Abstract:
Disclosed is a roll shade device provided with a shading sheet, guide belts, rail members, and a winding mechanism. The shading sheet is moved between a wound state and a deployed state. The guide belts extend in the movement direction of the shading sheet and are connected to the side end sections of the shading sheet. The side end sections are in the shading sheet width direction, which intersects with the movement direction at right angles. The rail members extend in the movement direction and slidably support the guide belts, thereby guiding the movement of the shading sheet. The winding device has a winding roller, which winds up the shading sheet and the guide belts. The guide belts have retaining sections. The retaining sections extend beyond the outer ends of the winding roller and are curved at right angles toward the surface on which the shading sheet moves in the deployed state. In the wound state, portions of the retaining sections that are adjacent to each other not only overlap each other in the shading sheet width direction but are capable of engaging one another.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a national phase application of International Application No. PCT/JP2010/066240, filed Sep. 17, 2010, and claims the priority of Japanese Application No. 2009-222410, filed Sep. 28, 2009, the contents of both of which are incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to a roller shade device for a vehicle having a light blocking sheet that is selectively wound and unwound. 
       BACKGROUND OF THE INVENTION 
       [0003]    Patent Document 1 discloses a roller shade device for a vehicle including a light blocking sheet and a winding cylinder for selectively winding and unwinding the light blocking sheet. The light blocking sheet has a pair of flat flexible guide belts, which extend along opposite edges of the light blocking sheet in its width direction. Each of the two guide belts extends in the unwinding direction of the light blocking sheet and is guided by a corresponding one of two guides. 
         [0004]    In the device disclosed in Patent Document 1, when the light blocking sheet is wound by the winding cylinder, the guide belts are wound by the winding cylinder in a manner extending parallel to the width direction of the light blocking sheet. 
       PRIOR ART DOCUMENT 
     Patent Document 
       [0000]    
       
         Patent Document 1: Japanese National Phase Laid-Open Patent Publication No. 2008-520859 
       
     
       SUMMARY OF THE INVENTION 
       [0006]    However, the device disclosed in Patent Document 1 may cause displacement of the light blocking sheet in the width direction of the light blocking sheet or wrinkle formation in the light blocking sheet when the light blocking sheet is wound by the winding cylinder, thus hampering winding of the light blocking sheet. 
         [0007]    Accordingly, it is an objective of the present invention to provide a roller shade device capable of preventing displacement of a light blocking sheet in the width direction of the light blocking sheet at the time when the light blocking sheet is wound. 
         [0008]    To achieve the foregoing objective and in accordance one aspect of the present invention, a roller shade device is provided that includes a light blocking sheet, a guide belt, a rail member, and a winding mechanism. The light blocking sheet is moved between a wound state, in which the light blocking sheet is wound to expose a translucent member of a vehicle, and a deployed state, in which the light blocking sheet is deployed to cover the translucent member. The guide belt extends in a movement direction of the light blocking sheet and is connected to an edge portion of the light blocking sheet in a width direction of the light blocking sheet. The width direction is perpendicular to the movement direction. The rail member extends in the movement direction and slidably supports the guide belt to guide movement of the light blocking sheet. The winding mechanism has a winding roller for winding the light blocking sheet and the guide belt. The guide belt has a holding portion that extends to reach a position outward of the winding roller in the width direction and is inclined in such a direction to cross a movement plane on which the light blocking sheet moves when in the deployed state. In the wound state, any adjacent sections of the holding portion are overlapped with and engageable with each other in the width direction of the light blocking sheet. The state of being “inclined in a direction transverse to a movement plane on which the light blocking sheet moves” refers to not only the state of being inclined perpendicular to the movement plane but also a state of being inclined even slightly with respect to the perpendicular direction. 
         [0009]    In this configuration, when in the deployed state, the holding portion extends to reach a position outward of the width of the winding roller and is inclined with respect to the direction perpendicular to the movement plane of the light blocking sheet. When in the wound state, the holding portion is rolled in an overlapped manner and any adjacent sections of the holding portion are held in contact with each other in the width direction of the winding roller. As a result, when the light blocking sheet is wound, the light blocking sheet is prevented from being displaced in the width direction. 
         [0010]    The light blocking sheet and the guide belt are preferably connected to each other at a position inward of the rail member in the width direction of the light blocking sheet. 
         [0011]    In this configuration, the light blocking sheet and the guide belt are connected to each other at a position inward of the rail member in the width direction. This prevents wear of the light blocking sheet and increase of sliding resistance of the light blocking sheet. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a perspective view showing a roof of a vehicle having a roller shade device according to a first embodiment of the present invention; 
           [0013]      FIG. 2  is a perspective view showing the roller shade device mounted in the vehicle illustrated in  FIG. 1 ; 
           [0014]      FIG. 3  is a schematic view showing the configuration of a rack belt for actuating a garnish for the roller shade device illustrated in  FIG. 1 ; 
           [0015]      FIG. 4  is a cross-sectional view showing a wound state of a light blocking sheet of the roller shade device illustrated in  FIG. 2 ; 
           [0016]      FIG. 5  is a cross-sectional view showing a deployed state of the light blocking sheet of the roller shade device illustrated in  FIG. 2 ; 
           [0017]      FIG. 6  is a cross-sectional view taken along line  6 - 6  of  FIG. 2 ; 
           [0018]      FIG. 7  is a cross-sectional view showing a winding roller of the roller shade device illustrated in  FIG. 2 ; 
           [0019]      FIG. 8  is a front view showing the winding roller illustrated in  FIG. 7  with the light blocking sheet shown in a cross section; 
           [0020]      FIG. 9  is a cross-sectional view showing a modification of the configuration illustrated in  FIG. 6 ; and 
           [0021]      FIG. 10  is a cross-sectional view showing another modification of the configuration illustrated in  FIG. 6 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0022]    A first embodiment of the present invention will now be described with reference to  FIGS. 1 to 8 . 
         [0023]      FIG. 1  is a perspective view showing a roof  1  of a vehicle having a roller shade device  100  according to the first embodiment of the invention. A roof panel  1   a , which configures the roof  1 , has an opening  1   b . A glass panel (a translucent member)  1   c  is mounted on the roof panel  1   a  to block the opening  1   b . The roller shade device  100 , which is shown in  FIG. 2 , is arranged below the roof panel  1   a . The glass panel  1   c  may be either fixed or movable with respect to the roof panel  1   a.    
         [0024]      FIG. 2  is a perspective view showing the roller shade device  100 . The roller shade device  100  has light blocking sheets  10 ,  11 , guide rails (rail members)  20 ,  21 , and a winding mechanism  30 . Each of the light blocking sheets  10 ,  11  is movable between a wound state in which the light blocking sheet  10 ,  11  is wound to expose the glass panel  1   c  to the interior of the passenger compartment and a deployed state in which the light blocking sheet  10 ,  11  is deployed to cover the glass panel  1   c  from inside the passenger compartment. 
         [0025]    The guide rails  20 ,  21  are mounted in the roof panel  1   a  at opposite sides of the opening  1   b  in the vehicle width direction (the width direction) and face each other. The guide rails  20 ,  21  extend in the vehicle forward-rearward direction. A front frame  22  extends between front end portions of the guide rails  20 ,  21  and a central frame  23  extends between middle portions of the guide rails  20 ,  21 . A resin housing  24  is arranged between rear end portions of the guide rails  20 ,  21 . 
         [0026]    An actuator  40  is arranged at a longitudinal central portion of the resin housing  24 . The actuator  40  has an electric motor (not shown) and an actuation gear  41 , which is actuated by the motor. As shown in  FIG. 3 , a pair of rack belts  42 ,  43  are meshed with the actuation gear  41 . As the actuation gear  41  rotates, each of the rack belts  42 ,  43  moves such that one end of the rack belt  42 ,  43  is drawn to the actuation gear  41  and the other end of the rack belt  42 ,  43  is fed out from the actuation gear  41 . The rack belts  42 ,  43  extend from the actuation gear  41  and project along the resin housing  24 . The rack belts  42 ,  43  are guided by the corresponding guide rails  20 ,  21 . 
         [0027]    A winding roller  31  and a winding roller  32  are arranged in a front portion and a rear portion, respectively, of the central frame  23 . Each of the winding rollers  31 ,  32  is supported by a winding shaft that extends in the vehicle width direction. The winding shafts are supported by the central frame  23 . A first end of each of the light blocking sheets  10 ,  11  (see  FIGS. 3 to 5 ), which is selectively wound and unwound, is connected to the corresponding one of the winding rollers  31 ,  32 . Each winding roller  31 ,  32  incorporates an urging member for constantly urging the winding roller  31 ,  32  such that the rotating force acting in the winding direction of the corresponding light blocking sheet  10 ,  11  is applied to the winding roller  31 ,  32 . 
         [0028]    A garnish  12  and a garnish  13 , which extend in the vehicle width direction (the width direction of each light blocking sheet  10 ,  11 ) and parallel to the winding rollers  31 ,  32 , are connected to a second end of the light blocking sheet  10  and a second end of the light blocking sheet  11 , respectively (see  FIGS. 2 to 5 ). 
         [0029]    Opposite longitudinal ends of each of the garnishes  12 ,  13  are connected to the rack belts  42 ,  43 . As the rack belts  42 ,  43  move, the garnishes  12 ,  13  move in the vehicle forward-rearward direction, together with the corresponding light blocking sheets  10 ,  11 . 
         [0030]      FIG. 3  is a schematic view showing the rack belts  42 ,  43 , which move the associated garnishes  12 ,  13 . The rack belt  42  is meshed with the actuation gear  41  from behind the actuation gear  41  in the vehicle and connected to a first end of the garnish  12  and a second end of the garnish  13 . The rack belt  43  is meshed with the actuation gear  41  from in front of the actuation gear  41  in the vehicle and connected to a second end of the garnish  12  and a first end of the garnish  13 . When the actuator  40  is actuated, the rack belts  42 ,  43  move in opposite directions. If the actuation gear  41  rotates in the CW direction (clockwise as viewed in  FIG. 3 ), the garnish  12  moves rearward in the vehicle (in an opening direction) and the garnish  13  moves forward in the vehicle (in an opening direction). As a result, the light blocking sheets  10 ,  11  are wound by the corresponding winding rollers  31 ,  32  and thus held each in a wound state (see  FIG. 4 ). When the actuation gear  41  rotates in the opposite direction to the CW direction (counterclockwise as viewed in  FIG. 3 ), the garnish  12  moves forward in the vehicle (in a closing direction) and the garnish  13  moves rearward in the vehicle (in a closing direction). This causes the winding rollers  31 ,  32  to deploy the corresponding light blocking sheets  10 ,  11 , thus bringing about a deployed state (see  FIG. 5 ) of each light blocking sheet  10 ,  11 . 
         [0031]      FIG. 6  is a cross-sectional view taken along line  6 - 6  of  FIG. 2 , showing the deployed state of the light blocking sheet  10 . The drawing illustrates engagement structure between the light blocking sheet  10  and the guide rail  21 . Flexible belts (guide belts)  60  are attached to either edge portion  10   a  of the light blocking sheet  10  in the vehicle width direction. Each of the flexible belts  60  is formed of flexible material (such as resin material) and has an elongated shape. The flexible belts  60  extend in the vehicle forward-rearward direction. The guide rail  21  slidably supports the corresponding flexible belt  60  and guides movement of the light blocking sheet  10 . The flexible belt  60  is wound by the winding roller  31  integrally with the light blocking sheet  10 . 
         [0032]    Each flexible belt  60  has a connecting portion  60   a  and a holding portion  60   b.  The connecting portion  60   a  is parallel to the movement plane P, on which the light blocking sheet  10  moves (the plane on which the light blocking sheet  10  passes while being wound or deployed). The connecting portion  60   a  is fixed to the top surface of the light blocking sheet  10  through sewing or using adhesive. A fixing portion  10   b  of the light blocking sheet  10  to which the connecting portion  60   a  is fixed is arranged inward of the guide rail  21  in the vehicle width direction. The light blocking sheet  10  is thus prevented from sliding on the guide rail  21 . This prevents wear of the light blocking sheet  10  and increase in sliding resistance. When the light blocking sheet  10  is in the deployed state, the holding portion  60   b  is inclined diagonally downward of the movement plane P. The guide rail  21  has an opening  21   a  and an engagement groove  21   d.  The opening  21   a  is located inward in the vehicle width direction and receives the connecting portion  60   a.  The holding portion  60   b  is arranged in the engagement groove  21   d.  The engagement groove  21   d  communicates with the opening  21   a  and is inclined diagonally downward of the movement plane P. A projection  21   c,  which has a flat surface  21   b  parallel to the movement plane P, is formed at the opening end of the opening  21   a  in the guide rail  21 . The flat surface  21   b,  which is the top surface of the projection  21   c,  may contact the connecting portion  60   a  of the flexible belt  60  and hold the connecting portion  60   a  parallel to the movement plane P of the light blocking sheet  10 , thus promoting smooth movement of the light blocking sheet  10  and the flexible belt  60 . Also, since the flat surface  21   b  is capable of contacting a portion of the flexible belt  60 , sliding resistance of the flexible belt  60  against the guide rail  21  is decreased. The inner surfaces of the guide rail  21  forming the engagement groove  21   d  contact the holding portion  60   b  of the flexible belt  60 . This prevents the flexible belt  60  from escaping inwardly in the vehicle width direction and applies tensile force to the light blocking sheet  10  in the vehicle width direction, thus preventing flipping of the light blocking sheet  10 . The engagement structure between the light blocking sheet  10  and the guide rail  20  and the engagement structure between the light blocking sheet  11  and each of the guide rails  20 ,  21  are identical to the above-described engagement structure between the light blocking sheet  10  and the guide rail  21 . Description thereof is thus omitted. 
         [0033]      FIG. 7  is a cross-sectional view showing the winding roller  31  as viewed from the left in the vehicle width direction. The rotational axis O of the winding roller  31  is located below the movement plane P of the light blocking sheet  10 . As the winding roller  31  rotates clockwise about the rotational axis O as viewed in  FIG. 7 , the winding roller  31  winds the light blocking sheet  10 . A ceiling member  70  is arranged below the winding roller  31  (the roller shade device  100 ) such that the winding roller  31  (the roller shade device  100 ) cannot be seen from occupants in the vehicle. The rotational axis of the winding roller  32  is arranged below the movement plane of the corresponding light blocking sheet  11 , as in the case of the winding roller  31 . When the winding roller  32  rotates counterclockwise about the rotational axis as viewed from the left in the vehicle width direction, the light blocking sheet  11  is wound by the winding roller  32 . 
         [0034]      FIG. 8  is a front view showing the winding roller  31  ( 32 ) with the light blocking sheet  10  ( 11 ) illustrated in cross section. The holding portions  60   b,    60   b  of the flexible belts  60 ,  60 , which are connected to the opposite sides of the light blocking sheet  10  ( 11 ) in the vehicle width direction, extend to reach positions outward of the winding roller  31  ( 32 ) in the vehicle width direction. When the light blocking sheet  10  ( 11 ) is in the deployed state, each of the holding portions  60   b  is inclined diagonally downward of the movement plane P of the light blocking sheet  10  ( 11 ). In contrast, when the light blocking sheet  10  ( 11 ) is in the wound state, each holding portion  60   b  is wound by the winding roller  31  ( 32 ) in a state inclined toward the rotational axis O. When the light blocking sheet  10  ( 11 ) is held in the wound state, the holding portion  60   b  is rolled in an overlapped manner in the vehicle width direction and any adjacent sections of the holding portion  60   b  are held in contact with each other in the vehicle width direction. In other words, when the light blocking sheet  10  ( 11 ) is in the wound state, any adjacent sections of each holding portion  60   b  are overlapped with each other and held in mutual contact in the vehicle width direction. As a result, when the light blocking sheet  10  ( 11 ) is wound by the winding roller  31  ( 32 ), the holding portions  60   b,    60   b  restrict leftward-rightward movement of the light blocking sheet  10  ( 11 ) in the vehicle width direction. This prevents displacement of the light blocking sheet  10  ( 11 ) in the width direction. Specifically, as long as any adjacent sections of each holding portion  60   b  can contact each other at the time when the winding roller  31  ( 32 ) winds the light blocking sheet  10  ( 11 ), the adjacent sections do not necessarily have to be held in contact with each other. In other words, as long as the light blocking sheet  10  ( 11 ) is not displaced in the width direction, any adjacent sections of each holding portion  60   b  are overlapped with each other without contacting each other. Once the light blocking sheet  10  ( 11 ) is displaced even slightly in the width direction, any adjacent sections of the holding portion  60   b  may come into contact with each other to prevent more displacement of the light blocking sheet  10  ( 11 ). Alternatively, a similar advantage may be obtained even if each holding portion  60   b  is modified to a shape inclined diagonally upward of the movement plane P. 
         [0035]    A second embodiment of the present invention will hereafter be described with reference to  FIG. 9 . 
         [0036]      FIG. 9  is a cross-sectional view showing a main portion of a roller shade device  200  according to the second embodiment of the invention. The second embodiment is a modification of the configuration illustrated in  FIG. 6  and differs from the first embodiment in terms of the engagement structure between a light blocking sheet  210  (a flexible belt  260 ) and a guide rail  221  (the shapes of a holding portion  260   b  and an engagement groove  221   d ). Since the other portions of the second embodiment are configured identically to corresponding portions of the first embodiment, description of these portions is omitted. 
         [0037]    The holding portion  260   b  has a downwardly inclined portion (a first inclined portion)  260   c  and an upward inclined portion (a second inclined portion)  260   d.  The downwardly inclined portion  260   c  is inclined diagonally downward of the movement plane P. The upwardly inclined portion  260   d  extends from the downwardly inclined portion  260   c  and is inclined diagonally upward with respect to the movement plane P. The downwardly inclined portion  260   c  and the upwardly inclined portion  260   d  are formed continuously with each other. 
         [0038]    The engagement groove  221   d  has a downward engagement groove section  221   e,  which is inclined diagonally downward with respect to the movement plane P, and an upward engagement groove section  221   f.  The upward engagement groove section  221   f  extends from the downward engagement groove section  221   e  in a manner inclined diagonally upward with respect to the movement plane P. The upward engagement groove section  221   f  and the downward engagement groove section  221   e  are formed continuously with each other. 
         [0039]    The downward engagement groove section  221   e  and the upward engagement groove section  221   f  are engaged with the downwardly inclined portion  260   c  and the upwardly inclined portion  260   d,  respectively. This prevents the holding portion  260   b  from escaping inwardly from the engagement groove  221   d  in the vehicle width direction. Further, when each light blocking sheet  10 ,  11  is wound by the corresponding winding roller  31 ,  32 , the holding portion  260   b  is rolled up in an overlapped manner and any adjacent sections of the holding portion  260   b  are held in contact with each other in the vehicle width direction. This restricts movement of the light blocking sheet  10 ,  11  in the width direction, thus preventing displacement of the light blocking sheet  10 ,  11  in the width direction. 
         [0040]    A third embodiment of the present invention will hereafter be described with reference to  FIG. 10 . 
         [0041]      FIG. 10  is a cross-sectional view showing a main portion of a roller shade device  300  according to the third embodiment of the invention. The third embodiment is another modification of the configuration illustrated in  FIG. 6  and differs from the first embodiment in terms of the engagement structure between a light blocking sheet  310  (a flexible belt  360 ) and a guide rail  321  (the shapes of a holding portion  360   b  and an engagement groove  321   d ). Since the other portions of the third embodiment are configured identically to corresponding portions of the first embodiment, description of these portions is omitted. 
         [0042]    The holding portion  360   b  has a inclined portion  360   c , which is inclined diagonally downward with respect to the movement plane P, and an engagement belt  360   d  having a circular cross section. The engagement belt  360   d  is formed at the distal end of the inclined portion  360   c.    
         [0043]    The engagement groove  321   d  has a downward engagement groove section  321   e,  which extends in a manner inclined diagonally downward with respect to the movement plane P, and an engagement hole  321   f  having a circular cross section. The engagement hole  321   f  is arranged at the distal end (the bottom) of the engagement groove section  321   e.    
         [0044]    The engagement groove section  321   e  and the engagement hole  321   f  are engaged with the inclined portion  360   c  and the engagement belt  360   d,  respectively. This prevents the holding portion  360   b  from escaping inwardly from the engagement groove  321   d  in the vehicle width direction. Further, when each light blocking sheet  10 ,  11  is wound by the corresponding winding roller  31 ,  32 , the holding portion  360   b  is rolled in an overlapped manner and any adjacent sections of the holding portion  360   b  are held in contact with each other in the vehicle width direction. This restricts movement of the light blocking sheet  10 ,  11  in the width direction, thus preventing displacement of the light blocking sheet  10 ,  11  in the width direction. Specifically, the engagement belt  360   d  does not necessarily require a circular cross section. That is, as long as the thickness of the engagement belt  360   d  is greater than the thickness of the inclined portion  360   c,  the engagement belt  360   d  may have a cross section with any other suitable shape, such as a square or triangular shape. 
         [0045]    Each holding portion  60   b,    260   b,    360   b  may be inclined in any suitable manner as long as the holding portion  60   b,    260   b ,  360   b  is inclined downward or upward in a manner crossing the movement plane P. That is, the holding portion  60   b,    260   b ,  360   b  may be inclined perpendicularly to the movement plane P. 
       DESCRIPTION OF THE REFERENCE NUMERALS 
       [0046]    P . . . Movement Plane,  1   c  . . . Glass Panel (Translucent Member),  10 ,  11  . . . Light Blocking Sheet,  10   a  . . . Edge Portion,  20 ,  21  . . . Guide Rail (Rail Member),  30  . . . Winding Mechanism,  31 ,  32  . . . Winding Roller,  60  . . . Flexible Belt (Guide Belt),  60   b,    260   b,    360   b  . . . Holding Portion,  100 ,  200 ,  300  . . . Roller Shade Device