  8 , and  9  it is illustrated that support  20  has a length and the length of support  20  may, according to one embodiment, be approximately the same as the combined length of the total number of housings  38 , each with a single biasing member  44 .  FIG. 7  shows support  20  approximately as long as three combined housings  38 ,  FIG. 8 , two and  FIG. 9  only one. Certainly, support  20  may be of a single length sufficient to retain multiple housings  38  covering its entire length or not. That is, fewer housings  38  are easily accommodated on a long support  20  and, as described above, held in place along the support  20  just as well without need for changing to a support  20  of a different length. 
     In whatever length, the important feature of the invention is that housings  38  and the single enclosed biasing member  44  may easily be added to or removed from the storage roll  18 . This is a tremendous advantage over the prior art which requires complicated removal of a large housing, if present, opening the housing, adding or removing biasing members  44  re-closing and re-installing the housing. According to the present invention, counterbalance tension as provided by the biasing members  44  may be accurately and easily adjusted to fit the needs. Further repair and replacement is just as easily accommodated. 
     The description of the present embodiments of the invention has been presented for purposes of illustration, but is not intended to be exhaustive or to limit the invention to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. As such, while the present invention has been disclosed in connection with an embodiment thereof, it should be understood that other embodiments may fall within the spirit and scope of the invention as defined by the following claims.