Abstract:
Multi-purpose drapery rod assembly uses unique rod and bracket construction to provide a superior drapery rod platform that can attach a non-motorized single drapery rod to surfaces at nearly any angle, or can motorize a traverse rod.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This is a divisional application filed after pending divisional application Ser. No. 13/892,002 and claiming the filing date of parent application Ser. No. 13/385,041 filed Jan. 30, 2012. This divisional application contains only subject matter disclosed in the parent application, which is hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention generally relates to window drapery hardware, and more specifically to drapery rods and their mounting brackets. 
         [0004]    2. Prior Art 
         [0005]    Drapery is used as a window enhancement for decorative purposes as well as for insulation, to provide privacy, and to control natural light. Drapery rods of a variety of shapes and sizes have been designed to support drapery or the structures to which the drapery is attached. Drapery rods are most often mounted to a substantially parallel vertical support surface such as a wall. A first member base plate typically engages the wall while a second member establishes the distance between the wall and the rod. The needs for easy horizontal adjustment of the second member and vertical adjustment of the base plate have long been addressed by inventors in the industry (e.g., U.S. Pat. No. 4,140,294 and U.S. Pat. No. 4,179,091). More recently, inventors have turned their attention to making drapery rod assemblies and brackets more adaptable to nontraditional surfaces, or to multiple surfaces or window coverings. U.S. Pat. No. 6,376,755 offers a single-drapery rod assembly adapted to be mounted across a doorway, U.S. Pat. No. 6,382,295 offers a bracket adaptable to either mini-blinds or curtain rods, and U.S. Pat. No. 7,322,552 offers one adaptable to both the roman shade and the crisscross curtain singularly and in combination. U.S. Pat. No. 7,861,989 offers a bracket which can mount to a wall, ceiling, or opposing surfaces by adding or removing some parts of the bracket. This is significant since the mounting of a rod to opposing surfaces previously required a bracket like U.S. Pat. No. 3,946,978 which is quite different from those used for ceiling or wall mounting. However, a multi-purpose bracket that does not require parts to be changed out for different surfaces would be preferred to U.S. Pat. No. 7,861,989. 
         [0006]    An assembly is needed that can easily mount a single-drapery rod to a ceiling or to a parallel or opposing vertical support surface using an inconspicuous bracket requiring little or no modification to adapt to differently-angled support surfaces. 
         [0007]    Another need relates to the motorization of drapery rods. Electric remote controlled mechanisms for operating traverse rods have appeared on the market in increasing numbers of late, but the functionally effective ones are expensive and difficult to install. The small light-weight motors deemed necessary are themselves very expensive, and few can be attached to an existing rod. Operational inefficiency has also been a problem. US 2006/0162877 A1 and U.S. Pat. No. 7,360,576 B2 can be attached to existing traverse rods, and the latter does improve the functioning of the drive pulley with a more complex double wheel system. But the performance of both inventions, like that of previous art, is still hindered by redirections of the traverse rod&#39;s transmission cord. The cord is redirected from a horizontal direction to a vertical one before engaging the drive pulley system, then redirected back from vertical to horizontal before returning to the traverse rod. Structural complexity and cost are increased as well as wear and tear and slippage of the transmission cord. Operational efficiency and effectiveness continue to decrease over time as the cord becomes smoother. A motorized assembly is needed which is structurally simpler, does not require the redirection of transmission cords done in prior art, is easy to install with traditional traverse rods, and can support and utilize a relatively inexpensive motor effectively and aesthetically. 
         [0008]    The present invention offers a multi-purpose drapery rod assembly which provides a superior drapery platform through unique rod and cooperating bracket construction. The drapery rod assembly has a flexible bracketing system which can attach the non-motorized single drapery rod to not only substantially parallel support surfaces such as walls, but also to ceilings and to opposing support surfaces such as those found with recessed windows. The ends of the rod can also be attached at different heights on opposed or parallel vertical support surfaces, making it adaptable to non-rectangular windows, recessed or not. 
         [0009]    The present invention also provides an assembly which motorizes a traverse rod. The easy to install assembly is structurally simple, does not require redirection of transmission cords, and can aesthetically and more effectively utilize a bigger and heavier but less expensive motor than available alternatives. 
         [0010]    3. Objects and Advantages 
         [0011]    The multi-purpose drapery rod assembly offers:
   1) a non-motorized single-drapery rod with unique cooperating mounting brackets that can be inconspicuously affixed to surfaces lying at nearly any angle to the rod;   2) and a drapery rod assembly which motorizes a traverse rod.   
 
       SUMMARY 
       [0014]    The multi-purpose drapery rod assembly provides an improved motorized and non-motorized assembly. The flexible bracketing system can attach the non-motorized single-drapery rod to substantially parallel support surfaces such as walls, to ceilings, or to opposing support surfaces such as those found with recessed windows. The ends of this rod can also be attached at different heights on opposed or parallel vertical support surfaces, making the rod adaptable to non-rectangular windows whether or not they are recessed. The multi-purpose drapery rod assembly can also motorize a traverse rod. 
     
    
     
       DRAWINGS 
         [0015]    Together with the detailed description, the accompanying drawings serve to explain and illustrate the principles and implementations of the multi-purpose drapery rod assembly and make its nature, objects, and advantages more apparent to those skilled in the art. The drawings, although not drawn to scale, illustrate multiple embodiments of the drapery rod assembly, both motorized and non-motorized. 
           [0016]      FIG. 1A  is a perspective view from above of the preferred non-adjustable wall mounting bracket of the multi-purpose drapery rod assembly. 
           [0017]      FIG. 1B  is a perspective view from above of the preferred adjustable wall mounting bracket. 
           [0018]      FIG. 2  is a side view of the preferred embodiment of the non-motorized single-drapery rod mounted on opposing vertical support surfaces. 
           [0019]      FIG. 3  is a side view of a second embodiment of that rod mounted on opposing vertical support surfaces. 
           [0020]      FIG. 4  is a side view of a non-motorized single-drapery rod comprised of a single rod rather than a plurality of telescoping rods mounted on opposing vertical support surfaces. 
           [0021]      FIG. 5  is a perspective view from above and to the right of the preferred embodiment of  FIG. 2  mounted to opposing surfaces at a substantially non-perpendicular angle. 
           [0022]      FIG. 6  shows the preferred embodiment of the non-motorized single-drapery rod with non-slip brackets. 
           [0023]      FIG. 7A  is a perspective view of the non-adjustable wall mounting bracket that cooperates with those non-slip brackets. 
           [0024]      FIG. 7B  is a perspective view of the adjustable bracket. 
           [0025]      FIG. 8  is a perspective front view of the components of a right-engaging motorized drapery rod assembly with a partial view of a cooperating traverse rod. 
           [0026]      FIG. 9  is a perspective view from below and behind the drive pulley housing of  FIG. 8 . 
           [0027]      FIG. 10  provides a front view of take-up and drive pulley housings with key components and a traverse rod between them. 
           [0028]      FIG. 11  is a perspective front view of a second embodiment of the drive pulley apparatus along with other key components of the assembly and a partial view of a cooperating traverse rod. 
       
    
    
     DETAILED DESCRIPTION OF INVENTION 
       [0029]    Those of ordinary skill in the art will realize that the following detailed description of the present invention is illustrative only and not intended to be in any way limiting. Other embodiments not shown here will readily suggest themselves to such skilled persons having the benefit of this disclosure. Reference will now be made to implementations of the present invention as illustrated in the embodiments shown in the accompanying drawings. In the interest of brevity and clarity, the drawings focus on the non-routine features of the invention and therefore do not show many routine features well known to those skilled in the art. Not shown or detailed, for example, are any number of means well known in the industry for securing mounting brackets to support surfaces, providing center support for rods, finishing the edges of telescopically inter-engaged rods, and using structural ribs, ridges, and the like to increase the strength of components. 
         [0030]    The non-adjustable and adjustable versions of the preferred wall mounting bracket are detailed in  FIGS. 1A and 1B . 
         [0031]      FIG. 1A  is a perspective view from above of the preferred non-adjustable wall mounting bracket. The wall mounting bracket includes a first member comprised of a base plate  35  with a vertically elongated body, a second member  36  with a horizontally elongated body extending substantially perpendicularly from  35 , and a third member  38  with a vertically elongated cylindrical body extending upwardly and substantially perpendicularly from  36 . Members  35  and  36  can be formed from a single elongated plate made of metal or a similarly strong material that is bent approximately 90 degrees, or two such plates can be attached by welding, brazing, or fusing them together. Third member  38  cannot be simply an angled extension of the second member since the two are shaped very differently. It is attached to  36  by some method such as welding, brazing, or fusion. 
         [0032]    Base plate  35  has screw holes  35 S penetrating it, and a surface adapted to engage and attach to a vertical support structure using screws, wall anchors, or other similar attachment means (not shown) while second member  36  engages the bottom surface of the drapery rod. Third member  38  is sized and shaped to fit into circular apertures penetrating the rod&#39;s top and bottom surfaces at an angle substantially perpendicular to the plane of the intermediate sections of the rod, engaging the surrounding surfaces of the apertures. An advantage to using cylindrical third members is that their surrounding surfaces can be strengthened by the insertion of easily manufactured tubular reinforcements (not shown) into the apertures of what are frequently hollow telescoping rods. The fact that cylindrical third members can rotate within the apertures also has distinct advantages when used with the non-motorized single-drapery rods, those advantages to be identified when describing  FIGS. 2-5 . 
         [0033]      FIG. 1B  is a perspective view from above of the preferred adjustable wall mounting bracket. The base plate and third member are as described with the non-adjustable bracket. The adjustable second member  36 ′ is similar to horizontally adjusting members shown for some time in prior art (e.g., U.S. Pat. No. 4,120,474). It is comprised of lower member  36 B′ and sliding upper member  36 A′. Longitudinally extending channel or slot  37 C in  36 B′ cooperates with an adjustment screw (not shown) operated with an attached head  37 S to adjust  36 ′ for desired clearance from the support surface without the need for tools.  37 S is turned to loosen the screw and allow  36 A′ to be extended or refracted along  37 C, with the range of motion being determined by the length of  37 C.  37 S is turned to tighten the screw at the appropriate point for desired clearance from the support structure. 
         [0034]    The preferred wall mounting brackets of  FIGS. 1A and 1B  can also be adapted to adjust vertically by using vertically elongated channels or slots rather than screw holes on the base plate. Although useful, they are well known in prior art and therefore not shown. The focus in these drawings is on the non-routine features of the multi-purpose drapery rod assembly. However, it should be recognized that the addition of such a vertical adjustment mechanism is within the scope of the present invention. 
         [0035]    The preferred wall mounting brackets of  FIGS. 1A and 1B  can be used to mount a drapery rod to a wall or ceiling, but the cooperating apertures in the latter case would have to penetrate through the rod horizontally rather than perpendicularly since third member  38  would extend horizontally in a ceiling mount. A collar or pin at the end of  38  would be advisable in that case to keep the rod from slipping off of  38 . Alternatively, the bracket could be modified to create a ceiling mount with a third member extending downward rather than horizontally from the second member. This would require the use of a collar or pin at the end of  38  to secure the rod, but would then not require a change in the disposition of the cooperating apertures on the dual-drapery rod. 
         [0036]      FIGS. 2-5  show non-motorized single-drapery rods mounted with the preferred non-adjustable mounting bracket of  FIG. 1A  onto opposing vertical support surfaces like that found surrounding recessed windows. Since the cylindrical shape of the third member allows it to rotate 360 degrees within the perpendicularly disposed receiving aperture, the base plate of the bracket can actually be attached to vertical support surfaces lying at nearly any angle from the single-drapery rod as long as the third member is further from the base plate than from the end of the rod at that angle. The brackets shown in  FIGS. 1A and 1B  could also be used to attach the single-drapery rods to the ceiling with the simple addition of a collar at the end of the bracket&#39;s third member. 
         [0037]      FIG. 2  is a side view of the preferred embodiment mounted on opposing vertical support surfaces. Single-drapery rod  64  is comprised of telescopically inter-engaging left and right rods  63 L and  63 R. Apertures penetrate the rod&#39;s top and bottom surfaces in a substantially perpendicular direction at points substantially adjacent to the left end of  63 L and right end of  63 R. Third members  38 L and  38 R of mounting brackets  26 L and  26 R fit through the apertures and engage the surfaces surrounding the apertures while second members  36 L and  36 R engage the bottom surfaces of  63 L and  63 R and  35 L and  35 R engage the opposing support surfaces. 
         [0038]      FIG. 3  is a side view of a second embodiment. It has more component rods than the first, but is less reliant on center support brackets and the strength of each of the component rods to prevent the rod from sagging under the weight of a wide expanse of drapery. In this embodiment, single-drapery rod  65  is comprised of center rod  68  telescopically inter-engaged between left and right rods  66 L and  66 R. Third members  38 L and  38 R engage the surfaces surrounding the apertures penetrating rods  66 L and  66 R as in  FIG. 2  while second members  36 L and  36 R engage the bottom surfaces of  66 L and  66 R and base plates  35 L and  35 R engage the opposing support surfaces. 
         [0039]      FIG. 4  is a side view of an embodiment comprised of a single rod  69  rather than a plurality of telescoping rods. Members  35 ,  36 , and  38 L and  38 R operate as in  FIGS. 2-3 . 
         [0040]      FIG. 5  is perspective view from above and to the right of the preferred embodiment of the non-motorized single-drapery rod. As in  FIGS. 2-4 , base plates  35 L and  35 R are shown as if mounted on a perpendicularly disposed support surface (not shown) like that found surrounding recessed windows. However,  35 L and  35 R have been mounted at substantially different heights on the opposing support surfaces. This is possible if second members  36 L and  36 R are sufficiently elongated since cylindrical third members  38 L and  38 R can rotate within their receiving apertures and rods  63 L and  63 R can also be rotated. Collars  38 C fitting tightly over  38 L and  38 R are an appropriate means of securing the rod to the brackets when their third members are substantially horizontal as in  FIG. 5 . 
         [0041]    All of the above have circular apertures that cooperate with the cylindrical third members of the preferred bracket of  FIGS. 1A and 1B . However, third members and corresponding apertures of different cooperating shapes are also possible, and may be preferred when apertures are formed with non-slip brackets rather than within the drapery rod itself as shown below. 
         [0042]      FIG. 6  shows an embodiment of the non-motorized single-drapery rod with non-slip brackets and comprised of telescoping substantially straight rods  71 L′ and  71 R′ together. Non-slip brackets attach to  70  at points substantially adjacent to the single-drapery rod&#39;s ends. Non-slip brackets  72 L and  72 R arch away from and back into the rods to form substantially perpendicularly disposed apertures  79 L and  79 R. Wall mounting brackets  76 L and  76 R attach to a wall or other substantially vertical support surface and cooperate with the surrounding surfaces of apertures between non-slip brackets  72 L and  72 R and rods  71 L′ and  71 R′ to secure the single-drapery rod. 
         [0043]      FIG. 7A  is a perspective view of the non-adjustable version of the wall mounting bracket that cooperates with non-slip brackets. Wall mounting bracket  76  includes a first member comprised of a base plate  85  with a vertically elongated body, a second member  86  having a horizontally elongated body extending substantially perpendicularly from base plate  85 , and a third member  88  having a vertically elongated body extending upwardly and substantially perpendicularly from second member  86 . The three members may be formed from a single elongated plate or made from two or more plates attached together using some method such as welding, brazing, or fusion. First member  85  is adapted to attach to a wall or other vertical support surface using screws, wall anchors, or other attachment means (not shown) while second member  86  engages the bottom surface of the non-slip brackets and third member  38  engages the surrounding surfaces of the apertures created by the opposing surfaces of the non-slip bracket and drapery rod. 
         [0044]      FIG. 7B  is a perspective view of the adjustable version. Second member  86 ′ of adjustable wall mounting bracket  76 ′ is comprised of upper and lower second members  86 A′ and  86 B′. Longitudinally disposed channel  87 C in  86 B′ cooperates with an adjustment screw (not shown) operated with an attached head  87 S to adjust  86 ′ for desired clearance from the support surface without the need for tools.  87 S is turned to loosen the screw and allow  86 A′ to be extended or refracted along  87 C, with the range of motion being determined by the length of  87 C.  87 S is turned to tighten the screw at the appropriate point for desired clearance from the support structure. 
         [0045]    Although many drapery rod embodiments have been shown and described, additional ones are possible. However, the embodiments described here should be sufficient to illustrate the principles and implementations of the non-motorized single drapery rod assembly and make its nature, objects, and advantages apparent to those skilled in the art. The embodiments displayed and described below illustrate the motorization of this assembly. 
         [0046]      FIGS. 8-11  show embodiments of the multi-purpose drapery rod assembly that motorize and mount a traverse rod on the preferred wall mounting bracket. The structure and operation of the traverse rod are described only to the extent necessary for context. Detailed descriptions of the traverse rod and its operation are available not only from early patents but also from a variety of readily available sources such as instructions that typically come with the rod and are available on how-to internet sites. 
         [0047]      FIG. 8  is a perspective front view of the components of a right-engaging motorized drapery rod assembly with a partial view of a cooperating traverse rod. (The placement of the assembly on the right side is arbitrary. A left-engaging assembly using the same components rearranged is also possible.) The assembly is less complex structurally than prior art and does not require the transmission cord to be redirected before it is wound around the motor&#39;s wheel or drive pulley. Prior art employs multiple wheels and/or clips with channels to redirect the cord vertically before engaging a pulley wheel, then redirects it back horizontally before the cord re-enters the traverse rod (e.g., see US 2006/0162877 A1 and 7360576 B2). This increases the complexity of the assembly and may decrease efficiency and contribute to slippage. U.S. Pat. No. 7,360,576 B2 purports to combat the slippage problem, but still requires redirection of the transmission cord and appears to increase rather than decrease structural complexity. 
         [0048]    Referring to  FIG. 8 , a traverse rod aperture  114 R penetrates the front surface of drive pulley housing  104  which contains a drive pulley  105  with a drive pulley groove  106  to receive a transmission cord (shown in  FIG. 10 ) from traverse rod  108 . Reverse electric motor  110  is positioned in front of and coupled with right-angled drive  112  to rotate  105 . Rubber (not shown) coats  106  to increase traction of the transmission cord. Traverse rod aperture  114 R is sized to receive the right end of horizontally disposed traverse rod  108  while said traverse rod&#39;s transmission cord is wound around  106  of drive pulley  105  (which replaces the traverse rod&#39;s right pulley and cord tension pulley). Since  105  is directly across from the open end of traverse rod  108  when the rod is inserted horizontally into aperture  114 R, the traverse rod&#39;s transmission cord does not have to be redirected before winding around  106 . A set screw (not shown) tightens to hold the traverse rod in place. 
         [0049]    Wall mounting bracket  126 R cooperates with a aperture  118 R shown in  FIG. 9  penetrating the bottom surface of  104  to support the assembly.  126 R is structurally identical to the preferred wall mounting bracket shown in  FIG. 1A , with a first member comprised of a base plate  135 R having a vertically elongated body, a second member  136 R having a horizontally elongated body extending substantially perpendicularly from  135 R, and a third member  138 R having a vertically elongated cylindrical body extending upwardly and substantially perpendicularly from  136 R. Base plate  135 R is adapted to attach to a wall or other vertical support surface while  136 R engages the bottom surface of  104  and third member  138  engages the surrounding surfaces of aperture  118 R (see  FIG. 9 ), thereby mounting the assembly and the right end of the traverse rod to a support surface. (The left end of the traverse rod is supported with a traditional traverse rod support bracket not shown). Face plate  115  attaches to the face of  104 . Small apertures penetrate the face and end of  104  and intersect with like apertures penetrating its bottom surface to receive drapery hooks that are used with traverse rods (not shown). This allows drapery that is hung from the traverse rod to also be hung across the face and around the back end of housing  104 . 
         [0050]      FIG. 9  is a perspective view from below and behind drive pulley housing  104 . Aperture  118 R penetrates the bottom surface of  104  at an angle substantially perpendicular to traverse rod  108 .  118 R is sized to receive third member  138 R of  126 R while second member  136 R engages the bottom surface of  104  and  135 R engages a wall. 
         [0051]      FIG. 10  provides a front view of take-up pulley housing  129  and drive pulley housing  104  with traverse rod  108  in between. Traverse rod  108  is separated in the middle to better show transmission cord  132 , which wraps around take-up pulley  130  and drive pulley  105 . Mounting brackets  126 L and  126 R are also separated from the housings, as are face plates  115  and  116  and cord guard  128  for take-up pulley  130 . Cord guard  128  keeps transmission cord  132  from slipping off pulley  130 . The ends of cord  132  are not shown, but are drawn tight and tied off at the traverse rod carriers as described in standard instructions accompanying the rods. A tension spring (not shown) is used at one end to maintain tension on the cord. 
         [0052]      FIG. 11  is a perspective front exploded view of a second embodiment of the drive pulley apparatus with other key components and a partial view of the cooperating traverse rod. The second embodiment is more complex than the first, incorporating additional parts designed to deal with the cord slippage problem common with motorized drapery rod assemblies. Traverse rod aperture  114 R penetrates the front surface of drive pulley housing  107  containing a drive pulley with a large-diameter portion  109  and a smaller-diameter groove portion  111 .  111  receives transmission cord  132  from traverse rod  108 . Reverse electric motor  110  is again positioned in front of and coupled with right-angled drive  112 . Traverse rod aperture  114 R (not shown) is sized to receive the left end of  108  while transmission cord  132  is wound around  111 . Friction wheel  140  and tension bushing  142  have holes in their centers which allow  140  and  142  to fit tightly around  111 .  111  is threaded at its end to receive tension nut  146 .  140  is first fitted over  111  and up against  132 , then  142  is fitted over  111  and up against  140 . A tension spring  144  is then slipped over  111  and held in place by  146 , which is tightened to create desired tension to prevent slippage of  132 . Tension cap  148  attaches to  107  with screws and includes a tension cap crown  149  which provides clearance for  111 . Wall mounting bracket  126 R supports the assembly, third member  138 R engaging the surrounding surfaces of aperture  118 R shown in  FIG. 9  while second member  136 R engages the bottom surface of  107  (not shown) and  135 R engages a wall.