Abstract:
A roman shade and method of manufacturing a roman shade are disclosed. The shade may include a first sheet having a plurality of lateral folds therein, a plurality of laterally drooping compartments as well as a second or back sheet which is planar in shape and completely separated from the first sheet. The first sheet may be connected to a cord for raising and lowering the shade through various mechanisms which may include a plurality of rings mounted about both the cords, and a ribbon connected to each of the folds of the first sheet.

Description:
FIELD OF THE DISCLOSURE 
     The disclosure generally relates to window coverings and, more particularly, relates to retractable window shades. 
     BACKGROUND OF THE DISCLOSURE 
     Treatments and coverings for windows, doors, and other architectural openings, are well known and myriad in their available styles. For example, venetian blinds, vertical blinds, mini-blinds, drapes, shades, and the like can all be used to block such openings to various degrees and to suit various aesthetic requirements and/or tastes. 
     One other type of covering is known as a roman shade. With such a device, a sheet is provided with a plurality of lateral pleats or folds to provide the device with a scalloped or downwardly cascading appearance when the covering is fully extended. A cord or ribbon is connected to each of the folds to ensure each is held at a height sufficient to produce the cascading appearance. 
     Colson, U.S. Pat. No. 5,425,408, discloses one such roman shade. Front and back sheets are provided and connected between top and bottom rails. The front sheet is substantially longer than the back sheet. The back sheet is planar in shape, while the front sheet is provided with a plurality of laterally-spaced folds. Each fold is fixedly attached to the back sheet as by sewing or adhesive. Each fold is so secured at a height sufficient to cause a series of droops or sags in the front sheet. 
     In another patent to Colson, U.S. Pat. No. 5,144,469, front and back sheets are again provided, but both include lateral pleats. However, the pleats are longitudinally offset. The front sheet pleats are then raised to the level of a corresponding back sheet pleat and secured thereto to create the desired cascading appearance. The respective pleats are secured together either by adhesive or stitching, with or without a separate strip material therebetween. 
     In still further embodiments, the back sheet is provided in the form of a plurality of pleated segments. U.S. Pat. No. 5,158,632, also issued to Colson, et al., discloses such a structure. Accordingly, not only is the backing sheet not planar, but the front sheet is again fixedly secured to the back sheet using adhesive. 
     A need therefore exists for a roman shade having first and second sheets forming a plurality of lateral cells, but having a planar back sheet to, among other things, ensure coverage of the architectural opening, and having a back sheet separate from the front sheet to, among other things, provide a clean aesthetic appearance. 
     SUMMARY OF THE DISCLOSURE 
     In accordance with one aspect of the disclosure, a shade is provided which may comprise, a head rail, a first sheet, a second sheet, a plurality of rings, a ribbon, and a cord. The first sheet may be connected to the head rail and include a plurality of lateral folds. The second sheet may also be connected to the head rail and include a plurality of apertures. The second sheet may be substantially planar when the shade is in a fully extended position. One ring or a plurality of rings may extend through each aperture in the second sheet. The ribbon is connected to the head rail and extends through each ring. The ribbon is further connected to each fold of the first sheet and is provided between the first sheet and the second sheet. The cord may be connected to the head rail and extend through each of the rings with the second sheet being placed between the ribbon and the cord. 
     In accordance with another aspect of the disclosure, a shade may be provided which may comprise a head rail, a bottom rail, a first sheet, a second sheet, a cord, and means for connecting the first sheet to the second sheet. The first and second sheets may extend between the head rail and the bottom rail. The cord may extend between the head rail and the bottom rail, the second sheet being placed between the first sheet and the cord. 
     In accordance with another aspect of the disclosure, a method of manufacturing a shade is provided which may include folding a first sheet so as to have a plurality of lateral folds, knotting a plurality of rings onto a ribbon, connecting a ribbon to the first sheet proximate each fold with at least one ring being provided on the ribbon between adjacent folds, extending each of the rings through apertures provided in a second sheet, stringing a cord through each of the rings with the second sheet being between the first sheet and the cord after such stringing, connecting first ends of the first sheet, ribbon, and second sheet to a head rail, connecting second ends of the first sheet, ribbon, and second sheet to a bottom rail, connecting a first end of the cord to the bottom rail, and stringing a second end of the cord through an opening in the head rail and through a brake mounted in the head rail. 
    
    
     These and other aspects and features of the disclosure will become more apparent upon reading the following detailed description when taken in conjunction with the accompanying drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front perspective view of a shade constructed in accordance with the teachings of the disclosure and depicted in an extended position; 
     FIG. 2 is a perspective view of the shade of FIG. 1, but depicted in a retracted position; 
     FIG. 3 is a rear perspective, cutaway view of the shade of FIG. 1; 
     FIG. 4 is an enlarged fragmentary front perspective view, with the head nail illustrated in detail; 
     FIG. 5 is an enlarged sectional view of FIG. 1 taken along line  5 — 5  of FIG. 1; and 
     FIG. 6 is a flowchart depicting a sample sequence of steps which may be taken according to the teachings of the disclosure. 
    
    
     Although the disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the disclosure to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the disclosure as defined by the appended claims. 
     DETAILED DESCRIPTION 
     Referring now to the drawings, and with specific reference to FIG. 1, a roman shade constructed in accordance with the teachings of the disclosure is generally referred to by reference numeral  20 . Although the shade  20  will be described below in reference to a window shade or covering, it is to be understood that such a structure can be used in conjunction with any type of opening, including architectural openings such as doors and the like. 
     The shade  20  may include a head rail  22  and a bottom rail  24  with a first front sheet  26  and a second or back sheet  28 , extending therebetween A cord or cords  30  may be used to retract the shade  20  from the extended position shown in FIG. 1 to the retracted position shown in FIG.  2 . It is to be understood that the shade  20  can of course be positioned in a variety of other positions to vary the degree of extension, by appropriate manipulation of the cord  30 . 
     As shown best in FIG. 1, when the shade  20  is provided in the extended position, the front sheet  26  is provided with a scalloped or cascading appearance in that a plurality of lateral folds  32  are provided and positioned so as to create a plurality of cells  33  separated by a plurality of sags or droops  34  in the material forming the first sheet  26 . The first sheet  26 , as well as the back sheet  28 , may be provided in the form of cloth such as cotton or linen, or could be provided in a variety of other materials including, but not limited to, plastic, paper, and other fabrics. 
     Referring now to FIGS. 3 and 5, it can be seen that while the first sheet  26  is substantially scalloped or cascading in cross section, the second sheet  28  is substantially planar in shape. In so doing, the first sheet  26  is able to provide the user with the desired aesthetic appearance, while the second sheet  28  is able to closely and accurately follow the shape of the opening (not shown) desired to be covered. 
     From FIGS. 3 and 5, it will also be noted that the first sheet  26  and back sheet  28  are not directly joined together, but rather the back sheet  28  is fully separate from the front sheet  26 . Such a feature has the advantage, among other things, of providing a clean, draping appearance for the shade  20 . 
     In order to raise and lower the shade  20  in an orderly fashion, the cord  30 , however, is indirectly connected to the first sheet  26 . As shown in FIG. 3, this may be provided in the form of a connection or connecting means including a ribbon  36  as well as a plurality of rings  38 . As will be noted, the ribbon  36 , which may be provided in the form of a cloth strip or the like, extends from the head rail  22 , and connects to the first sheet  26  at a plurality of locations  40 , each being proximate to one of the lateral folds  32 . The ribbon  36  may be so connected by adhesive, stitches, or the like. Between each location  40 , it will be noted that one ring  38  is provided. Each of the rings  38  is mounted about the ribbon  36 , as well as the cord  30 . The second sheet  28  is provided with a plurality of apertures  42  enabling the rings  38  to pass therethrough. It is to be understood that while the rings  38  are provided in the form of annular members, any other shape including, but not limited to, ovals, squares, rectangles, or any other form of polygon would suffice. 
     In one embodiment, as shown best in FIG. 3, the second sheet  28  may be provided with first and second columns  44 ,  46  of apertures  42 . In addition, first and second ribbons  36  are provided and aligned with the first and second columns  44 ,  46 . Accordingly, first and second sets of rings  38  are provided for mounting about each of the ribbons  36 , and passage through the apertures  42  of the first and second columns  44  and  46 . 
     In order to maintain the lateral rigidity of each of the lateral folds  32 , a reinforcing bar  48  may be mounted into each of the folds  32 . More specifically, as shown in FIG. 5, a metal rod  48  may be positioned within each of the folds  32 , with adjacent sides of the first sheet  26  then being stitched or adhered together as indicated by a joint  50  to secure the reinforcing bar  48  therein. Such a bar  48  has the benefit of ensuring that each of the folds  32  maintains a substantially horizontal shape and therefore maintains the desired aesthetic appearance for the shade  20 . 
     Referring now to FIG. 4, the head rail  22  is shown in further detail. The head rail  22 , which may be provided in the form of a plastic, wood, or the like, includes a front surface  52 , as well as a back surface  54 , an interior chamber  56 , cord apertures  58 ,  60 , and a bottom surface  62 . While the ribbon  36  and front sheet  26  is mounted to the bottom surface  62 , the back sheet  28  may be mounted to the back surface  54 . Moreover, the back sheet  28  may extend above the head rail  22  and forms an additional scallop  64 . The additional scallop  64  is able to wrap around or droop over the front surface  52  of the head rail  22  (see FIG. 1) so as to hide the head rail  22  and thus preserve the aesthetic appearance of the shade  20 . In addition, the scallop  64  may include a strip (not shown) proximate the back surface  54  of the head rail  22  whereon an attachment mechanism such as a strip of tongue and loop fasteners may be provided. In turn, the second sheet  28  may include a strip (not shown) of similar fasteners enabling the second sheet  28  to be secured to the front sheet  26  in a removable fashion to facilitate cleaning and the like. It is to be understood that other forms of fasteners, including but not limited to buttons, strings, ties, and the like, are certainly possible. 
     The first and second cord apertures  58  and  60  are provided to enable the cords  30  to pass therethrough for connection to a brake  76  as shown in FIG.  4 . The brake  76  is mounted within the chamber  56  and may be provided in the form of a conventional brake having a fixed shaft or mandrel  78  as well as a movable gear wheel  80 . As is conventional, the chamber  56  may include an actuate interior surface (not shown) having a plurality of gear teeth  82  of similar size and pitch to those of the gear wheel  80 . The interior surface  81  of the chamber  56  is actuate to facilitate braking of the cords between the gear wheel  80  and the mandrel  78 . More specifically, when the first and second cords  30  are trained between the mandrel  78  and the gear wheel  80  and the cord is pulled in a first direction, the gear wheel  80  drops, via gravity, out of contact with the interior surface and thereby allows the gear wheel  80  to rotate freely and for the cords to move freely. Such movement enables the shade  20  to be easily extended. If it is desired to lock the shade  20  into a given position, the cords  30  can simply be pulled in the opposite direction. In so doing, sufficient force is exerted on the movable gear wheel  80  to force its gear teeth into engagement with the gear teeth provided on the interior surface of the chamber  56 . Accordingly, when a user partially releases the cords  30 , and the weight of the shade  20  tends to pull downwardly, while the cords are continued to be pulled in the first direction, the gear wheel  80  rotates while in contact with the interior surface until the user completely lets go, and the cords are trapped between the mandrel  78  and the now engaged teeth of the wheel  80  and the interior surface. 
     In order to manufacture such a shade  20 , a variety of methods can be employed. However, as indicated in the flow chart of FIG. 6, one possible method may include a first step  88  of forming a plurality of lateral folds  32  into the first sheet  26 . A second step  90  may then be to mount the reinforcing bars  48  within each of the folds  32 . Third and fourth steps  92  and  94  may be to mount a plurality of rings  38  about a ribbon  36  and then connect the ribbon  36  to the first sheet  26 . The ribbon  36  may be connected to the first sheet  26  at the plurality of locations  40  such that at least one ring  38  is provided between adjacent pairs of locations. Once such an assembly is formed, the second sheet  28  can be positioned over the first sheet  26  and ribbon  36  such that the rings  38  pass through the plurality of apertures  42 . This is indicated in the step  96  in FIG.  6 . The cord  30  can then be strung through each of the rings  38  as indicated by a step  98 . The head and bottom rails  22  and  24  can then be connected to each of the first sheet  26 , back sheet  28 , and ribbon  36 , as indicated in steps  100 ,  102 , respectively. In another step  104 , a first end  104  of the cord  30  may be secured to the bottom rail  24 , and in a step  106 , a second end  108  of the cord  30  may be strung through cord aperture  58  and trained between the mandrel  78  and the gear wheel  80  to complete the shade  20 . 
     From the foregoing, it will be appreciated that the disclosure provides a shade apparatus and method of manufacturing same.