Patent Publication Number: US-6338377-B1

Title: Skylight assembly with head rail-mounted actuator

Description:
TECHNICAL FIELD 
     The present invention relates generally to coverings for motorized skylights and other non-vertical openings. 
     BACKGROUND OF THE INVENTION 
     Skylights are windows that are installed in the roof or ceiling of a building, e.g., a home. Skylights are often used to enhance the ambiance of rooms within business buildings and dwellings by providing a direct source of natural light and a view of the sky. In addition to aesthetic enhancements, skylights also minimize the cost of lighting buildings during the day by providing alternate sources of light. On particularly sunny days, skylights also serve as alternative heat sources for the buildings in which they are installed. 
     In order to regulate the amount of light propagating into a room having skylights, the skylights are often equipped with shades that can be opened or closed in order to maximize or minimize the amount of sunlight passing into the building through the skylights. Thus, the shades can be opened during the day to permit sunlight to enter the room, or closed during particularly warm days to prevent overheating of the room and fading of material within the room. Likewise, the shades can be closed at night to prevent heat within the roni from dissipating through the window into the cool evening air. 
     Manual shades have been provided for skylights, but since skylights are typically elevated beyond the reach of a person without the aid of a ladder or an elongated handle, the present invention recognizes that it is advantageous to provide for remote or automatic positioning of the shades. For example, it would be advantageous to provide for the automatic nighttime closing of skylight shades in a business building for security reasons and energy conservation, rather than to rely on personnel to remember to manually close all skylight shades before vacating the premises for the evening. Also, remote operation of the skylight shades would enable persons to regulate the amount of light entering their rooms, without requiring the persons to climb a ladder or manipulate an awkward handle. 
     In light of the above problems, the present invention recognizes a need for a comparatively simple device for remotely or automatically opening and closing skylight shades. 
     SUMMARY OF THE INVENTION 
     A skylight assembly with actuator includes a head rail and a shaft rotatably disposed within the head rail. A collapsible shade is engaged with the shaft and is movable between an open configuration, wherein the shade is fully collapsed, and a closed configuration, wherein the shade is extended. The skylight assembly also includes at least one electric motor in the head rail that is coupled to the shaft and at least one dc battery that is supported by the head rail and is electrically connected to the motor. 
     In a preferred embodiment, the skylight assembly includes at least one extender cord that is attached to the shade and partially wound around the shaft. The extender cord causes the shade to move to the closed configuration as the shaft rotates in a first direction. Preferably, the skylight assembly also includes at least one retractor cord that is attached to the shade and partially wound around the shaft. The retractor cord causes the shade to move to the open configuration as the shaft rotates in a second direction. 
     Preferably, the collapsible shade is an accordion-type shade. Furthermore, the skylight assembly includes at least one static cord that is looped through the shade to provide at least two semi-rigid guides along which the shade slides between the open configuration and closed configuration. The skylight assembly also includes at least one tensioning device to keep the static cord taut. Preferably, the tensioning device is a spring attached to at least one end of the static cord. In a preferred embodiment, the battery is the sole source of power for the motor and the battery is mounted in the head rail. 
     In another aspect of the present invention, a device for moving a collapsible shade in a skylight assembly includes an actuator that has at least one electric motor in a head rail of the skylight assembly. In this aspect, the electric motor is coupled to a shaft in the head rail and rotates the shaft to move the shade between an open configuration, wherein the shade is collapsed, and a closed configuration, wherein the shade is extended. This aspect of the present invention also includes at least one direct current alkaline or lithium battery. 
     In another aspect of the present invention, a powered skylight covering assembly includes a head rail and a shaft rotatably disposed therein. A collapsible shade is coupled to the shaft, such that as the shaft rotates, the shade moves between an open configuration, wherein the shade is collapsed, and a closed configuration, wherein the shade is extended. This aspect of the present invention also includes an electric motor that is disposed in the head rail and a coupling operably engaged with the motor to engage the motor with the shaft for rotating the shaft. Also included is at least one primary dc battery that is the sole source of energy associated with the skylight covering. The battery is supported by the head rail. 
    
    
     The present invention will now be described, by way of example, with reference to the accompanying drawings, in which: 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded plan view of the skylight assembly with head rail mounted actuator; 
     FIG. 2 is a top view of the head rail; and 
     FIG. 3 is a perspective view of the actuator, with a battery shown in phantom. 
    
    
     DESCRIPTION OF AN EMBODIMENT OF THE INVENTION 
     Referring initially to FIG. 1, a skylight assembly with head rail mounted actuator is shown and generally designated  10 . It is to be understood that the present invention applies to covering non-vertical openings in general, such as but not limited to recreational vehicle windows, angled boat portholes, etc. Also, the present principles can be applied to spring-drive roll-up shades, as well as accordion-type window coverings. 
     FIG. 1 shows that the skylight assembly  10  includes a head rail  12  and a foot rail  14 . Furthermore, the skylight assembly  10  defines a left side  16  and a right side  18 . FIG. 1 shows that the skylight assembly  10  includes a transparent or translucent generally flat, is rectangular panel  20  that is installed between the head rail  12  and the foot rail  14 . A collapsible shade  22 , e.g., an accordion-type shade, having approximately the same length and height of the panel  20  is slidably disposed along the surface of the panel  20 . It is to be appreciated that when the skylight assembly is installed in a business building or dwelling, the shade  22  is juxtaposed with the interior surface of the panel  20 . FIG. 1 shows that the shade  22  includes a rail  24  having a first connection point  26  and a second connection point  28 . 
     A spindle assembly  30  is disposed within the head rail  12 . The spindle assembly  30  defines a central axis  32  about which the shaft, described below, rotates. FIG. 1 also shows an actuator  34  coupled to the end of the spindle assembly  30 . When energized, the actuator  34  causes the spindle assembly  30  to rotate about the axis  32  and, as described below, the rotation of the spindle assembly  30  causes the shade  22  to open and close. 
     As shown in FIG. 1, the skylight assembly  10  includes a first extender cord  36  that defines a proximal end  38  and a distal end  40 , and a second extender cord  42  that likewise defines a proximal end  44  and a distal end  46 . Additionally, the skylight assembly  10  includes a first retractor cord  48  that defines a proximal end  50  and a distal end  52 , and a second retractor cord  54  that defines a proximal end  56  and a distal end  58 . FIG. 1 shows that the proximal ends  38 ,  44 ,  50 ,  56  of the cords  36 ,  42 ,  48 ,  54  are wrapped around the spindle assembly  30 , as described in greater detail below. On the other hand, the distal ends  40 ,  52  of the first extender cord  36  and the first retractor cord  48  are attached to the first connection point  26  on the rail  24 , and the distal ends  46 ,  58  of the second extender cord  42  and the second retractor cord  54  are attached to the second connection point  28  on the rail  24 . 
     Still referring to FIG. 1, the skylight assembly  10  includes a static cord  60  having a first end  62  and a second end  64 . As can be appreciated by looking at FIG. 1, the static cord  60  is woven through the shade  22  such that a rectangular loop paralleling the outer edges of the shade  22  is created by the static cord  60 . The first end  62  of the static cord  60  is connected directly to the foot rail  14  and the second end  64  of the static cord  60  is connected to a tension spring  66  which, in turn, is connected to the foot rail  14 . When pulled taut by the spring  66 , the static cord  60  provides a pair of somewhat rigid guides along which the shade  22  slides back and forth as indicated by arrow  68  and arrow  70  and described more fully below. 
     FIG. 1 also shows a left “L” bracket  72  and a right “L” bracket  74  that are installed over the left and right sides  16 ,  18  of the skylight assembly  10 , respectively, in order to protect the cords  36 ,  42 ,  48 ,  54 ,  60  installed along the left and right edges of the shade  22 . Moreover, to aid in mounting the skylight assembly  10  within an appropriately sized opening, a pair of upper brackets  76  and a pair of lower brackets  78  are also included. 
     Referring to FIG. 2, details regarding the head rail  12  and the spindle assembly  30  disposed therein can be seen. FIG. 2 shows that the spindle assembly  30  includes a shaft  80  having a first end  82  and a second end  84 . A travel screw  85  is threadably engaged with the second end  84  of the shaft  80 , such that as the shaft  80  rotates, it travels linearly along the screw  85 . 
     The shaft  80  is supported along its length by plural supports  86  that support the shaft  80  while allowing it to rotated about the axis  32 . The first end  82  of the shaft  80  is coupled to the actuator  34 . Specifically, in one preferred implementation, a square metal rod  83  connects the shaft  80  to the actuator  34 . The rod  83  rotates with and reciprocates within the shaft  80  as the shaft travels along the screw  85 . A hollow end cap  88  supports the screw  85  and, hence the second end  84  of the shaft  80 . Accordingly, the end cap  88  includes the screw along which the shaft moves linearly. The pitch of screw  85  equals width of cords disclosed herein, so that as the shaft  80  moves along the screw  85 , the cords wind and unwind on the shaft  80  without overlapping and otherwise tangling. Further details of the cooperation between the screw  85  and shaft  80  are set forth in U.S. Pat. No. 5,184,660, incorporated herein by reference. 
     As shown in FIG. 2, the shaft  80  includes a first extender cord winding area  92 , and a second extender cord winding area  94  around which the extender cords  36 ,  42  respectively are wound. Additionally, the shaft  80  includes a first retractor cord winding area  96  and a second retractor cord winding area  98  around which the retractor cords  48 ,  54  respectively are wound. 
     Referring now to FIG. 3, the actuator  34  includes a preferably dc motor  100  coupled to a preferably dc power source  102 , e.g., one or more dc batteries. The batteries are primary batteries supported by the head rail  12 . The batteries can be type AA alkaline or lithium batteries, and in any case, are the sole source of power for the motor  100 . The batteries can be disposed within or alongside the head rail  12 . 
     FIG. 3 also shows that the actuator  34  includes at least one sensor  103  which receive signals from a hand-held signal generator  200  to activate the actuator  34  to move the shade  22 . Manual control buttons  104  can also be provided to manually energize and/or program the motor to open and close the shade. 
     As shown in FIG. 3, the motor  100  includes a flexible coupling  108  into which the rod  83  is disposed. The actuator  34  fits into the end of the head rail  12  and the rod  83  is slidably coupled to the first end  82  of the spindle assembly shaft  80 , as shown in FIGS. 1 and 2. Details of the circuit and operation of the motor  100  is shown in one or more of the following U.S. Patents herein incorporated by reference: U.S. Pat. Nos. 5,444,339; 5,495,153; 5,698,958; 5,729,103; 5,883,480; and 5,907,227. The cord take-up system shown in U.S. Pat. No. 5,725,040, incorporated herein by reference, can be used in cooperation with the present invention. 
     OPERATION 
     Referring back to FIG. 1, as the actuator  34  rotates the spindle assembly shaft  80  counter clockwise, causing the shaft  80  to linearly move along the screw  85 , the retractor cords  48 ,  54  wind around the shaft  80  causing the shade  22  to move in the direction indicated by the arrow  70  toward the open configuration. On the other hand, as the actuator  34  rotates the shaft  80  in the clockwise direction, causing it to move back along the screw, the extender cords  36 ,  42  wind around the shaft  80  causing the shade  22  to move in the direction indicated by arrow  68  toward the closed configuration. It is to be appreciated that as the retractor cords  48 ,  54  wind around the shaft  80 , the extender cords  36 ,  42  unwind from the shaft  80 . Conversely, as the extender cords  36 ,  42  wind around the shaft  80 , the retractor cords unwind from the shaft  80 . 
     It is to be appreciated that when retrofitting existing skylights to include the skylight assembly with head rail mounted actuator  10  of the present invention it is unnecessary to include the transparent panel  20 . Accordingly, without the panel  20  the skylight assembly  10  is installed proximal to an existing skylight such that the shade  22  is juxtaposed with the interior surface of the skylight material. 
     With the configuration of structure described above, it is to be appreciated that the skylight assembly with head rail mounted actuator provides a device that can be used to remotely or automatically open and close skylight shades. Additionally, the present invention is comparatively simple in its operation and installation. 
     While the particular skylight assembly with head rail mounted actuator as herein shown and described in detail is fully capable of attaining the above-described objects of the invention, it is to be understood that it is the presently preferred embodiment of the present invention and thus, is representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.” All structural and functional equivalents to the elements of the above-described preferred embodiment that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it is to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. section 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.”