Abstract:
A mounting bracket for mounting a headrail employing an upper plate and a lower plate wherein the two plates are rotatably connected.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application for utility patent claims priority from Provisional Patent Application 60/804,290 with a filing date of Jun. 9, 2006. 
     
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    n/a 
       FIELD OF INVENTION 
       [0003]    The present invention lies in the field of mounting brackets useful for mounting such items as venetian blinds, headrails or similar structures. 
       BACKGROUND 
       [0004]    Venetian blinds and other blinds systems have long been used to provide shade, privacy and decoration over doors and windows. Traditionally, these blinds include a head rail from which is hung opaque materials to accomplish these goals. Venetian blinds, for example, employ horizontal slats, which may be opened or closed, and which are hung from a head rail to accomplish these purposes. 
         [0005]    Venetian blinds have been traditionally manufactured using a wide variety of material including steel, aluminum, and wood. In recent years, however, manufacturers have begun producing slats and head rails from different materials capable of extrusion including plastics such as polyvinyl chloride or PVC. 
         [0006]    These materials are relatively inexpensive to fabricate, offer ease of maintenance and are capable of taking on different decorative appearances. They can be colored, textured, patterned or printed with patterns and from an aesthetic perspective present a substantial and solid appearance. 
         [0007]    Often, for example, the blinds are manufactured and processed to resemble wood with “fauxwood” blinds considered to be a staple product in the home improvement industry. Fauxwood is an industry catch phrase for vinyl products that are extruded in a typically hollow format and then injected with a blowing agent. The result is a low cost material that can take on the characteristics of wood without some of wood&#39;s disadvantages which include cost, yellowing, warping, chipping and similar problems. 
         [0008]    There are, however, certain disadvantages associated with use of materials such as vinyl or other plastics. A significant one is the increased weight of such blinds in comparison to blinds made of wood or metal and the relative flexibility of such head rails in comparison to those made of other more rigid materials. For example, a 72″ long blind can easily weigh up to twenty pounds. A common and pervasive problem with larger Venetian blinds made from such materials and related to their weight is the bending stress such weight applies to the head rail. As the size of a blind increases, its weight will cause the head rail to sag and visibly deform downward under the load of the blind assembly. Not only does this result compromise the aesthetic appearance of the blind, but such deformed blinds are insecure and may collapse. Thus, the increased weight of the blind and the deformation it causes may each present safety concerns as well. 
         [0009]    Various techniques and devices have been employed to attempt to resolve the deformation caused by the blind&#39;s weight. Typically, Venetian blinds are installed, for example, in a window frame by affixing side hanging brackets to the inside of the frame near its upper portion. The head rail is installed into the side hanging brackets, which are then closed to secure the blind in place. This technique is industry standard. Where wider blinds are installed, manufacturers and installers include additional center support brackets for mounting on the upper member of the window frame and into which the head rail rests. This also is industry standard. The theory is that these additional brackets will support the added weight and lessen deformation. 
         [0010]    In practice, however, such solutions produce unsatisfactory results. The brackets are often of insufficient strength or rigidity to fully support the additional weight which deforms the bracket itself. Or, the bracket may not fully support the weight of head rail and blind elements. In those cases, the downward bowing of the head rail remains visible. Indeed, when installing larger blinds, for example those spanning a length of 72″, a bowing of at least ¾″ has been observed even when two center support brackets are employed to help support the weight of the blind. 
         [0011]    Further, the center support brackets do not anchor the blinds and provide little added structural support. Thus, the head rail and entire unit may be easily pulled out of the mount by, for example, a child pulling on the blind. 
         [0012]    In an attempt to lessen the deformation caused by the weight of the blind and the relative flexibility of the head rail, some manufacturers have incorporated elongated supports running along the length of the head rail in an effort to strengthen and stiffen the softer vinyl head rail. U.S. Pat. No. 6,263,945 to Nien and U.S. Pat. Nos. 6,615,895 and 6,880,607 B2 to Marocco, for example, attempt to lessen deformation by incorporating such supports. 
         [0013]    These solutions, however, have failed to produce satisfactory results. While the support may keep the head rail in a more taut position, the weight of the blind is still primarily carried by the screws or fasteners holding the side hanging brackets. Further, the supports themselves are often made of metal and add additional weight to the blind thus further contributing to the cause of the deformation of the head rail. Additionally, the supports are often not rigid enough to fully prevent deformation. Thus even where the head rail incorporates an elongated support, significant bowing nevertheless is present, visible and remains problematic. 
         [0014]    The fabrication of blinds from extruded materials presents a further difficulty resulting from the relative softness of the material. Virtually all vinyl blinds are manufactured utilizing a 3-sided U-shaped head rail incorporating rolled edges on the upper lip of the side walls. While mass produced blinds are manufactured and stocked in standard sizes, consumers install them into window frames and door frames of significantly differing dimensions. Accordingly, many retail stores stock standard size blinds that are then cut to the dimension the consumer needs. To do so, merchants utilize various in store cutting machines that cut the head rails and slats to the desired size. When cutting a Venetian blind to size, however, significant damage to the relatively flexible head rail may occur as the rail bends or splits when in contact with the cutting blade. This can lead to significant damage to the head rail and render it unusable. 
         [0015]    In order to prevent that damage to the head rail during the cutting process, various techniques have been devised to strengthen and stiffen the head rail in the area where it is being cut. U.S. Pat. No. 6,263,945 to Nien and U.S. Pat. Nos. 6,615,895 and 6,880,607 B2 to Marocco, mentioned above, for example, utilize wall stiffener plugs made of a material generally more rigid than the head rail and that are inserted in the ends to be cut when sizing the head rail. According to those patents and similar techniques, this added rigidity provides lateral support and increased structural integrity to the ends thereby allowing for a cleaner cut and preventing splitting or other damage to the head rail. Once the cut is made, however, the plugs are discarded and serve no other function in relation to the blinds. 
         [0016]    Finally, the use of elongated supports to mitigate the bowing issue described above presents difficulties in cutting the blinds to size. Either the cutting device used to size the blinds must be suitable to cut the elongated support as well as the softer vinyl head rail and wall stiffener plugs, or the elongated support may not extend the entire length of the head rail. 
       SUMMARY OF THE INVENTION 
       [0017]    The present invention discloses a completely novel system of mounting brackets that support a head rail or similar structure at a plurality of anchor points from above the head rail or similar structure rather than from the sides as, for example, is the industry standard today in hanging Venetian blinds. The system presents numerous advantages and more effectively uses walls, ceilings and/or window and door frames or other anchor points to support the weight of the blind thereby eliminating the problem of sagging and more securely mounting the blind. Elongated supports are not needed as the weight of the blind is more evenly distributed across the length of the head rail. Further, in the invention, separate wall stiffener components are not needed as the novel mounting brackets themselves are used to stiffen the softer vinyl head rail during the cutting process. 
         [0018]    The bracket disclosed herein is composed of a material having sufficient stiffness, rigidity and strength to support the weight of the blind and allow the head rail to be clipped into place. The brackets may be made out of various plastics, metals or any material sufficient for the above purposes. The bracket is composed of two separate elements, an upper plate and a lower plate. The upper and lower plates are each more or less rectangular in shape. Further, the plates are flat except along the sides of the lower plate that define the rectangular shapes&#39; width which are flanged. The upper and lower plate are also rotatably fixed together by means of a spindle having a threaded, distal end and protruding downwardly from the upper plate and into a receiving port on the lower plate. The use of a threaded spindle and nut, however, is not intended as a limitation on the device and other fastener may be used as long as they rotatably fix the two plates together. Furthermore, while a removable nut may be employed as part of the device to secure the lower plate to the upper plate, there is no requirement that the nut or similar structure be removable as in application, the user does not remove or tighten the nut or similar element. In one embodiment, a nut is used to secure the plates together. The flanges on the lower plate are of a size and shape that the rolled edges of the U-shaped vinyl head rail may rest in the flange. When the lower plate is rotated at a right angle to the upper plate the flanges are exposed and, in conjunction with the mounted upper plate, support the hanging blind. 
         [0019]    In an “inside mount”, the mounting brackets are mounted above the head rail into the upper jamb of a window or door frame. The head rail is hung from the brackets by clipping the head rail into place over the brackets. The brackets thereby directly support the weight of the blind from above. In smaller blinds, left and right brackets are affixed into the jamb or other anchor point and the head rail is clipped into place over the bracket. When mounting longer blinds, additional middle support brackets are also used. In an “outside mount”, the mounting brackets disclosed herein are affixed to L-shaped brackets which may be fastened to a wall and allow support from above the head rail as in the other application. The head rail is similarly attached to the bracket. 
         [0020]    In the present invention, the same mounting brackets are employed to act as wall stiffeners during the process of cutting the blinds to size. When used as a wall stiffener, however, the bracket is set in place in proximity to the area where the cut is to be made, with its plates configured parallel to each other. In that position, the bracket acts as a clamp and secures and stiffens the side walls sufficiently to facilitate cutting and prevent the bending and splitting of the vinyl side wall of the head rail. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]      FIG. 1(   a ) is a top left view of a typical headrail used for hanging a venetian blind or other window treatment. 
           [0022]      FIG. 1(   b ) is a cross-section of a typical headrail. 
           [0023]      FIG. 2(   a ) is a top left view of a prior art headrail wall stiffener. 
           [0024]      FIG. 2(   b ) is a top left view of said prior art headrail wall stiffener in conjunction with a headrail. 
           [0025]      FIG. 2(   c ) and  FIG. 2(   d ) are cross-sectional views of the prior art wall stiffener and headrail of  FIGS. 2(   a ) and  2 ( b ). 
           [0026]      FIGS. 3(   a ),  3 ( b ) and  3 ( c ) are top left views of prior art mounting systems. 
           [0027]      FIG. 4(   a ) is an exploded cross sectional view of one embodiment of a mounting bracket according to the instant invention in conjunction with a headrail. 
           [0028]      FIG. 4(   b ) is a top view of one embodiment of a mounting bracket according to the instant invention in conjunction with a headrail. 
           [0029]      FIG. 4(   c ) is an exploded view of a mounting bracket in accordance with the instant invention. 
           [0030]      FIG. 4(   d ) is a cross sectional view of one embodiment of a mounting bracket according to the instant invention in conjunction with a headrail. 
           [0031]      FIG. 5(   a ) is a top left view of a window with an installed venetian blind. 
           [0032]      FIG. 5(   b ) is a top left exploded view of a window frame, a Venetian blind, and a mounting bracket according to the instant invention. 
           [0033]      FIG. 6(   a ) is a top right view of a mounting bracket according to the instant invention in conjunction with a standard L bracket. 
           [0034]      FIG. 6(   b ) is a top right view of a mounting bracket according to the instant invention in conjunction with a standard L bracket and a headrail. 
           [0035]      FIG. 6(   c ) is a top right view of a headrail. 
           [0036]      FIG. 7(   a ) is a top right exploded view of a window frame, an L bracket, a headrail and a mounting bracket according to the instant invention. 
           [0037]      FIG. 7(   b ) is a top right view of a window frame, an L bracket, a headrail and a mounting bracket according to the instant invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0038]      FIGS. 1(   a )-( b ),  2 ( a )-( d ), and  3 ( a )-( c ) represent the current state of the art in the industry and depict a typical head rail, wall stiffener and mounting brackets. 
         [0039]      FIGS. 1(   a ) and  1 ( b ) show a typical prior art Venetian blind head rail. The U-shaped head rail  11  is an industry standard. The arcuate, rolled upper edges  12  of the head rail are typical in vinyl head rails. When fabricated with plastics or other extruded materials, the head rails are relatively heavy and are somewhat flexible. When subjected to cutting even with machines designed specially for the purpose, the head rails are prone to damage as the force of the cutting implement causes the side walls  13  to flex and bend. Splitting at the cut end is also a problem known to occur as a result of the properties of the material. 
         [0040]      FIGS. 2(   a )- 2 ( d ) depict one prior art attempt to resolve the problems associated with cutting the head rails to size.  FIGS. 2(   a ) and  2 ( d ) show a wall stiffener plug intended to prevent damage to the head rail during cutting.  FIGS. 2(   b ) and  2 ( c ) show the wall stiffener plugs inserted into a head rail. In these typical applications, the wall stiffener plug  21  is inserted into the U-shaped groove  22  of the head rail as shown in  FIGS. 2(   b ) and  2 ( c ). While the wall stiffener plug  21  is designed to add rigidity and strength to the head rail to allow for a cleaner cut, it serves only that one limited function, and is discarded after use, increasing manufacturing costs. 
         [0041]      FIGS. 3(   a )- 3 ( c ) show standard mounting brackets  31  that are utilized throughout the industry. The brackets  31  are affixed to the sides of the interior of a window or door frame by fasteners driven through the screw holes  32 . For larger blinds, a center support bracket  33  is mounted to the upper jamb and, in theory, is intended to provide additional support. During installation, the gate  34  is opened and the head rail is inserted into the socket  35  and, if necessary, also into the center support bracket. The gates  34  are then closed securing the head rail into place. This system, however, has yielded less than satisfactory results, particularly when mounting larger blinds, as the whole weight of the blind is primarily borne by the screws affixing the side brackets into the frame through the screw holes  32 . Furthermore, heavier blinds mounted by this technique are easily pulled out of the mount by the exertion of downward and outward pressure, for example, by a child pulling on the blind. Such mounts therefore present a safety concern as well because they are inadequately anchored. 
         [0042]      FIGS. 4(   a )- 4 ( d ) presents one embodiment of the mounting brackets disclosed in the present invention. While the mounting brackets are described herein as used in the field of blinds installation, it should be appreciated that the brackets may be used to mount any similar structure where the issue of weight or deformability is present. Further, while particularly useful in mounting heavier relatively flexible structures from above, the invention is not limited to above-mounted structures.  FIG. 4(   a ) shows a typical head rail  11  with rolled edges  12  in association with the bracket&#39;s upper plate  41 , lower plate  42 , flanges  43 , spindle  44 , spindle threads  45  and fastener nut  46 .  FIG. 4(   b ) presents an overhead view of the bracket when used to mount the head rail. In  FIG. 4(   b ), the upper plate  41  has been affixed to the upper jamb of, for example, a window frame through screw holes  47  in the upper plate. The lower plate  42  has been rotated at a right angle to the upper plate  41  thereby exposing the flanges  43  on the lower plate. The rolled edges of the head rail rest securely in the flanges  43  of the lower plate  42  thereby anchoring and supporting the blind. 
         [0043]      FIG. 4(   c ) is an exploded view of the bracket showing screw holes in the lower plate  48 , screw holes in the upper plate  47 , and the port  49  into which the spindle  44  is inserted.  FIG. 4(   c ) also shows the nut  46  used to secure the upper plate  41  and lower plate  42 . In the configuration shown in  FIG. 4(   c ), the lower plate  42  is rotated at a right angle to the upper plate  41  as when the bracket is used to mount a head rail  11 . In that configuration, the screw holes in the lower plate  42  align with the screw holes in the upper plate  41  and allow the bracket to be anchored, for example, into a window or door jamb. The screws further secure the two plates  41 ,  42  into their position by restricting further rotation. 
         [0044]      FIG. 4(   d ) shows the bracket used as a wall stiffener during the cutting process. While it is shown here as used in conjunction with stiffening a Venetian blind head rail for cutting, the bracket may be used in any similar contexts. In  FIG. 4(   d ), the upper plate  41  and lower plate  42  are parallel and affixed by means of the threaded spindle  44 ,  45  and fastener nut  46 . While the drawings herein depict a threaded spindle and nut used to secure the upper and lower plate, the depiction of the threading and nut are not intended as limitations. Other fasteners capable of rotatably fixing the two plates may be used. 
         [0045]      FIG. 4(   d ) also depicts the rolled edges  12  of the head rail  11  resting in the flange of the lower plate  43 . In one embodiment depicted here, the flanges  43  are shown to be arcuate. The arc shape of the flange, however, is not intended as a limitation and the lip of the flanges may be disposed in a substantially parallel configuration as well as long as the flange is capable of supporting the rolled edges  12  of the head rail  11 . 
         [0046]      FIG. 5(   a ) shows the brackets in conjunction with a Venetian blind employed for an “inside mount” into the upper jamb of a window frame  52 . Here, the mounting screws  53  are driven through the screw holes  47 ,  48  of the bracket plates and into the frame  52 .  FIG. 5(   b ) depicts the head rail clipped into place over the bracket assembly. 
         [0047]      FIG. 6(   a ) depicts the mounting bracket  61  in association with an L bracket  62  as used in an “outside mount”. In this configuration, the mounting bracket  61  is bolted into the upper face of the L bracket  63  through screw holes  47 ,  48  by means of bolts  64 . Other fasteners or means of attaching the bracket to the upper face of the L bracket  63  may be used. The lower face of the L bracket  65  is fastened into the wall by means of screws.  FIG. 5(   b ) shows a typical head rail mounted on the bracket  61  with the rolled edges  12  resting in the bracket flanges  43 . 
         [0048]      FIGS. 7(   a ) and  7 ( b ) show an “outside mount” and depict the bolts  64  affixing the mounting bracket  61  to the upper face of the L bracket  63  and the screws  71  fastening the lower face of the L bracket  65  to wall or other surface. Also shown is a screw assembly  72  that can be mounted on either or both sides of the blind assembly to prevent the head rail from shifting either right or left upon installation. 
         [0049]    It should be appreciated that while the brackets disclosed in this invention are particularly useful in installing and sizing Venetian blinds and other blinds or similar devices mounted using a U-shaped head rail or similar structure, the brackets may be useful for mounting and clamping any similar structure. Accordingly, the embodiments depicted above are not intended as limitations but rather as examples of the present invention as applied to one particular art.