Abstract:
A method and apparatus for making image ladened louvers having a louver bracket support system from which a plurality of louvers depend, each louver having a substantially flat elongated panels with an outer face, the outer faces of the panels forming a copy surface on which a composite image is displayed, each outer face displaying a sub-part of the composite image such that the conglomeration of the plurality of louvers forms a continuous whole of the image, and a method of making the same comprising the steps of (1) selecting a size of the louvers to fit a predetermined sign location, (2) selecting a template corresponding in size to the selected size of the louvers, the template for temporarily securing the louvers, (3) securing the louvers within the template, (4) calculating the magnitude of a transition loss, the transition loss being the portion of the composite image in an unprintable region between the louvers, (5) determining the sub-parts of the composite image based on a size of the copy surface, the width of the louvers, and the magnitude of the transition loss, (6) selecting a method of adhering the sub-parts of the composite image to the copy surface, (7) adhering the image to a cleaned copy surface such that corresponding ones of the plurality of outer faces each display a sub-part of the composite image.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/056,404, filed Aug. 26, 1997 and is a continuation-in-part of U.S. patent application Ser. No. 09/115,264 filed on Jul. 14, 1998 now abandoned. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to louvered blinds. More specifically, the invention is a method and apparatus for making image ladened louvers as an advertisement medium or as window coverings with a discernible pattern of indicia. 
     2. Description of Related Art 
     The use of louvered vertical or horizontal blinds as a functional covering for a window or door or the like is well known. Often a need exists, or it is desirable, to decorate louvered vertical blinds, as evidenced by the art described below. 
     For example, U.S. Pat. No. 4,049,038, issued to David L. Hyman et al. on Sep. 20, 1977 discusses this need regarding a vertical blind having flanged channels extending along the edges of each louver for insertion of a panel having a pattern to match a room decor. U.S. Pat. No. 5,101,876, issued to Helga M. Zak on Apr. 7, 1992 describes vertical blinds wherein each louver is surrounded by a sheath of an upholstery or wallpaper matched piece of fabric. 
     The coloring of vertical blinds is also often important. Thus, there is a need for a vertical blind having a carefully matched color scheme. This need is discussed in U.S. Pat. No. 4,195,680, issued to David L. Hyman et al., on Apr. 1, 1980, for the use of interchangeable transparent colorized sheets with the blinds of Hyman &#39;038, described above. 
     When a pattern is applied to a vertical blind, it is unstable and easily damaged. Thus, there is a need for a protective laminate that secures and protects a pattern applied to a vertical blind. This problem and need are discussed in U.S. Pat. No. 4,842,036, issued to Barry I. Goodman on Jun. 27, 1989 for a laminate for vertical blinds. 
     The aforementioned patents disclose inventions relating to general patterns and color schemes, such as typify wallpaper and upholstery, for use with vertical blinds. However, there is a need for vertical blinds which include a composite image which convey a message, particularly for commercial uses such as advertising. U.S. Pat. No. 4,911,220, issued to Kevin L. Hiller on Mar. 27, 1990 discusses this need and other problems associated with some of the previously recited patents in a patent for a removable tubular covering for the louvers in vertical blinds. 
     Though the need is recognized, none of the above inventions and patents describe the application of a single composite graphical image to a vertical blind. Likewise, none of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed. 
     SUMMARY OF THE INVENTION 
     The present invention is a method and apparatus for making image ladened louvers comprising a louver bracket support system from which a plurality of louvers, having substantially flat elongated panels with outer faces. The outer faces of the panels form a copy surface on which a composite image is adhered to and displayed, each outer face displaying a sub-part of the composite image such that the conglomeration of the plurality of louvers forms a continuous whole of the image with minimized transition loss between sub-parts of the composite image. Additionally, a method is included wherein a louver assembly is produced via the method the steps of (1) selecting a size of the louvers to fit a predetermined composite image location, (2) selecting a template corresponding in size to the selected size of the louvers, the template for temporarily securing the louvers, (3) securing the louvers within the template via a bracket assembly, (4) calculating the magnitude of a transition loss, the transition loss being the portion of the composite image in an unprintable region between the louvers, (5) determining the sub-parts of the composite image based on a size of the copy surface, the width of the louvers, and the magnitude of the transition loss, (6) selecting a method of adhering the sub-parts of the composite image to the copy surface, (7) adhering the image to the copy surface such that corresponding ones of the plurality of outer faces each display a sub-part of the composite image, and (8) smoothing the adhered composite image to reduce air-pockets and the like therbetween. 
     Accordingly, it is a principal object of the invention to provide a method and apparatus for making an image ladened louver assembly for displaying at least one composite graphical image. 
     It is another object of the invention to provide a bracketing technique which duplicates a pre-selected composite image onto a plurality of louvers with minimized transition loss. 
     It is a further object of the invention to reduce air pockets between the copy surface and an applied composite image and its sub-parts which produces image distortion and image degradation over time. 
     It is an object of the invention to provide improved elements and arrangements thereof in a method and apparatus for making imaged ladened louvers which is inexpensive, dependable and fully effective in accomplishing its intended purposes. 
     These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     FIG. 1 is an environmental perspective view of an image ladened louver assembly according to the present invention. 
     FIG. 2 is a perspective view of the bracketing assembly for making an image ladened louver assembly according to the invention. 
     FIG. 3 is a perspective view of the bracket assembly, illustrating the louver mounting strap and spacer blockers according to the invention. 
     FIG. 4 is a perspective view of the louver copy surface according to the invention, illustrating the application of cleaner solution. 
     FIG. 5 is perspective view of an image ladened louver assembly according to a second embodiment. 
     FIG. 6A is a perspective view of the louver assembly, illustrating sub-parts of a composite image. 
     FIG. 6B is a perspective view of the louver assembly according to the invention, illustrating smoothing of the sub-parts of FIG.  6 A. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The present invention is directed to a method and apparatus for making image ladened louvers. The preferred embodiments of the present invention are depicted in FIGS. 1-6B, and are generally referenced by numeral  10 . 
     FIG. 1 shows an image ladened louver assembly  10  in a store front window  12 . Any number of conventional louver activating mechanisms can be used to operatively close and open louvers or panels  16  to respectively show images thereon. Bracket support means or rail  14  is uniformly disposed and spaced at the top of the window  12  on the interior of the window  12 . A plurality of associated elongated louvers  16  hang vertically down from the support rail  14  covering the inside of the window  12 . A substantially flat elongated panel of such makes up the body of each of the louvers  16 . The louvers  16  are rotatably attached in a conventional manner to the support rail  14  and depend vertically therefrom. 
     As best seen in FIGS. 2-3, a louver support bracket assembly  11  is shown wherein the bracket assembly  11  comprises a template  11   a,  louver strapping means  11   b  having at least one attachment end  11   b ′ for attachment to a louver spacer blocker  11   c  and an associated plurality of louver support means or rails  14 . The plurality of rails  14  wherein at least one of said plurality retains at least one louver  16  as a fixed louver attachment. The plurality of associated elongated louvers  16  each comprising substantially flat elongated panels having an inner face  16   a  and an outer face  16   b.  Each of the elongated louvers  16  are preferably uninterrupted, substantially flat copy surfaces. To ensure proper adhesion the copy surface (louvers without and image) is washed or cleansed with a cloth  11   e  substantially saturated with an evaporative solution such as ethyl alcohol or the like. This layer can also include the application of a protective layer, such as a laminate layer of plastic to prevent material contamination from air carrying particles such as dust, mites etc. 
     FIG. 2, also illustrates the use a first  11   f  and second  11   g  bracket alignment means for uniformly adjusting each of the plurality of louvers in a vertical V and horizontal H fashion. Each respective alignment means is a screw mechanism which allows for adjustment along the face of the template  11   a  for adjusting the copy surface with minimum gaps between respective louvers  16 . 
     Similar rails  14 ′ are disposed on another end of the bracket assembly  11  prior to image application and subsequent installation of each louver  16  in a respective window, door, etc. The laminate layer can include at least one composite image  26  disposed thereon. FIGS. 5,  6 A, and  6 B disclose other embodiments  27  and  29  of image ladened louvers. The particular composite image is preferably disposed on the copy surface as a preprinted, die cut, adhesive decal at least. As diagrammatically illustrated in FIG. 6A and 6B each image ladened louver is cut via a cutting means or “zacto” knife  31  into sub-parts  29   a.  A smoothing means or “squeegee”  33  such as a ceramic bar or other smooth surface material having a pitched surface area for smoothing out accumulated air pockets or superfluous adhesive solution therefrom. The apparatus according to claim  1 , wherein the louvers are made according to a predetermined length and width An operator activates via a rotation motion a control wand  22  which twists the control wand  22 , the louvers  16  rotate in the support rail  14 . When the louvers  16  are in a fully closed position an inner face  16   a  on each panel or louver  16  faces away from the window  12  and an outer face  16   b  on each panel  16  faces toward the window  12 . Thus, in the fully closed position, the plurality of associated flat elongate panels  16  form a substantially flat, substantially uninterrupted copy surface  26  facing outward from the window  12  as shown each respective figure. 
     A composite image  28  is visible on the copy surface  26 . In FIG. 1, the composite image  28  comprises indicia such as “WINDOW COVERINGS SALE”, VISA™, etc. in large or lower case block letters. The composite image  28  is significantly larger than any one of the plurality of outer faces  16   b  such that no one outer face  16   b  can possibly contain the entire image  28 . Thus, it is necessary to break the composite image  28  into a plurality of sub-parts as shown as  29   a  in a particular embodiment in FIG.  6 B. One sub-part  29   a  of the composite image  29  is visible on each one outer face  16 . By combining the sub-parts  29  together in a substantially continuous whole across the outer faces  16   b  of the associated louvers  16 , the composite image  29  (including  28 ) is visible as if it were printed on a single uninterrupted plane. Apertures  29   b  are also disposed within each respective louver at a top portion and optionally  29   b ′ at the bottom of each respective louver for attachment with the rails  14 . 
     The steps of the process to make the above described louver assembly will now be described in detail. First, a size of the louvers  16  must be selected. The selection of the size of the louvers  16  depends primarily on the size of a predetermined window  12 , door, or other opening that the vertical sign blind  10  is intended to cover, and secondarily on whether the image ladened louver  10  will cover the predetermined window  12  from the outside or from the inside. References herein to the window  12  should not be construed as limited to a window, but should be understood to include an application of the image ladened louver  10  to a door or other opening as well. 
     When the image ladened louvers  10  cover the window  12  from the outside, it is recommended that the dimensions of the area formed by the outer faces  16   b  when the vertical sign blinds  10  are in the fully closed position exceed the dimensions of the window  12  by at least three inches in length and at least three inches in height. In order to achieve an optimal level of privacy and light blockage, it is recommended that the dimensions of the area formed by the outer faces  16   b  exceed the dimensions of the window  12  by eight inches in height. Otherwise the dimensions of the panels  16  are considered acceptably sized as long as the height and length of the panels  1  meets or exceeds the corresponding dimension of the window  12 . Similar adjustments are made for stacking height and stacking vane widths as is known in the art when the covered opening is a patio door rather than a window  12 . 
     By experience, the smallest size panel  16  observed in a blind  10  is one inch wide and twelve inches high. In this smallest application, the dimensions of the area formed by the outer faces  16   b  when the blinds  10  are in the fully closed position is twelve inches by fourteen inches. Likewise, the largest size panel or louver  16  observed in a blind  10  has been three and a half inches wide and twelve feet high. The dimensions of the area formed by the outer faces  16   b  when this largest vertical sign blind  10  is in the fully closed position is twelve feet by fifteen feet. 
     The next step in the process to make the vertical sign blind  10  is the selection of a template. The selected template is shaped to secure the panels  16  around the edges of the panels  16  with the outer faces  16   b  facing up. Thus, different sized templates correspond to different sized louvers  16 . Once the template is selected, the louvers  16  are placed and secured in the template thus stabilizing the outer faces  16   b  of the panels  16 . 
     Two calculations must be made prior to the application of the sub-parts  30  of the composite image  28  to the outer faces  16   b.  First, the dimensions of the copy surface  26  must be determined. If the blind  10  is installed to the exterior of the window  12 , the copy surface  26  is equal to the entire surface formed by the outer faces  16   b  of the panels  16  in the fully closed position. When the blind  10  is installed to the interior of the window  12 , in order to make the entire copy surface  26  visible from the exterior of the window  12 , the copy surface  26  must be smaller in area than the entire surface area formed by the outer faces  16   b  when the louvers  16  are in the fully closed position. Moreover, the deeper the sill of window  12 , and hence the farther removed the copy surface  26  is from the window pane, the greater the difference must be between the area of copy surface  26  and the area of the surface formed by the outer faces  16   b  when the louvers  16  are in the fully closed position for an observer positioned an angle to the edge of the window pane to be able to see the entire copy surface. Otherwise, to see the entire copy surface, it would be necessary to stand directly in front of the window  12 . 
     The second calculation that must be made prior to the application of the sub-parts  30  of the composite image  28  to the outer faces  16   b  concerns a concept known as a transition loss. The transition loss is caused by small gaps between the panels  16 . Even in the fully closed position, the edges of the panels  16  do not sit completely flush with each other. If the edges of the panels  16  did sit completely flush in the fully closed position, then the louvers  16  would not be able to freely rotate out of or back into the fully closed position. However, the composite image  28  cannot be printed in the region of the gaps  32 . Thus, by designing the panels  16  with small gaps  32  between them so that the louvers  16  rotate freely, the continuity of the composite image  28  is interrupted. 
     Because the gaps  32  exist between the panels  16 , the copy surface  26  is not completely continuous. Thus, the composite image  28  must be modified to compensate for the loss of a small portion of the image  28  that would appear in the unprintable region of the gaps  32 . It has been determined that the appearance of the composite image  28  is not compromised when the magnitude of the transition loss is ascertained and compensated for prior to the application of the sub-parts  30  to the outer faces  16   b.  Again using the example of the standard vertical blind  10  pictured, it has been determined that the transition loss for the smallest panel  16 , the one inch wide panels  16  mentioned above, is one thirty-second of an inch. Similarly, it has been determined that the transition loss for the largest panel  16 , the three and a half inch wide panels  16  mentioned above, is one-eighth of an inch. It should be apparent that the transition loss for other sizes and styles of blinds is determined through the use of linear extrapolation from the numbers supplied above. 
     Once the transition loss has been calculated, the next step is to determine the sub-parts  30  of the composite image  28 . To determine the sub-parts, it is recommended that first, the composite image  28  be scanned into a computer and electronically reproduced as a graphics file in a graphics program. Then, the dimensions of the copy surface  26  are entered and the composite image  28  is conformed to those dimensions. Next, the width of the panels  16  and the transition loss is entered. Finally, the graphics program eliminates a sliver portion of the composite image  28  that would appear in unprintable the area of the transition loss and assigns the remaining portions of the composite image  28  to each sub-part  30  for electronic digital reproduction. Lines in the composite image  28  are extrapolated across the area of the transition loss by the graphics program to maintain an even appearance of the composite image  28  on the copy surface  26 . 
     Once the sub-part  30  corresponding to each one outer face  16   b  has been determined, a method of adhering the sub-parts  30  to the outer faces  16   b  must be selected from those known in the art such as printing on a die cut adhesive decal for sticking on the outer faces  16   b,  printing on adhesive stickers for sticking on the outer faces  16   b,  and printing directly on the outer faces  16   b.    
     Furthermore, a method of printing the sub-parts  30  must also be selected from those known in the art such as thermal transfer vinyl graphics, silk screening, ink-jet graphics, and electrostatic graphics. Due to variations in quality and cost, it is recommended that a different type of print be selected depending on the number of copies of the composite image  28  to be reproduced. When the number of copies of the composite image  28  to be reproduced is a single digit, the recommended method of printing is electrostatic graphics. When the number of copies to be reproduced is a double digit, ink-jet graphics is the recommended method of printing. And when the number of copies of the composite image  28  to be reproduced is at least one hundred, the recommended method of printing the sub-parts  30  is thermal transfer graphics. 
     When the method of adhering the sub-parts  30  to the outer faces  16   b  is to print the sub-parts  30  directly on the outer faces  16   b,  then the process is complete once the sub-parts  30  are printed. When the method of adhering the sub-parts  30  to the outer faces involves adhesive decals or stickers, then the process is completed by adhering the decals or stickers to the outer faces  16   b.    
     It is recognized in the art that a many problems are solved by the application of a transparent laminate on the copy surface  26 . Thus, as a final step in the preferred embodiment, a transparent laminate is applied to stabilize and protect the panels  16 . 
     It should be recognized that in some cases a need will exist to change the composite image  28  visible from the exterior of a window. For example, when the vertical sign blind  10  is used by a commercial business, the business owner may want to seasonally display a specific holiday promotion in the composite image  28  once a year. In this situation, a second set of louvers  16  is supplied with the ones of the panels  16  displaying the sub-parts  30  of the second composite image  28 . When the time arrives to change the composite image  28  visible from outside the window  12 , the first set of louvers  16  is removed from the support rail  14  and the second set of louvers  16  is secured to the support rail  14 . This process of changing one set of louvers  16  for another set of louvers  16  takes no more than five or ten minutes. Thus, it is equally, if not more, convenient than the other apparatuses and methods known to achieve the same function of changing an image displayed by a vertical blind  10 . 
     It is to be understood that the present invention is not limited to the embodiment described above. For example, though the embodiment described above is only printed on the outer faces, it should be apparent that the invention is capable of application to the inner faces as well, thus adhering composite images to the same set of louvers on opposite faces, respectively. Thus, it is to be understood that the present invention encompasses any and all embodiments within the scope of the following claims.