Patent Publication Number: US-2012043029-A1

Title: Dual Panel Window Shade Apparatus with Improved Bottom Weight Bar and Rail

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to window treatment apparatus, and more particularly to a vertically shifting dual panel roll-up window shade apparatus with an improved bottom weight bar and rail assembly to bring and hold the panel surfaces together as close as possible when the panels are extended. 
     BACKGROUND OF THE INVENTION 
     Window treatments are well known. In addition to aesthetic features, window treatments also provide privacy, protection from sunlight, and thermal insulation. U.S. Pat. No. 58,668 to Morris, discloses a double panel curtain window treatment, where a pair of panels, when extended, are spaced apart by a distance equal to the diameter of the upper roller to which each panel is attached. The two panels extend from the two different sides of the upper roller. Each separate panel is connected along bottom portions thereof by tacking to a bottom block. Each of the panels includes a series of aligned apertures. When the upper roller is rotated a small amount, the alignment of the apertures in each panel changes, adjusting the passage of light and air through the panels. The Morrison patent does not disclose a bottom weight bar in a housing or rail assembly that applies different tension forces on the shade panels when the shade panels are lifted together as compared to when the shade panels are shifting vertical positions relative to each other. 
     U.S. Pat. No. 2,280,358 to Tietig discloses a pair of window shade panels disposed either on a single roller or on a pair of rollers, whereby a small movement of one panel relative to the other panel will act to exclude light wholly or partially. In one embodiment, the panels comprise polarized elements which block light when the panels are in register with each other. As the polarized portions are moved further apart from registration, the amount of light that passes through the panels changes. In another embodiment, alternate opaque and transparent strips or sheets are employed. An elastic strip is provided on either one or both of the sheets so that the panel having the elastic strip can be moved relative to the other panel without rotating the rollers. The Tietig patent does not disclose a bottom weight bar or rail assembly nor a dual panel window shade comprising a single piece of shade material. 
     U.S. Pat. No. 6,189,592 to Domel discloses a single piece dual panel adjustable shade having one upper end attached to a moveable roller tube, and the other upper end attached to a stationary, non-rotating tube or head rail. To weight the shade, Domel discloses a cylindrical metal or plastic rod in the bight formed at the bottom of the dual shade panels. As one of the shade panels is rolled onto the moveable roller tube, the rod in the bight continually rotates, causing the shade panels to wear out from the added friction caused by the rotating rod. Domel does not teach a combination single-piece, dual panel shade with a weight bar or rail assembly, wherein the weight bar only rotates a small increment when the shade panels are shifted relative to each other, but does not rotate against the panel fabric when both shade panels are raised simultaneously. 
     A transitional shade system is commercially available from Lafayette Venetian Blind, Inc. of West Lafayette, Ind. 47496 and sold under the brand name “Allure™.” The Allure shade system includes a weight rail at the lower portion of a retractable and adjustable shade, with a large weight bar rotatably mounted in a fixed vertical position relative to the weight rail between two fixed end caps of the rail. The Allure weight bar is not vertically moveable within the weight rail, rotates at all times when the Allure shade is raised, lowered, or adjusted to vary light passage, and does not include a weight rail housing that maintains the two panels forming the shade in close proximity. 
     U.S. Pat. No. 6,651,720 to DiSilvestro and Gaskill, the same co-inventors of the present invention, discloses a dual panel vertically shiftable window treatment that does not include a bottom weight rod assembly, or a single piece shade material forming a bight between shade panels at the bottom of the panels. 
     Prior art window treatments are relatively complicated in construction and operation, and have the additional disadvantages discussed above. A need exists for a simple, easy to manufacture dual panel window shade made of a single piece of material in combination with a bottom weight bar and rail assembly that is easy to manufacture and install, and will not prematurely wear out the fabric comprising the shade panels. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a, dual panel vertically shiftable window shade apparatus having the dual panels formed from a single piece of material, and an improved bottom weight bar and rail assembly. The apparatus includes a single piece of shade fabric doubled over to form a front panel and a rear panel. The panels have opposed and alternate opaque and translucent portions. A cord or chain controls the operation of the panels to lift both panels simultaneously as they are wound on a spool, or to shift one panel vertically with respect to the other to vary the amount of light passing through the shade. A canopy houses the panels when they are wound on the spool. The panels can be made, for example, from fabric, paper, vinyl or the like. The spool is mounted for rotation within the canopy. The upper portion of the panels are attached at radially separate locations on the outer surface of the spool. The lower end of the dual panels form a bight through which a weight bar extends. The weight bar also rotates in a bottom weight rail assembly such that the weight bar does not rotate as both panels are raised simultaneously. Further, the weight bar of the present invention is free to move vertically in a hollow portion of the rail assembly when the relative vertical position of each panel is adjusted. 
     In the illustrated embodiment, the respective panels extend from the spool and over a rigid guide surface, such as a smooth edge of the canopy. The panels hang generally downward from the spool, and the spool is selectively rotatable via a cord and a clutch mechanism to move the panels generally vertically simultaneously in either direction, or to move the panels relative to one another. For example, as one panel moves up, the other panel moves down, and vice versa. Changing the diameter of the spool affects the vertical offset shift dimension of the two panels. 
     In the illustrated embodiment the designs formed in the panels define alternate rows of translucent and opaque elements of material. For example, the front panel may comprise alternate rows of opaque portions, with sheer or scrim portions between the opaque design wherein light can pass through the sheer or scrim portions. The rear panel correspondingly includes sheer or scrim portions in alignment with the opaque design on the outer panel, and opaque designs in alignment with the sheer or scrim designs on the outer panel. As the spool is rotated, the corresponding sheer and opaque portions become offset with respect to one antoher, varying the amount of light which passes through the shade apparatus. 
     When the shade panels are rotated simultaneously around the spool, the weight bar and its associated rail assembly rise with the bight formed at the bottom of the two panels. During this operation, the weight bar does not rotate, and there is no wear to the panel material caused by the weight bar. When the spool is rotated incrementally to adjust one of the panels relative to the other and vary the light passing through the dual panel shade, the weight bar rotates only a relatively small amount in the bight. The surface of the weight bar slides across the inner surface of the panel fabric only a minimal amount, thereby causing no or minimal wear of the panel material. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a front elevational view of a single piece dual panel window shade apparatus with a bottom weight bar and rail assembly, showing a partial cut-away to reveal a portion of the rear panel, and illustrating alternate rows of translucent and opaque material forming the dual panel shade structure positioned to allow no or minimal light to pass through the shade apparatus; 
         FIG. 2  is a side elevational view of the window shade apparatus of  FIG. 1 ; 
         FIG. 3  is a front perspective view of the window shade apparatus of  FIGS. 1 and 2 , showing the front panel in partial cut-away to expose a view of a portion of the rear panel, and showing the alternate rows of translucent and opaque material forming the dual panel structure in a position to allow a medium amount of light to pass through the shade panels; 
         FIG. 4  is a front perspective partial cut away view of the window shade apparatus of the present invention similar to  FIG. 3 , where the alternate rows of the translucent and opaque material in the front and rear panels forming the dual panel structure are positioned to allow the maximum amount of light to pass through the shade apparatus; 
         FIG. 5  is a sectional schematic view of the shade apparatus taken along line X-X of  FIG. 1 , showing the dual panels of the single piece shade material in a partially retracted position; 
         FIG. 6  is a sectional schematic view of the shade apparatus taken along line X-X of  FIG. 1 , showing both of the dual panels of the shade material fully extended, with the alternate rows of translucent and opaque shade material aligned as shown in  FIG. 1  to allow no or minimum light to pass through the shade panels; 
         FIG. 7  is a sectional view of the shade apparatus taken along line X-X of  FIG. 1 , showing both of the dual panels extended downward from the canopy, with the alternate rows of translucent and opaque shade material having been moved relative to each other from the position shown in  FIG. 6  to allow the maximum amount of light to pass through the shade panels; 
         FIG. 8  is a front and side perspective detail view of the bottom weight bar and rail assembly of the present invention, showing the positions of the weight bar and the bight of shade material when the shade is retracted onto the spool by raising both panels simultaneously; 
         FIG. 9  is a front and side perspective detail view of the bottom weight bar and rail assembly of the present invention, showing the positions of the weight bar and the bight of shade material when one of the panels is being moved relative to the other panel; 
         FIG. 10  is a cross-sectional view of an embodiment of the bottom weight bar and rail assembly taken along line Y-Y of  FIG. 9 ; 
         FIG. 11  is a front detail cut-away view of the canopy, shade spool and panel guide surface of the present invention; and 
         FIG. 12  is a side detail view of the canopy, shade spool and panel guide surface of the present invention taken along line Z-Z of  FIG. 11 . 
     
    
    
     DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT 
     Referring to the drawings and  FIGS. 1-7  in greater detail, the reference number  10  refers to a dual panel window shade apparatus. The shade apparatus  10  includes a single piece of material  12  formed in a loop and having a front panel  14  and a rear panel  16 . As seen in  FIG. 7 , the upper portion of single piece of material  12  extends over and around the outer surface of spool or roller  18 , and is fastened to spool  18  at two radially spaced apart locations, designated  20  and  22  in  FIG. 7 . At the bottom of shade material  12 , panels  14  and  16  loop around to form a bight  24 , as seen in  FIGS. 8-10 . 
     Referring to  FIGS. 1-4 ,  7  and  11 - 12 , the shade apparatus comprises a canopy  26  at the top of the apparatus. The canopy  26  is adapted to be fastened to a wall or sill over a window (not shown) as is known in the fastening art. The canopy includes opposed end flanges  28 ,  30 . As shown in  FIGS. 11 and 12 , the ends of spool  18  are rotatably fastened to end flanges  28 ,  30  of canopy  26 , such as by roller bearing  32 . A cord or chain  34  is operatively connected to a clutch mechanism (not shown) to rotate spool  18  for vertical movement of front and rear panels  14 ,  16 , either simultaneously to raise and lower the panels over the window (not shown), or to adjust the vertical position of panels  14  and  16  relative to each other, as will be explained. 
     Referring to the embodiment of the invention illustrated in  FIG. 1 , the single piece of shade material  12  that comprises front panel  14  and rear panel  16  includes alternate lateral portions of opaque material  36  and translucent or clear material  38 . The front and rear panels  14 ,  16 , when extended as shown in  FIG. 2 , are in close juxtaposition to one another, and the amount of light passing from the window through the shade material  12  is controlled by the positions of front panel  14  and rear panel  16  relative to one another. 
     For example, in  FIG. 1 , each portion of opaque material  36  of front panel  14  is directly adjacent a portion of translucent or clear material  38  of rear panel  16 . In this position, no or a severely restricted or minimal amount of light is allowed to pass through shade apparatus  10 .  FIG. 3  illustrates another position of front panel  14  and real panel  16 , where the two panels have vertically and incrementally moved relative to each other, and the opaque material portions  36  and translucent portions  38  are partially adjacent one another. In this position of the front panel  14  and the rear panel  16 , a medium or partial amount of light passes through the front and rear panels  14 ,  16  from the window located adjacent the shade apparatus  10 . 
     Referring to  FIG. 4 , the front and rear panels  14 ,  16  are adjusted vertically and incrementally from their relative positions shown in  FIG. 1  or  3 , wherein the opaque material portions  36  of both the front panel  14  and the rear panel  16  are adjacent one another. The translucent portions  38  of each panel  14 ,  16  are also aligned adjacent each other. In the position shown in  FIG. 4 , the maximum amount of light can pass through the window and through the shade apparatus  10 . 
     In the illustrated embodiment of  FIGS. 1 ,  3  and  4 , the opaque material  36  and translucent material  38  are shown as horizontally extending slat-like pieces of material. However, it is within the framework of the present invention to incorporate any positive design on one of panels  14 ,  16  and a corresponding negative design on the other of panels  14 ,  16 . For example, the front panel  14  may comprise a plurality of circles as opaque portions of a design, while the remaining portion of the front panel  14  comprises translucent sheer or scrim material. Conversely, the rear panel  16  may comprise a corresponding series of circle designs of translucent sheer or scrim material, while the remaining portion of panel  16  is opaque. In this configuration, the front panel  14  may have opaque portions of the design on the surface thereof, with translucent sheer or scrim portions between the opaque design elements, with light passing through the translucent sheer or scrim portions. The rear panel  16  correspondingly includes translucent sheer or scrim design portions in horizontal alignment with the opaque design on the front panel  14 , and opaque designs in horizontal alignment where the design on the front panel  14  is sheer. In an embodiment of the present invention, the opaque portions of one or the other panels  14 ,  16  are slightly oversized to provide total privacy when the panels are closed, as illustrated in  FIG. 1 . 
     Referring to  FIGS. 1-10 , a weight bar and rail assembly  40  is located at the bottom of shade apparatus  10  to provide a downward force on the single piece of shade material  12  as the panels  14 ,  16  are lowered, raised, and moved relative to each other to ensure the smooth and efficient operation of the shade apparatus  10 , to stretch the material  12  and remove potential wrinkles in the material  10 , and for other purposes to be explained. 
     Weight bar and rail assembly  40  comprises a rail housing  42  extending the horizontal length of the bottom of panels  14  and  16 . In the illustrated embodiment, the rail housing  42  has a hollow portion  44 , and is somewhat triangular in shape with an opening  46  at the apex of the triangular housing. A downwardly extending flange  48  is located at the bottom of rail housing  42  to provide added weight to the housing. The opening  46  at the apex of rail housing  42  is formed by two vertically upstanding and horizontally extending flanges  50 ,  52  ( FIGS. 8-10 ). Extending downward and outward from the bottom of each flange  50 ,  52  are side walls  54 ,  56  of rail housing  42 . Each wall  54 ,  56  is connected to a respective bottom wall  58 ,  60 , which are shown slightly angled in the embodiment shown in  FIG. 10 . The bottom walls may also extend horizontally, as shown in  FIGS. 8 and 9 . Hollow portion  44  of rail housing  42  is formed between side walls  54 ,  56 , and bottom walls  58 ,  60 . 
     Weight bar or rod  62  is located in hollow portion  44  of rail housing  42 . Weight bar  62  extends the full horizontal length of the bottom of panels  14  and  16 , which panels are joined at bight  24 . As seen in  FIGS. 8-10 , weight bar  62  is lodged in bight  24 , with the bottom portions of front panel  14  and rear panel  16  extending around and in contact with weight bar  62 . Front and rear panels  14 ,  16  also extend upward from contact with weight bar  62  and through opening  46  in rail housing  42 . The upper ends of panels  14 ,  16  extend around spool  18 , as seen in  FIGS. 5-7 . 
     Referring to  FIGS. 8 and 9 , weight bar  62  is freely inserted into hollow portion  44  of rail housing  42 , and is capable of moving vertically upward and downward in hollow portion  44  depending on the operation of shade apparatus  10 , as will be explained. The diameter of weight bar  62  is greater than the width of opening  46 . 
     Referring to  FIG. 7 , the spool  18  is mounted within the canopy  26  for rotation about axis  64 , indicated for example by arrow C, relative to the canopy  26 . Rotation of spool  18  is manually, or automatically, controlled by cord or chain  34 . A low friction guide surface  66  is rigidly attached to the canopy  26  to guide the exit of the panels  14 ,  16  from the canopy  26  through an opening  68  formed in a lower portion of the canopy  26  at or near the rear lower edge of canopy  26 , directing the panels  14 ,  16  to a vertical plane in close proximity to each other and in close proximity to the window over which canopy  26  is installed. 
     The upper portions of panels  14 ,  16  are formed from the single piece of material  12 . As seen in  FIG. 7 , the front panel  14  is rigidly connected to spool  18  at circumferential fastening location  20 , and rear panel  16  is rigidly connected to spool  18  at separate fastening location  22  on the circumference of spool  18 . The panels  14 ,  16  extend around spool  18  and out through opening  68  in canopy  26 . Prior to reaching opening  68 , the panels  14 ,  16  extend over, and are supported by guide surface  66 . 
     In operation, the panels  14 ,  16  move generally vertically up and down relative to each other in the range of up to several inches. For example, as the front panel  14  moves down, the rear panel  16  moves up, and vice-versa, upon rotation of spool  18 . Additional rotation of spool  18  will raise or lower both panels  14  and  16  simultaneously. 
     Referring to  FIG. 5 , starting with the position whereby both of the panels  14 ,  16  are wound around the spool  18 , the spool  18  is rotated on axis  64  in the direction shown by arrow B through well known methods comprising manipulation of two strands comprising the cord or chain  34  ( FIGS. 1 ,  2 ). The panels  14 ,  16  move in unison downwards over guide surface  66  and in front of the adjacent window as a result of weight bar  62  lodged in bight  24  at the bottom of each of the panels  14 ,  16 . When the panels  14 ,  16  reach the position shown in  FIG. 6 , the panels  14 ,  16  are both in the fully extended position, and fastening locations  20  and  22  are in the spaced apart position shown in  FIG. 6 . 
     Referring to  FIG. 7 , to shift the position of the panels  14 ,  16  relative to each other, the spool  18  is rotated incrementally from the position shown in  FIG. 6 , as shown by arrow C in  FIG. 7 , whereby fastening location  20  moves arcuately away from guide surface  66 , and fastening location  22  moves arcuately toward the guide surface  66 . As shown in  FIG. 7 , the front panel  14  has thus moved vertically upward, while the rear panel  16  has moved vertically downward as single piece of material  12  moves around weight bar  62 . This relative movement of the front and rear panels adjusts the position of opaque and translucent materials  36 ,  38 , thus altering the amount of light passing through panels  14 ,  16 . 
     To raise the panels  14 ,  16  away from the front of the window, the spool  18  is rotated in a direction opposite to that shown by arrow C in  FIG. 7 , whereby the panels  14 ,  16  are first moved into a position substantially co-extensive with each other, and then are both rewound upon the spool  18  and into the canopy  26 , as shown in  FIG. 5 . 
     When spool  18  is rotated to raise panels  14  and  16  and the panels are wound around spool  18 , the upward movement of the panels applies a force at bight  24  that causes weight bar  62  and the bottom portions of panels  14 ,  16  to rise in hollow portions  44  of rail housing  42 . Referring to  FIG. 8 , panels  14  and  16  extend around weight bar  16  and exit rail housing  42  through the apex of the triangular housing  42  formed at opening  46 . As weight bar  62  rises relative to rail housing  42 , the outer surfaces of panels  14  and  16  are wedged into engagement with the interior surfaces of side walls  54 ,  56  of rail housing  42 , thereby lifting weight bar  62  and rail housing  42  of weight bar and rail assembly  40  as spool  18  continues to rotate. This wedging action, acting in combination with the weight of weight bar  62 , prevents panel  14  from moving relative to panel  16 , and vice-versa, as the panels  14 ,  16  are being raised and wound around spool  18 . The weight of weight bar and rail assembly  40  also keeps panels  14 ,  16  taut and adjacent one another as the panels are being raised in unison. The same combination of forces provided by weight bar and rail assembly  40  act to keep the panels  14 ,  16  in close proximity to each other as the panels are lowered from spool  18 . 
     When panels  14 ,  16  are desired to be moved relative to each other to adjust the amount of light entering the room through the window, or the view from the room, as shown in  FIGS. 7 ,  9  and  10 , the panels  14 ,  16  are initially in their fully extended position ( FIG. 6 ). The spool  18  is rotated incrementally in one circular direction or the other, as described above and shown in  FIG. 7 , such that fastening location point  20  moves away from (or towards) guide surface  66 , and location point  22  moves towards (or away from) guide surface  66 . During this motion, there is less, or no, force on weight bar  62  tending to pull the weight bar upward in hollow space  44  of rail housing  42 . As a result, during the operation of shifting the vertical position of one panel  14 ,  16 , relative to the other as seen in  FIGS. 9 and 10 , the weight bar  62  and bight  24  move downward away from opening  46  of housing  42 , releasing the wedging action between the triangular configuration formed by the inside surfaces of side walls  54 ,  56  of rail housing  42  and panels  14 ,  16 . This allows the bottom portions of panels  14 ,  16  to move over the surface of weight bar  62 , or alternately cause weight bar  62  to rotate as the bottom portions of panels  14  and  16  engage and rotate weight bar  62 . 
     As panels  14 ,  16  are raised and lowered as illustrated in  FIG. 5 , weight bar  62  does not rotate against the interior surfaces of single piece of material  12 , thereby providing longer wearability of the material making up panels  14 ,  16 . The weight bar  62  of the present invention rotates only the distance of the shift between panels  14 ,  16 , and only during the shifting motion after the panels  14 ,  16  have been fully lowered over the window. This release of the previously described wedging action allows the panels  14 ,  16  in bight  24  to move substantially frictionlessly around weight bar  62 , providing less wear and tear on the material comprising panels  14  and  16 . 
     While the specification of the invention is described in relation to certain implementations or embodiments, many details are set forth for purposes of illustration. Thus, the foregoing merely illustrates the principles of the invention. For example, this invention may have other specific forms without departing from its spirit or essential characteristics. The described arrangements are illustrated and not restricted. To those skilled in the art, the invention is susceptible to additional implementations or embodiments and certain of the details described in this specification can be varied considerably without departing from the basic principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown here, embody the principles of the invention. They are thus within the spirit and scope of the invention.