Abstract:
A shade roller support is provided to support a window shade. In an exemplary embodiment, the support includes a stationary pin, a housing attached to the shade roller, and a first and second bearing rotatably connecting the pin to the housing. The housing and bearings are positioned at least partially inside the shade roller.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/784,079, filed Mar. 14, 2013, entitled WINDOW SHADE ROLLER SUPPORT to Harold Seib, the entire disclosure of which is expressly incorporated by reference herein. 
     
    
     FIELD 
       [0002]    The present disclosure relates to window shades, and more particularly to supports for rollers of a window shade. 
         [0003]    One type of window shades includes rollers upon which fabric is wrapped. During use, the roller is rolled in one direction to lower the fabric and rolled in the opposite direction to wind up the fabric on the roller to raise the fabric. 
       SUMMARY OF THE DISCLOSURE 
       [0004]    In one exemplary embodiment, a shade roller support is provided to support a window shade. The support includes a stationary pin, a housing attached to the shade roller, and a first and second bearing rotatably connecting the pin to the housing. The housing and bearings are positioned at least partially inside the shade roller. 
         [0005]    According to another embodiment of the present disclosure, a shade roller support assembly is provided. The assembly includes a shade roller having an interior and a first open end, a housing positioned in the first open end of the shade roller and positioned at least partially in the interior of the shade roller, a pin located partially in the interior of the shade roller and extending through the first open end of the shade roller, the shade roller and housing being able to freely rotate about the pin. A first bearing is positioned in the interior of the shade roller rotatably connecting the pin to the housing, and a second bearing is positioned in the interior of the shade roller rotatably connecting the pin to the housing. 
         [0006]    According to another embodiment of the present disclosure, a shade roller support assembly is provided. The assembly includes a shade roller having an interior and a first open end, a housing positioned in the first open end of the shade roller, a pin located partially in the interior of the shade roller and extending through the first open end of the shade roller, the shade roller and housing being able to freely rotate about the pin. A first bearing rotatably connects the pin to the housing, and a second bearing rotatably connects the pin to the housing. The first and second bearings are spaced apart from each other along a longitudinal axis of the pin. 
         [0007]    In a more particular embodiment of any of the above embodiments, the housing includes a first end portion, a second end portion, and a central portion located between the first and portion and the second end portion, the central portion having a smaller diameter than the first end portion and the second end portion. In a further more particular embodiment, the housing is substantially barbell shaped. 
         [0008]    In a more particular embodiment of any of the above embodiments, the position of the housing is fixed relative to the shade roller along at least two contact edges in each of a clockwise direction and a counter-clockwise direction. 
         [0009]    In a more particular embodiment of any of the above embodiments, the assembly further comprises a mounting bracket including a notch with an open end, the pin being configured to be non-rotatably inserted into the notch through the first open end of the shade roller. 
         [0010]    In a more particular embodiment of any of the above embodiments, the housing has an exterior having a plurality of grooves and the interior of the shade roller has a plurality of projections. In a further particular embodiment, each of the plurality of projections is configured to be positioned within one of the plurality of grooves. In another particular embodiment, the shade roller includes an exterior and a shade attachment groove, the shade attachment groove being radially aligned with one of the plurality of projections in the interior of the shade roller. 
         [0011]    In a more particular embodiment of any of the above embodiments, the shade roller and the housing are configured to freely rotate about the pin, and wherein the pin is unable to move relative to the housing in a direction along an axis of rotation of the housing. 
         [0012]    In a more particular embodiment of any of the above embodiments, the assembly further comprises a fabric configured to be wrapped around the housing. 
         [0013]    In a more particular embodiment of any of the above embodiments, the assembly further comprises a roller clutch operatively coupled to a second end of the shade roller. In a further more particular embodiment, the roller clutch is operatively coupled to a bead chain. 
         [0014]    In a more particular embodiment of any of the above embodiments, the shade roller support assembly does not include a spring because the pin does not move longitudinally relative to the housing. 
         [0015]    In another more particular embodiment of any of the above embodiments, a motor is positioned at least partially in the interior of the shade roller which provides rotational motion to the shade roller. 
         [0016]    In a more particular embodiment of any of the above embodiments, a ratio of the diameter of the pin to the diameter of the shade roller is about 5.7. 
         [0017]    In a more particular embodiment of any of the above embodiments, a ratio of the diameter of the pin to the diameter of the bearing is about 2.3. 
         [0018]    In a more particular embodiment of any of the above embodiments, a ratio of the length of the pin to the length of the shade roller tube being is about 5:1 or higher. 
         [0019]    In a more particular embodiment of any of the above embodiments, a ratio of the length of the pin to the length of the shade roller tube is about 20:1 or higher. 
         [0020]    According to another embodiment of the present disclosure, a method of assembling a window shade is provided. The method includes positioning a support body having a first end and a second end around a shaft; coupling a first ball bearing set and a second ball bearing set to the shaft, the first and second ball bearing sets fixing the longitudinal position of the support body on the shaft, each ball bearing set including an inner race rotatably fixed with the shaft and an outer race configured to be coupled to the support body and rotate with the support body about the shaft; inserting at least a portion of the support body into a roller tube; and securing a fabric to the roller tube, the fabric being configured to roll on to the roller tube when the roller tube is rotated in a first direction and unroll from the roller tube when the roller tube is rotated in a second direction. 
         [0021]    In a more particular embodiment, the method further comprises receiving the shaft in a bracket, the bracket being coupled to the shaft such that the bracket does not rotate relative to the shaft. 
         [0022]    In a more particular embodiment, the support body includes a middle portion positioned between the first end and the second end, the middle portion having a diameter smaller than the diameter of the first end and the second end. 
         [0023]    In another more particular embodiment, the support body has an exterior includes a plurality of grooves and the interior of the shade roller has a plurality of projections, and inserting at least a portion of the support body into the roller tube includes receiving the plurality of projections into the plurality of grooves. 
         [0024]    In yet another more particular embodiment, securing the fabric to the roller tube includes receiving a portion of the fabric in a rib in the roller tube and securing the portion of fabric with adhesive or a fastening rod. 
         [0025]    According to another embodiment of the present disclosure, a method of raising or lowering a window shade is provided. The method includes at least partially covering a window opening with a fabric, the fabric being configured to be wrapped around a roller tube, the roller tube operatively coupled to a roller clutch, the roller tube being coupled to a first bracket by the roller clutch and a second bracket by a roller support, the roller support including a shaft non-rotatably coupled to the bracket and first and second ball bearings rotatably coupling the shaft to the roller tube, the first and second ball bearings being positioned in an interior of the roller tube; and pulling an actuator extending from the roller clutch to a tensioner, the actuator configured such that pulling a first portion of the actuator unrolls the fabric from the roller tube and pulling a second portion of the actuator rolls the fabric on to the roller tube. 
         [0026]    In a more particular embodiment, the actuator is a continuous loop actuator. In still a more particular embodiment, the actuator is a bead chain. 
         [0027]    In a more particular embodiment, the fabric is movable between a fully raised position, a fully lowered position, and an intermediate position between the fully raised and lowered position. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]    The above-mentioned and other features of the disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description taken in conjunction with the accompanying drawings, wherein: 
           [0029]      FIG. 1  is a diagrammatic view of a window shade in an architectural opening, such as a window, showing the window shade including a roller, fabric supported by the roller, a roller clutch supporting a left end of the roller, a roller support supporting a right end of the roller, and a bead chain (or other flexible actuation device) used to operate the window shade; 
           [0030]      FIG. 2  is a perspective view of a roller support for use with the roller window shade of  FIG. 1 ; 
           [0031]      FIG. 3  is a perspective view of the roller support of  FIG. 2  aligned with a bracket and roller tube; and 
           [0032]      FIG. 4  is an assembly view of the roller support of  FIG. 2  showing the various components of the roller support. 
       
    
    
       [0033]    Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner. 
       DETAILED DESCRIPTION 
       [0034]    The embodiments disclosed herein are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. 
         [0035]    According to the present disclosure, a window shade  10  is provided that includes a roller tube  14 , fabric  16  wrapped on roller tube  14 , roller clutch  18  coupled to roller tube  14 , bead chain  20  coupled to roller clutch  18 , and a tensioner  22  applying tension to bead chain  20 . One end of roller tube  14  is typically supported by roller clutch  18  in a window opening  24  and the other end by a roller support  26  that provide rotational support of the ends of roller tube  14 . Roller clutch  18  may be supported in window opening  24  by a separate bracket (not shown) or integrated with a bracket or otherwise configured to be supported in window opening  24 . Window shade  10  may be positioned directly within window opening  24 , adjacent to window opening  24 , above window opening  24  or otherwise to block sunlight and/or air flow through window opening  24 . 
         [0036]    Normally, fabric  16  of window shade  10  is stationary in one of a fully raised position allowing more light to pass through window opening  24  into a room, a fully lowered position allowing less or none of the light to pass through window opening  24  into the room, or in an intermediate position between the fully raised and lowered positions. To change the position of fabric  16 , a user pulls either side of bead chain  20  up or down to roll or unroll fabric  16  from roller tube  14 . 
         [0037]    Bead chain  20  is the preferred embodiment of a continuous loop actuator that extends between tensioner  22  and roller clutch  18 . According to alternative embodiments, the actuator may be unbeaded, such as a cord, non-continuous, such as having one or more terminal ends, or other suitable actuator configurations known to those of ordinary skill in the art. Additional details of a suitable roller clutch  18  is provided in PCT Patent Publication No. WO2012/122108, titled ROLLER CLUTCH, to Harold Seib, filed Mar. 5, 2012, the entire disclosure of which is expressly incorporated by reference herein. 
         [0038]    Roller support  26  is shown in greater detail in  FIGS. 2-4  and includes a support body  28  and a shaft  30  extending through support body  28  and extending beyond one end thereof. According to the preferred embodiment of the present disclosure, support body is made of a plastic material and shaft  30  is made of chrome-plated steel. 
         [0039]    Roller support further includes a snap ring  32 , washer  34 , first ball bearing  36 , second ball bearing  38 , washer  40 , and snap ring  42 . As shown in  FIGS. 2 and 3 , snap ring  32  is normally positioned in a groove  44  in shaft  30  to retain washer  34  on shaft  30 . Similarly, snap ring  42  is normally positioned in a groove  46  in opposite end of shaft  30  to retain washer  40  on shaft  30 . 
         [0040]    During assembly, shaft  30  is press fit into one of ball bearings  36 ,  38 , support body  28  is positioned over shaft  30 , and the other one of ball bearings  38 ,  36  is press fit onto shaft  30 . This press fit locks the longitudinal position of ball bearings  36 ,  38  onto shaft  30  and ball bearings  36 ,  38  trap support body  28  therebetween to likewise lock the longitudinal position of support body  28  on shaft  30 . According to the preferred embodiment, roller support  26  does not include a spring because shaft  30  does not move longitudinally relative to support body  28 . Later in assembly, washers  34 ,  40  are positioned over shaft  30  and snap rings  32 ,  42  are positioned in respective grooves  44 ,  46 . 
         [0041]    As shown in  FIGS. 2-4 , support body  28  is dumbbell shaped having first and second enlarged ends  48 ,  50  and a substantially smaller middle portion  52 . First and second ends  48 ,  50  are sized to receive ball bearings  36 ,  38  and middle portion  52  is sized to receive shaft  30 . As a result of the dumbbell shape, support body  28  includes wide groove or annular recess  54  positioned between enlarged first and second ends  48 ,  50 . Additionally, the outer diameter of middle portion  52  is smaller than the outer diameter of ball bearings  36 ,  38 . Because middle portion  52  extends between first and second enlarged ends  48 ,  50 , first and second enlarged ends  48 ,  50  rotate together along with the outer races of first and second ball bearings  36 ,  38 . 
         [0042]    First end  48  of support body  28  has a larger diameter than second end  50 . This larger diameter is provided by a disk or cap  56  that is larger than the inside and outside diameter of roller tube  14  so that first end  48  caps the open end  47  of roller tube  14 . 
         [0043]    During installation, support body  28  is positioned in roller tube  14  so that notches  49  in support body  28  align with ribs  51  in roller tube  14  and support body  28  is indexed into roller tube  14 . One of larger rib  5  in roller tube  14  receive a portion of fabric  16 . Adhesive and or a fastening rod is used to secure the portion of fabric  16  in this rib  51 . As such, one of notches  49  of support body  28  may also receive a portion of fabric  16 . 
         [0044]    As shown in  FIGS. 2-4 , shaft  30  includes a pair of grooves  58  positioned on opposite sides of shaft  30 . A bracket  60 , which is mounted to window opening  24 , includes a slot  62  defined by edges  64  that receives shaft  30  so that edges  64  are received by grooves  58 . Grooves  58  have flat bottoms that abut edges  64  so that shaft  30  does not rotate relative to bracket  60  after installation. Rotation between roller tube  14  and shaft  30  (and bracket  60 ) is provided by ball bearings  36 ,  38  such that the inner race of ball bearings  36 ,  38  are stationary and the outer races of ball bearings  36 ,  38  rotate with support body  28  and roller tube  14 . 
         [0045]    While this invention has been described as having preferred designs, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains.