Idler for a window treatment

A window treatment system includes a roller tube, a covering material, a motor drive unit, and an idler. The covering material is coupled to the roller tube such that the covering material is configured to be wound and unwound from the roller tube when the roller tube rotates. The motor drive unit is configured to rotate the roller tube. The idler includes a bearing sleeve, a bearing, a bearing retainer, and a pin. The bearing sleeve and the roller tube rotate together. The bearing sleeve includes a cavity and a flange. The bearing is disposed at least partially within the cavity and also defines a bore. The bearing retainer is disposed between the flange and an outboard face of the bearing to maintain the bearing's position. The pin is disposed in the bore such that the bearing sleeve and the roller tube rotate with respect to the pin.

BACKGROUND

A window treatment may be mounted in front of one or more windows, for example to prevent sunlight from entering a space and/or to provide privacy. Window treatments may include, for example, roller shades, roman shades, venetian blinds, or draperies. A roller shade typically includes a flexible shade fabric wound onto an elongated roller tube. Such a roller shade may include a weighted hembar located at a lower end of the shade fabric. The hembar may cause the shade fabric to hang in front of one or more windows over which the roller shade is mounted. A typical window treatment can be mounted to structure surrounding a window, such as a window frame. Such a window treatment may include brackets at opposed ends thereof. The brackets may be configured to operably support the roller tube, such that the flexible material may be raised and lowered. For example, the brackets may be configured to support respective ends of the roller tube. The brackets may be attached to structure, such as a wall, ceiling, window frame, or other structure.

SUMMARY

In one aspect, a window treatment system includes a roller tube, a covering material, a motor drive unit, and an idler. The roller tube extends from a first end to a second end and has a longitudinal axis extending between the first end and the second end. The covering material is coupled to the roller tube such that the covering material is configured to be wound and unwound from the roller tube when the roller tube rotates about the longitudinal axis. The motor drive unit is coupled to the first end of the roller tube and is configured to rotate the roller tube about the longitudinal axis. The idler is coupled to the second end of the roller tube and includes a bearing sleeve, a bearing, a bearing retainer, and a pin. The bearing sleeve is coupled to the roller tube such that the bearing sleeve and the roller tube rotate together about the longitudinal axis. The bearing sleeve includes a body defining a cavity and a flange extending into the cavity. The bearing is disposed at least partially within the cavity of the bearing sleeve and the bearing defines a bore. The bearing retainer is disposed between the flange and an outboard face of the bearing such that the bearing retainer maintains the bearing within the bearing sleeve. The pin is at least partially disposed in the bore of the bearing such that the bearing sleeve and the roller tube are able to rotate about the longitudinal axis with respect to the pin.

In another aspect, an idler for a window treatment system includes a bearing sleeve, a bearing, a bearing retainer, and a pin. The bearing sleeve includes a body defining a cavity and a flange extending into the cavity. The bearing is disposed at least partially within the cavity of the bearing sleeve and defines a bore. The bearing retainer is disposed between the flange and an outboard face of the bearing such that the bearing retainer maintains the bearing within the bearing sleeve. The pin is at least partially disposed in the bore of the bearing such that the bearing sleeve is able to rotate with respect to the pin.

In another aspect, a method of assembling an idler for a window treatment system includes inserting a bearing into a cavity of a bearing sleeve. The method further includes positioning a bearing retainer between the bearing and a flange of the bearing sleeve. The method further includes inserting a pin through a bore of the bearing.

In another aspect, an assembly includes a bearing sleeve, a bearing, a bearing retainer, a pin, and a tube sleeve. The bearing sleeve includes a body defining a cavity and a flange extending into the cavity. The bearing is disposed at least partially within the cavity of the bearing sleeve and defines a bore. The bearing retainer is disposed between the flange and an outboard face of the bearing such that the bearing retainer maintains the bearing within the bearing sleeve. The pin is at least partially disposed in the bore of the bearing such that the bearing sleeve is able to rotate with respect to the pin about a rotation axis of the bearing. The tube sleeve is coupled to the bearing sleeve such that the tube sleeve is capable of axial translation along the rotation axis.

DETAILED DESCRIPTION

The window treatment systems described herein include idlers that may have improved structural performance when compared to prior art idlers. These idlers may be configured to ensure that the components of the idler remain engaged throughout use. Such idlers may allow for the use of larger window treatments that may not have been possible with prior art idler designs. For example, window treatments including the idlers described herein may include a window covering material with dimensions up to 12 feet wide by 12 feet long, for example. This may allow for larger windows to be covered by a single window treatment.

FIG. 1illustrates a perspective view of an example motorized window treatment, such as a motorized roller shade100. The motorized roller shade100may be configured to detect and respond to at least one state or state change, in accordance with some embodiments. The motorized roller shade100may include a covering material110(e.g., a flexible material, such as a shade fabric) windingly received around a roller tube120. The roller tube120may extend from a first end120ato a second end120b. A longitudinal axis122may extend from the first end120ato the second end120b. The roller tube120may be rotatably supported by mounting brackets130, which may be attached to structure adjacent a window (e.g., a wall or ceiling) that may be covered by the covering material110. The roller tube120may be constructed of any appropriate material, such as, for example, aluminum, stainless steel, or plastic.

A hembar140may be connected to a lower edge of the covering material110and be oriented parallel to the lower edge of the covering material110. The hembar140may be configured to weigh down the covering material110and provide an aesthetically-pleasing cover over the lower edge of the covering material110. Rotation of the roller tube120about the longitudinal axis122may cause the covering material110to be wound or unwound from the roller tube120to raise and lower the hembar140.

The motorized roller shade100may comprise a motor drive unit150and an idler160that may each be configured to be connected to one of the respective mounting brackets130. The motor drive unit150may be located inside of, or otherwise coupled to, the first end120aof the roller tube120and the idler160may be coupled to the second end120bof the roller tube120. The motor drive unit150may include a motor configured to rotate the roller tube120to adjust the covering material110between a fully-closed position and a fully-open position and may be configured to retain the covering material110at any position intermediate to the fully-closed position and the fully-open position. The idler160may be coupled to the roller tube120(e.g., at the second end120b) to allow for rotation of the roller tube120relative to the mounting brackets130as the motor drive unit150rotates the roller tube120. The motor drive unit150may include any appropriate drive member (not shown), such as, for example, a DC motor, an AC motor, or a stepper motor. The motorized roller shade100may include one or more batteries configured to power the motor drive unit150. Alternatively, or additionally, the motor drive unit150may be configured to connect to a home's electrical system. For example, the roller shade100may include an electrical cable configured to be connected to the home's electrical system. The motor drive unit150may further include a wireless communication circuit, such as a radio-frequency (RF) receiver or transceiver, for receiving wireless signals (e.g., RF signals). The motor drive unit150may be configured to raise and lower the hembar140to control the amount of daylight entering a space in response to a command received via the wireless signals.

One embodiment of the idler160is shown inFIGS. 2 and 3and in exploded views inFIGS. 4 and 5. As shown best inFIGS. 4 and 5, in various embodiments, the idler160may include a tube sleeve170, a spring180, a bearing sleeve190, a pin retainer200, a bearing210, a bearing retainer220and a pin230. The tube sleeve170may be configured to couple to the roller tube120of the roller shade100. The tube sleeve170may include a body172that may be substantially cylindrical and sized and dimensioned to fit within the roller tube120. The body172may include one or more longitudinal slots173configured to receive ribs of the roller tube to prevent relative rotation of the roller tube120with respect to the tube sleeve170such that the roller tube120and the tube sleeve170rotate together as a unit. The body172may include an inner wall174that may define an internal chamber176that may be configured to receive other components of the idler160, such as the bearing sleeve190, as will be described in more detail herein. The tube sleeve170may further include one or more recesses178extending into the body172from the inner wall174. As will be described in more detail herein, the recesses178may be configured to receive protrusions of the bearing sleeve190to couple the bearing sleeve190to the tube sleeve170such that the bearing sleeve190and the tube sleeve170rotate as a unit and such that the bearing sleeve190is axially translatable along the longitudinal axis122with respect to the tube sleeve170. The tube sleeve170may further include a ledge179extending radially inward from the body172at the inboard end of the tube sleeve170, as best shown inFIG. 5. As will be described herein, when assembled, the ledge179may be in contact with one end of the spring180such that the spring180can apply a force between the tube sleeve170and the bearing sleeve190.

The spring180may be any appropriate member capable of imparting an axial force (e.g., along the longitudinal axis122) on the bearing sleeve190or the bearing210to drive the bearing sleeve190toward an extended position. For example, the spring180may be a helical compression spring. In some embodiments, the spring180may be a conical spring. Such springs may be constructed of any appropriate material, such as, for example, steel. In other embodiments, the spring180may be in the form of a compressible member, such as, for example, an elastomeric member (e.g., a compressible cylinder).

The bearing sleeve190may include a body191that may be, for example, substantially cylindrical. The body191may define a cavity192. The body191may also include one or more arms193extending from the body191(e.g., parallel to the longitudinal axis122) with protrusions194disposed at the end of the arms193. In some embodiments, the arms193may be flexible arms such that the arms193may flex inward toward the center of the body191. The protrusions194may be positioned at the inboard end of the bearing sleeve190. The protrusions194may include a ramped face that may be configured to contact the body172of the tube sleeve170as the bearing sleeve190is inserted into the tube sleeve170during assembly. This contact may cause the arms193to deflect radially inward during insertion to allow the protrusions194to engage the recesses178. When the protrusions194are engaged with the recesses178, this engagement couples the bearing sleeve190and the tube sleeve170such that they rotate together. However, the protrusions194are able to translate axially within the recesses178to allow axial translation of the bearing sleeve190with respect to the tube sleeve170.

The bearing sleeve190may further include a ledge195extending from the body191into the cavity192. The ledge195may assist in locating the bearing210in the cavity192when the bearing210is inserted into the cavity192of the bearing sleeve190. The ledge195may also support and restrain the bearing210to allow the pin230to be press-fit into the bearing210. The spring180may also be in contact with the ledge195to provide an axial force on the bearing sleeve190to bias the bearing sleeve190toward an extended position. In various embodiments (not shown), the ledge195may be continuous. In other embodiments, as shown, for example, inFIG. 4, the ledge195may be divided into multiple discrete elements.

The bearing sleeve190may further include a flange196extending into the cavity192. In various embodiments (not shown), the flange196may be continuous around the circumference of the bearing sleeve190. In other embodiments, as shown inFIG. 4, for example, the flange196may be formed by a plurality of tabs197. In various embodiments, the flange196may be positioned adjacent the outboard end of the bearing sleeve190. As described further herein, the flange196may be configured to engage the bearing retainer220to prevent the bearing210from disengaging from the bearing sleeve190after assembly. The flange196may be made up of any number of tabs197. For example, in one embodiment, the flange196may be made up of six tabs. The tabs197may be equally spaced around the circumference of the cavity192.

The bearing sleeve190may be constructed of any appropriate material. For example, the bearing sleeve190may be constructed of plastic (e.g., ABS or Nylon). In addition, the bearing sleeve190may be manufactured using any appropriate process. For example, the bearing sleeve190may be manufactured using an injection molding process. By forming the ledge195and the flange196of discrete elements, the bearing sleeve190may be manufactured using a simple mold having a straight pull without needing any side action.

In various embodiments, the pin retainer200may include a disc-shaped body202and a plurality of teeth204extending radially inward from the disc-shaped body202. As explained in more detail herein, the pin retainer200may be configured to be positioned adjacent to the inboard face of the bearing210within the cavity192of the bearing sleeve190. The teeth204may be configured to engage the pin230to retain the pin230in position and prevent movement of the pin230relative to the bearing sleeve190.

The bearing210may be any appropriate component adapted to facilitate rotation of the bearing sleeve190relative to the pin230and the mounting bracket130. For example, the bearing210may be a rolling-element bearing such as a ball bearing, a roller bearing, or a needle roller bearing. Alternatively, the bearing210may be a sliding bearing such as a bushing that may be configured to reduce the friction between the bearing sleeve190and the pin230. The bearing210includes an outer face212that may be in contact with the inner face214of the bearing sleeve190and an inner face214configured to contact the pin230. The inner face214defines a bore216through which a portion of the pin230may be inserted.

The bearing retainer220may be configured to retain the bearing210in position in the bearing sleeve190. In various embodiments, the bearing retainer220may be in the form of a C-clip. In other words, the bearing retainer220may be a retaining clip that is a partial circle. The bearing retainer220may be configured such that it can be compressed from a first, unstressed outer diameter to a second, reduced diameter by compressing the ends of the C-clip closer together. This may allow the bearing retainer220to be compressed, inserted between the outboard side of the bearing210and the flange196of the bearing sleeve190, and then released toward the bearing retainer220's unstressed configuration to retain the bearing210. The bearing retainer220may be constructed of any appropriate material. For example, the bearing retainer220may be constructed of spring steel, stainless steel, or copper. In some embodiments, the bearing retainer220may be configured to be installed and/or removed using retaining ring pliers.

The pin230may include a bracket engaging portion232configured to engage a mounting bracket130. The bracket engaging portion232may take on any appropriate form. For example, the bracket engaging portion232may include an extension for engaging an aperture in the mounting bracket130. The pin230may also include a shaft234extending from the bracket engaging portion232. The shaft234may be a stepped shaft with a first portion234aconfigured to be inserted in the bore216of the bearing210. The shaft234may also include a second portion234bconfigured to engage the teeth204of the pin retainer200. In some embodiments, the second portion234bmay have a smaller diameter than the first portion234a. When assembled, the second portion234bmay be positioned inboard in relation to the first portion234a.

FIG. 6shows a cross-sectional view of the assembled idler160. As shown, the shaft234of the pin230may be disposed within the bore216of the bearing210with the inner face214of the bearing210in contact with the shaft234. In various embodiments, the pin230may form a press-fit with the inner face214of the bearing210. The outer face212of the bearing210may be in contact with or adjacent to the body191of the bearing sleeve190. Hence, the bearing210facilitates rotation of the bearing sleeve190relative to the pin230. For example, in use, the pin230may be fixed in position by engagement with a mounting bracket130and the bearing sleeve190may rotate with the tube sleeve170and the roller tube120.

As further shown inFIG. 6, the bearing retainer220may be positioned between the outboard face of the bearing210and the flange196of the bearing sleeve190. In this position, the bearing retainer220and the flange196act together to prevent the bearing210from exiting the cavity192of the bearing sleeve190. In use, the weight of the window covering may cause bending of the roller tube120. This bending may result in an effective shortening of the roller tube120that causes the tube sleeve170and bearing sleeve190to be pulled inward toward the center of the window treatment. In prior art window treatment systems, this movement may cause the bearing sleeve to disengage from the bearing. In contrast, in the embodiments described herein, the bearing retainer220and the flange196prevent the bearing sleeve190from disengaging the bearing210.

FIG. 6also shows that the teeth204of the pin retainer200may be engaged with the shaft234of the pin230(e.g., with the second portion234b). The pin retainer200may be positioned adjacent to, or in contact with, the inboard face of the bearing210. The engagement of the pin retainer200with the pin230may prevent movement of the pin230relative to the bearing210and the bearing sleeve190. For example, any relative movement of the pin230may cause the body202of the pin retainer200to bear against the bearing210. This may further prevent pull-out of the pin230and the bearing210from the bearing sleeve190.

As shown inFIG. 6, the spring180may be disposed in the internal chamber176of the tube sleeve170with a first end of the spring180in contact with the ledge179of the tube sleeve170and the second end of the spring180in contact with the ledge195of the bearing sleeve190. As described above, the protrusions194of the bearing sleeve190are engaged with the recesses178of the tube sleeve170such that the bearing sleeve190and the tube sleeve170may translate with respect to one another along the longitudinal axis122of the roller tube120. For example, during mounting of the roller tube120to the mounting brackets130, the bearing sleeve190—along with the bearing210and the pin230—translate inward toward the center of the roller tube120to allow the idler160(e.g., the bracket engaging portion232of the pin230) to be engaged with the mounting bracket130. After mounting, the spring180may apply a force on the bearing210to bias the bearing sleeve190, and the pin230, toward an extended position. This may assist in maintaining engagement of the pin230with the mounting bracket130.

In another aspect, a method1000of assembling the idler160is illustrated inFIG. 7. At step1002, the bearing210may be inserted into the cavity192of the bearing sleeve190. For example, the bearing210may be positioned between the ledge195and the flange196of the bearing sleeve190. At step1004, the bearing retainer220may be positioned between the bearing210and the flange196of the bearing sleeve190. In some embodiments, the bearing retainer220may be a C-clip and positioning the bearing retainer220includes reducing the outer diameter of the bearing retainer220so that it can be inserted past the flange196. At step1006, the pin230may be inserted through the bore of the bearing210. In some embodiments, the pin230may be press-fit into the bore of the bearing210. In some embodiments, at step1008, the pin retainer200may be inserted into the cavity192of the bearing sleeve such that the teeth204of the pin retainer200engage the shaft234of the pin230to retain the pin230in place. The method may also include, at step1010, inserting the spring180into the cavity192of the bearing sleeve190. The method may further include, at step1012, inserting the spring180and the bearing sleeve190into the tube sleeve170.

While the foregoing description and drawings represent preferred or exemplary embodiments of the present disclosure, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope and range of equivalents of the accompanying claims. In particular, it will be clear to those skilled in the art that the embodiments disclosed herein may be embodied in other forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. One skilled in the art will further appreciate that the window treatment systems described herein may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the window treatment systems, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present disclosed herein. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope being defined by the appended claims and equivalents thereof, and not limited to the foregoing description or embodiments. Rather, the appended claims should be construed broadly, to include other variants and embodiments, which may be made by those skilled in the art without departing from the scope and range of equivalents. All patents and published patent applications identified herein are incorporated herein by reference in their entireties.