Abstract:
Various systems, processes, and techniques may be used for producing a long modular window assembly for an aircraft. In particular implementations, a long modular window assembly may, among other things, include a frame, a motor, and a shade. The frame may include an inner shell and an outer shell. The inner shell may have a lens opening, and the outer shell an opening but no lens. The frame may have a frame interior. A lens may be provided for engagement to the lens opening of the inner shell. A multiplicity of brackets may attach the frame to engage the assembly to a side wall, typically curved, of an aircraft interior. An electric motor may engage the frame in the frame interior along the frame. A first shade is provided with a shade rail. The shade and the shade rail are dimensioned for receipt into the interior of the frame.

Description:
RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Patent Application No. 62/040,760, filed Aug. 22, 2014. This prior application is herein incorporated by reference in its entirety. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This application relates to aircraft cabin windows, and more specifically, to modular windows for aircraft cabins. 
       BACKGROUND OF THE INVENTION 
       [0003]    It is often beneficial to be able to select the amount of light coming through a window in a structure, such as in an aircraft cabin. Custom aircraft cabin windows typically use a pleated shade, including a housing, which is a modular unit having an inner lens with manual or electric controls that allow the passenger to move the shade so as to adjust the amount of light coming through the window. 
         [0004]    Applicant incorporates herein by reference, U.S. Pat. No. 4,679,610. The &#39;610 patent is often considered the “pioneer” patent in the area of upscale aircraft cabin windows. The &#39;610 patent discloses a modular, self-contained window insert made of a frame with two panes or lenses of impact resistant plastic, which will prevent the entry of dust into the interior of the unit. A shade, typically in the form of a double accordion collapsible sheet, is placed within the window unit between the inner and outer lenses and can be moved upward and downward by use of a manual or electric control mechanism secured to the frame. 
         [0005]    The window assembly in the &#39;610 patent is roughly about as wide as it is tall and is configured to receive light from a single fuselage cabin window as in the &#39;610 patent  FIG. 1 , element  62 .  FIGS. 5, 5A, and 5B  of the &#39;610 patent show cables  88 / 90  provided as guides to eliminate vibration and to maintain proper vertical alignment of the shade assembly (i.e., one side being higher than the other) during ascent and descent of the shade. In the &#39;610 patent, there is disclosed a single window shade, a single shade rail, and a single manually operated lever and cable system to manually raise and lower the shade rail. 
         [0006]    U.S. Pat. No. 6,481,486 is assigned to Assignee of the present invention and incorporated herein by reference. The &#39;486 patent discloses dual shade rails and dual shades, one stacked upon another.  FIGS. 3A-3H  of this patent detail the manner in which strings or cords are used to move the shade rails up and down as well as a system of cords and strings that allow maintenance of the shades in a parallel alignment. 
         [0007]    Publication US 2009/0283227 (assigned to Assignee of the present invention) and incorporated herein by reference discloses a modular unit having a single shade and belt or chain drive on either side of the shade rail to move a shade, driven by a motor and sprocket, which in turn drives the belt and chain, between an open and closed position. No alignment means are illustrated. 
         [0008]    Applicant incorporates herein by reference, U.S. Pat. No. 6,832,641 (assigned to Assignee of the present invention) entitled “Electric Dual Shade Aircraft Window.” In the &#39;641 patent, a side-by-side dual shade is provided for each of the first or second shade having a shade rail. The &#39;641 patent discloses a single belt for each side, one belt attached to one of the rails and driven by one motor on one side of the frame, and the other belt attached to the second rail on the other side of the frame and driven by a second motor. Shades may be engaged with shade leveling cords for alignment to keep the shade rails horizontal as they move between the open and closed position. All of the foregoing are modular shades that typically include a rear lens. 
       SUMMARY 
       [0009]    The following describes various implementations of a modular window assembly for an aircraft. In particular implementations, a module window assembly, among other things, may include a frame, a motor, and a shade. The frame may have top, bottom, front and rear walls, and side walls and include an inner shell and an outer shell. The inner shell may have a lens opening and the outer shell an opening but no lens. The frame may have a frame interior. A lens may be provided for engagement to the lens opening of the inner shell. A multiplicity of brackets may attach the frame to engage the assembly to a side wall, typically curved, of an aircraft interior. An electric motor may engage the frame in the frame interior along the frame. The motor may include a drive shaft with a drive sprocket on the end thereof. A first shade is provided with a shade rail. The shade and the shade rail are dimensioned for receipt into the interior of the frame. The window assembly may also include an idler sprocket, which may be aligned with the drive shaft but mounted to the frame opposite thereto. 
         [0010]    A live axle may be rotatably mounted to the frame on or near the bottom wall thereof, and a first and second pair of following sprockets may be fixedly engaged to the removed ends of the live axle. A belt pair may be provided for engaging the drive and idler sprockets. One of the belt pair may engage the drive sprocket and a first of the following sprockets, and the other belt may engage the idler sprocket and the second following sprocket. 
         [0011]    Certain implementations may include a multiplicity of alignment cords that run through the shade. Particular implementations may include at least three cords adapted to maintain alignment of the shade. The cords may be routed from the bottom wall of the frame to the shade rail of the shade, through the shade, and into the top of the frame, with two of the cords traversing from alternate sides of the shade to the other side of the shade and one of the cords traversing from one side of the shade to an area between the other two cords. 
         [0012]    Some implementations may include a second electric motor and a second shade. The second electric motor may be mounted to the frame in the frame interior along the frame top, the motor on the opposite side of the frame from the first motor and having a drive shaft with a drive sprocket on the end thereof. The second shade may be mounted inboard of the first shade and have with a shade rail, the second shade and the shade rail dimensioned for receipt into the interior of the frame, the second shade having an upper edge attached to the top of the frame. 
         [0013]    Various implementations provide various features. For example, some implementations allow a modular window that has no rear lens. As another example, some implementations provide for a modular window with a lateral axis that is significantly longer than the height (i.e., high aspect ratio) while still allowing shades to function properly. As an additional example, particular implementations provide drive assemblies that maintain proper alignment of long shades as they are raised and lowered. 
         [0014]    Other features will be apparent to those skilled in art in view of the following description and the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  is a perspective view partially cutaway of Applicant&#39;s modular long window as viewed from the inside of the aircraft. 
           [0016]      FIG. 1A  is a perspective view of the modular long window exploded away from a fuselage section FS of an aircraft exterior having fuselage windows FW. 
           [0017]      FIG. 2  is a rear or outer elevational view of the inner shell (outer shell removed) of Applicant&#39;s modular long window showing the mechanical elements attached on the walls thereof. 
           [0018]      FIGS. 3A and 3B  are elevational views of the detail of  FIG. 2 , bottom left corner and bottom right corner, respectively. 
           [0019]      FIGS. 3C and 3D  show side views of the lower right corner showing a drive belt and follower sprocket in  FIG. 3D , and a drive belt in  FIG. 3C . 
           [0020]      FIG. 4  is a close-up detail of  FIG. 2 , top right corner of the window, taken from outside the window looking in towards the cabin, showing one motor with a motor sprocket, one idler sprocket, two belts, and the outer shade as well as other details. 
           [0021]      FIGS. 4A and 4B  are side cutaway views of the drive and idler sprockets on the top right corner of the inside shell. 
           [0022]      FIGS. 4A and 3C  together show the inner belt on the right side.  FIGS. 4B and 3D  show the outer belt on the right side. 
           [0023]      FIG. 5  is the same view as  FIG. 4 , but showing the top left-hand corner of  FIG. 4  with a second motor, a second idler sprocket, and third and fourth belt, as well as the outer shade. 
           [0024]      FIG. 6  illustrates a portion of a shade rail and shade in the manner in which it attaches to the belt. 
           [0025]      FIGS. 7 and 7A  illustrate the alignment cords for helping to prevent “sagging” of the shades as well as to assist in proper alignment of the shade rails. 
           [0026]      FIG. 8  shows a perspective rear view of Applicant&#39;s modular long window. 
           [0027]      FIG. 9  is a side view of the wire drive manual override with a housing cutaway which may be used with an electric window and, in one embodiment, with the modular long window disclosed herein. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0028]      FIGS. 1-7A  illustrate Applicant&#39;s modular long window  100 . Modular long window  100  is seen to comprise a frame or housing  102  which may be, in a preferred embodiment, comprised of, completely or partially, fiberglass or other suitable material and slightly curved in side view. The housing may comprise an outer shell  104  into which an inner shell  106  may be snugly received. The outer and inner shells, in one embodiment, being rectangular and similarly dimensioned, except that the inner shell having slightly smaller length and height dimensions so as to fit within the perimeter walls of the outer shell  104 . The shells may be affixed to one another by any suitable means, including fasteners. Mounting brackets  108  are engaged, in one embodiment, to outer perimeter walls of outer shell  104 , the mounting brackets being adapted to be received on a side wall panel of an aircraft interior. Inner shell  106  may have an inner face  110 , which defines a cutout for receiving an inner lens  112 , such as a transparent Lexan® inner lens. When the outer shell  104  and inner shell  106  are secured together, they form an interior of housing  102 , into which a number of the following elements may be mounted. In one embodiment, most or all the mechanical elements are engaged to the inner shell. 
         [0029]    In certain embodiments, the length of housing  102  is between about 50 to 70 inches, and the height is between about 18 to 32 inches. In a preferred embodiment, the length is about 61 inches, and the height is about 25 inches. In some embodiments, the length of the housing may be longer (e.g., 84 inches) or shorter (e.g., 42 inches). The aspect ratio (i.e., length/height ratio) may, in certain embodiments, be between about 1.75:1 and 6:1. The housing thickness may be between about 1.5 and 3.5 inches. A long window (whether by width or high aspect ratio) has problems that shorter windows do not, some of the problems which are provided with solutions set forth herein. 
         [0030]    A pair of shades, inner shade  114  and outer shade  116 , are adapted, in the following manner and with the following structure, to move between an open and closed position independently of one another so as to be operator selectively positioned somewhere between (or at) an up or down position, which will allow light to pass through the window, more specifically, through inner lens  112 . In one embodiment, one of the inner or outer shades may be somewhat translucent (about  50 % light passing through) and the other substantially opaque (about  90 % plus light blocked). One or both of shades  114 / 116  may either be in a down or closed position which would substantially or partially prevent light from passing through inner lens  112 . Furthermore, either the inner or the outer shade may be selectively set anywhere between the open and closed position to selectively control the light passing through the lens and the view from the window. Inner lens and inner shell means being toward the interior of the section of the aircraft (closer to a seated passenger), and outer shell and outer shade meaning being away from or outside with respect to the interior of the aircraft. 
         [0031]    A first electric motor  118  is attached by conventional brackets or other suitable structure to the inside upper right of the inner frame as best seen in  FIG. 5  and drives a first drive sprocket  119 , which drive sprocket drives the first, motor driven belt  126 . Mounted in the upper left-hand inside of the inner shell, as best seen in  FIG. 6 , is a second electric motor  124 , which drives a second drive sprocket  125 , which second drive sprocket  125  has entrained upon it a third belt  130 , the third belt being a motor driven belt. Thus, there are two electrical motors  118 / 124 , independently passenger operated from switches  150 / 151 , driving motor driven belts  126 / 130 . The motors are seen to be staggered, that is, having their drive axis staggered one slightly higher than the other. For example, in  FIG. 5 , motor  118  is seen to be slightly higher than motor  124  as seen in  FIG. 6 . Moreover, it is seen that coincident (along the same axis) with the drive shaft of motor  118  is a first idler sprocket  120  mounted on the opposite side of the frame to the motor, seen at the top left in  FIG. 6 . Likewise, extending the drive shaft (drive axis) of second drive sprocket  125 , as seen in  FIG. 5 , one will find a second idler sprocket  122  mounted coincident with the drive shaft of motor  124 , but on the opposite side. 
         [0032]    Turning now to the lower right and lower left-hand corners of the inner frame and as best seen in  FIGS. 3A-3D , it is seen that there are four passive (non-driven) or “following or follower” sprockets  134 / 136 / 138 / 140 . The term “following” or “follower” means they are not driven by direct attachment to a motor and they are removed at the removed end of the belts (mounted on the lower end corners of the housing) from the drive and idler sprockets mounted on the upper end portions of the inside of the shell. First and second following sprockets  134 / 136  are mounted on a live axle  142 , in which in turn is mounted to the shell on stanchions  146  (which may include ball bearings), with following sprockets  134 / 136  engaging belts  132 / 130 , the inner belts as seen in  FIGS. 3A and 3B , and the two belts  132 / 130  driven by second motor  124 . Likewise, third following sprocket  138  and fourth following sprocket  140  are secured at the ends of second live axle  144 , which is also rotatably mounted on other stanchions  146 . Following sprockets  138 / 140  engage belts  126 / 128  (see  FIGS. 3A and 3B ) which are driven by first motor  118 . A flat (hidden) spacer  141  (see  FIGS. 2, 3A, 3C ) may extend vertically along the left and right side of the windows to help keep the shade rails and belts spaced apart—but will typically not extend past the inner face and will thus be “hidden” from view.  FIGS. 4A and 3C  together show the inner belt on the right side.  FIGS. 4B and 3D  show the outer belt on the right side. 
         [0033]      FIG. 6  illustrates how belts  126 / 128 / 130 / 132  may be attached to shade rails  115 / 117  (see also  FIG. 5 ) to help maintain alignment. The shade rails are attached to the belts at their removed ends—one end on a drive belt, the other at the same level position on a driven belt of the drive/driven position. Drive belt  130  may engage a lower shade rail  117  of outer shade  116  to move the outer shade between an open and closed position. In addition, the same attachment of the shade rails  115 / 117  occurs on the opposite side of each shade rail from where that shade rail is attached to the drive belt, but the attachment being to the driven belts  130 / 132 . Thus, one attaches shade rail  115  to first belt  126 , and second belt  128  at the same level, thus maintaining the shade rail in a level position as it moves between the open and closed position. Likewise, third belt  128  and fourth belt  132  (a drive/driven belt combination driven by motor  124 ) will be attached to the other of inner rail or outer rail  115 / 117  to again help maintain the shade in a level position. 
         [0034]    A side view discloses that not only may the drive axes of motors  118 / 124  be staggered as seen in  FIGS. 5 and 6 , but in a side view, they may be slightly staggered side-to-side. The frame has a slight curve to it to conform to the curvature of the cabin panel to which it mounts (see  FIG. 1A ). While the axis is not a true vertical axis because of the slight bend, we can envision, in one embodiment, the two drive axes of the two motors being separated along the “vertical” axis and separated or staggered along the horizontal axis as best seen in  FIG. 4B . Likewise, live axles  142 / 144  may be staggered. 
         [0035]    Another aspect of some embodiments of Applicant&#39;s long window is the cord system of  FIGS. 7 and 7A  as, in some embodiments, Applicant&#39;s system has no rear lens. That is to say, outer shell  104  merely has an opening, without a lens in it, and this creates certain problems, one of which may be sagging or billowing of the shade or shades, including the outer shade. Using an alignment system of cords may help prevent sagging of billowing of either or both shades  114 / 116 . 
         [0036]    Details of the shade cord system and how it is adapted to incorporate two shades, side by side (inner and outer) are seen in  FIGS. 7 and 7A .  FIGS. 7 and 7A  illustrate a lower stationary rail  152  that extends along the lower inside of the shade below any openings so as not to be seen by a passenger. It extends from left to right along the lower bottom and engages a number of alignment cords as set forth hereinafter. It may also serve to mount the stanchions  146 . Likewise, an upper stationary rail  154  which may be L-shaped, which may have the motors (and controls) attached (or may be separate) or any other suitable structure, will be adapted to receive the removed ends of a number of alignment cords that originate at lower stationary rail  152 . The alignment cords will originate and finish at the lower and upper rails, and will undergo a change in direction through use of a bushing (to help prevent fraying), a Teflon loop or any other suitable means at the inner and outer shade rails, outer shade rail  117  illustrated in  FIG. 7 . 
         [0037]    In one embodiment, there are three alignment cords for each shade, six total, though only the three for the outer shade are shown. More specifically, with respect to  FIGS. 7 and 7A , three alignment cords  156 / 158 / 160  are illustrated. All three of the alignment cords slideably engage outer shade rail  117 , so outer shade rail  117  can move up and down with respect to the three alignment cords and, while the three alignment cords will stay stationary. The alignment cords are set to pass through the shade material  114 / 116  (see  FIG. 7A ). Adjusters  162 , such as sliding plates engaged to a top surface of upper stationary rail  154 , may be used to apply a desired tension in the alignment cords where they engage the upper stationary rail (see  FIG. 5 ). 
         [0038]    Turning now to  FIGS. 2 and 7 , the first alignment cord  156  originating at and being physically attached to a lower stationary rail  152  trends vertically upward along the right perimeter of the frame (typically hidden from view by the inner end or faces or other structure). First alignment cord  156  slideably engages and couples to outer shade rail  117  and trends along the bottom thereof, making a 90° turn up through a grommeted hole  164  and through a second grommeted hole  166  at the top rail, makes a 90° turn and ties off at adjuster  162 . Very close to (adjacent) the first alignment cord  156  and trending upward and across is second alignment cord  158 , which goes past hole  164  across the outer shade rail  117  to grommeted hole  168 , where it turns upward, goes through outer shade rail  117 , and through grommeted hole  170 , in upper stationary rail  154  and is tensioned and tied off at an adjuster  162 . 
         [0039]    The third alignment cord  160  begins at the lower left edge of the housing and is typically tied off beneath lower stationary rail  152 , runs upward vertically to the bottom left-hand corner of outer shade rail  117 , undergoes a change of direction at the shade rail, and is strung all the way cross to the right side, where it turns to go vertically upward through grommeted hole  172  in the outer shade rail, through grommeted hole  174  in upper stationary rail  154 , undergoes a 90° change in direction and is tied off at adjuster  162 . 
         [0040]    The inner shade alignment system is substantially identical to what is illustrated in  FIG. 7 , and is not illustrated. What occurs on the inner shade and shade rail is that, in the view seen in  FIG. 7 , the three cords used on the inner shade have two originating in the lower left-hand corner and one originating in the lower right-hand corner of the lower stationary rail  152 . Moreover, the cords are tied off, spaced apart from the cords see in  FIG. 7  and closer to the inner walls of the housing, just as the inner shade is closer to the inner walls of the housing. Thus, for the inner shades, two cords originate on the lower left stationary rail and cross over from left to right on the inner shade rail, and one goes up the center and one goes up the far right to the upper stationary rail. One inner shade cord originates on the lower right-hand portion of the frame, trends upward, crosses all the way across the lower side of the inner shade rail, turns and goes up through the left-hand side and is tied up with adjusters typically on the upper side of the surface of upper stationary rail  154 .  FIG. 7A  shows how alignment cords may be entrained within the folding pleats of shade material making up shade  114 / 116 . 
         [0041]    Although the window assembly has been discussed with respect to two shades, it should be recognized that the window assembly may only include one shade. The principles discussed herein are equally applicable to that embodiment. Additionally, more cords could be added to further stabilize a shade or as the window is made longer. 
         [0042]      FIG. 9  illustrates a wire drive manual override  1  for engagement with an electric motor of an electrically driven window shade. Wire drive manual override  1  is designed to include a housing  2  that can be hand held. By holding housing  2  in one hand, crank arm  3  may be rotated vigorously and DC motor acting as a DC generator  8  contained inside housing  2  will convert the rotary kinetic energy generated by the hand to an electrical current output. The DC motor may, for example, be such as is available from MicroMo Part No. 2233-V0008, manufactured by Faulhaber (Germany). 
         [0043]    This output will be transferred through, in one embodiment, a flexible insulated cord  6  (containing leads or lines  10 / 13 ) to a connector or jack  7 . Jack  7  may, in one embodiment, be a headphone jack with a pair of electrodes  7 A/ 7 B. When used with the long window disclosed herewith, jack  7  is insertable into either of two override ports  148  (depending on which shade—and therefore motor, you wish to move) typically in the front wall of housing  102  or any housing of an electrical window. In one embodiment (two electric motors, two shades), placing jack  7  in one override port and cranking will cause one of the two shades to be energized and move up or down depending on the switch condition. Placing jack  7  into the other override port and cranking will energize the other window shade. Override ports  148  are connected up by conductive wires in any suitable configuration to provide DC power independently to both motors  118 / 124  (to the motors positive and negative terminals or poles thereof). 
         [0044]    Wire drive manual override  1  which, in one particular embodiment, is used in Applicant&#39;s long window, may be adapted for use with any aircraft or any electrically powered, driven shade vehicular window. In one embodiment, it is used as a backup electrical power if there is failure in the main electrical power to the shade motor or motors, which power typically and usually comes from the aircraft electrical circuit. 
         [0045]    Crank arm  3  may be mounted on an axle  4 . A roller handle  5  makes it easy for a hand to grip the crank arm and for easy rotation. Cord  6  may include leads  10 / 13 , which engage the prong (unnumbered) on connector jack  7 . Pin/fastener  11  may help hold axle  4  in place. A re-enforcement sleeve  12  (which may be heat shrink) may be provided where cord  6  enters the jack and where the cord enters housing  2 , which may include a rubber grommet  14  to prevent chafing and for strain relief, which may be secured with a tie wrap  17 . Armature drive shaft  16  is connected to a magnet/wound coil assembly, which acts in typical generator fashion, to rotate magnets/coil windings with respect to one another to generate electric potential and a current output when engaged with a circuit, such as a DC motor circuit in an aircraft window. 
         [0046]    In one embodiment, housing  2  of handheld wire drive manual override  1  has a longest dimension of between about 2 inches and about 6 inches, and may be either rectangular, circular or other suitable shape. The crank arm may be between about 1 inch to about 2½ inches long, thereby defining the radius of curvature of the circle transcribed by the rotation of the crank arm. In one embodiment, the rotation is stepped down in a ratio of  76  motor rotations to one rotation of the crank arm on a DC motor. 
         [0047]    Motors  118 / 124 , such as 24v DC motors, are engaged independently to a controller with switches  150 / 151  and switches are mounted in any suitable place, such as on the front of housing  102 . Electrical switches may be configured in any manner, including a shade selection switch (inner, outer, both), an up or down switch or any other suitable configuration. The switches may be momentary—a quick touch and the selected shade (inner for one switch, outer for the other) will move to full up or full down, hold and release will position the shade when your finger is released. 
         [0048]      FIG. 9  shows outer wall  105  as part of outer shell  104 , but no lens used in this embodiment. Electrical connector  178  may engage the electrical circuit of the window to the aircraft&#39;s circuit. 
         [0049]    The invention has been described with reference to specific embodiments, and several other embodiments have been mentioned or suggested. Additionally, various additions, deletions, substitutions, and modifications will be readily suggested to those of ordinary skill in the art while still achieving a long modular aircraft window. Thus, the scope of the protected subject matter should be judged based on the following claims, which may encompass one or more aspects of one or more embodiments.