Patent ID: 12221832

The drawings are not necessarily to scale. The drawings are merely representations, not intended to portray specific parameters of the disclosure. The drawings are intended to depict exemplary embodiments of the disclosure, and therefore are not be considered as limiting in scope. In the drawings, like numbering represents like elements.

DETAILED DESCRIPTION

Various features, aspects, or the like of an architectural-structure covering will now be described more fully hereinafter with reference to the accompanying drawings, in which one or more features will be shown and described. It should be appreciated that the various features may be used independently of, or in combination, with each other. It will be appreciated that the various features as disclosed herein may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will convey certain illustrations of the features to those skilled in the art.

Referring toFIGS.7A-9, in accordance with one separate and distinct aspect of the present disclosure that may be used separately from, or in combination with, the other aspects of an architectural-structure covering disclosed herein (e.g., the separate and distinct aspect may be used in combination with the other features described herein (e.g., scoop and/or external booster), or may be used with a conventional architectural-structure covering having all or some of the features disclosed herein), an improved covering110for use in an architectural-structure covering100is disclosed.

As will be described in greater detail below, a covering according to the present disclosure includes a vertically suspended front sheet, a vertically suspended rear sheet, and a plurality of horizontally-extending, vertically-spaced flexible vanes. Each of the vanes may be secured along horizontal lines of attachments such as, for example, an adhesive line, to each of the front and rear sheets. As such, in use, the front and rear sheets and vanes may form a plurality of elongated, vertically-aligned, longitudinally-extending cells, which collectively may be referred to as a cellular panel. However, in contrast to known conventional coverings where, in the final, fully extended or deployed position, the vanes extend substantially horizontal between the front and rear sheets, in accordance with one or more features of the present disclosure, in the final, fully extended or deployed position, the covering is arranged and configured to be over-rotated so that the vanes are positioned substantially perpendicular to the incoming light (e.g., sunrays).

In one embodiment, the horizontal lines of attachment of the vanes to the front and rear sheets are spaced a distance from a front edge or portion of the vanes and a rear edge or portion of the vanes. Thus, the front and rear edges of the vanes are spaced a distance from the horizontal lines of attachment. Placement of the attachment (e.g., attachment lines or adhesion lines) of the vanes to the front and rear sheets (e.g., distancing or spacing the horizontal lines of attachments of the vanes from the front and rear ends of the vanes, respectively) also ensures that the layers (e.g., first top layer and second bottom layer) of each vane properly separate in the over-rotated position.

Thus arranged, the covering is arranged and configured so that in the open configuration of the fully extended position, the front edge of the vanes can be over-rotated relative to a position of the rear edge of the vanes such that the front edge of the vane is positioned vertically above the rear edge of the vane, the horizontal lines of attachment between the front sheet and the vanes reside above the placement of their attachment to the horizontal lines of attachment between the rear sheet and the vanes, and the front and rear edges of the vanes are spaced a distance from their respective horizontal lines of attachments thereby positioning the vanes substantially perpendicular to the incoming light (e.g., sunrays).

In one embodiment, during use, the covering may be coupled to and wrappable about a rotatable member so that rotation of the rotatable member in a first direction retracts the covering and rotation of the rotatable member in a second, opposite direction extends the covering. In accordance with one or more features of the present disclosure, the covering may be wrapped about or unwrapped from a rear side of the rotatable member, with a rear side of the rotatable member positioned between a front or room-facing side of the rotatable member and an associated underlying architectural structure (e.g., window side).

In use, the covering may be over-rotated by any suitable device, mechanism, system, method, etc. now known or hereafter developed. For example, in one embodiment, the architectural-structure covering may include a booster or supplemental revolution assembly operatively coupled with the rotatable member of the covering. In use, the booster or supplemental revolution assembly is operatively couple to the rotatable member of the covering to apply an additional torque or rotation to the rotatable member to further move, rotate, etc. the rotatable member when the covering reaches its fully deployed position (e.g., the booster or supplemental revolution assembly applies an additional torque to the rotatable member to provide additional rotation to the rotatable member and thus the covering). One example of an external booster or supplemental revolution assembly will be disclosed herein in connection withFIGS.11-17B.

Referring toFIGS.7A-8E, various views of an embodiment of an architectural-structure covering100including a covering110in accordance with one or more features of the present disclosure is shown. As shown and described herein, the architectural-structure covering100includes a rotatable member105operatively coupled to the covering110. As illustrated, the covering110includes a front sheet120, a rear sheet140, and a plurality of vanes160extending between the front and rear sheets120,140.

As illustrated, the covering110may include a top edge or portion112operatively coupled to the rotatable member105and a bottom edge or portion operatively coupled to a bottom rail (not shown). In use, the front sheet120may be connected at connection point122to the rotatable member105and at another connection point to the bottom rail. Similarly, the rear sheet140may be connected at connection point142to the rotatable member105and at another connection point to the bottom rail. In use, as previously mentioned, rotation of the rotatable member105causes the covering110to wind and unwind (e.g., wrap and unwrap) about the rotatable member105so that the covering110moves between a retracted position and a deployed or extended position. As illustrated, in one embodiment, the covering110is arranged and configured to unwrap from a rear side of the rotatable member105(e.g., side positioned closer to the underlying architectural-structure (i.e., counter-clockwise rotation of the rotatable member inFIGS.8A-8E)).

In use, in the fully deployed or extended position, the covering110is movable from a closed configuration (depicted inFIGS.7A and8A) wherein the front and rear sheets120,140of the covering110are relatively close together (e.g., the front and rear sheets120,140are positioned directly adjacent to each other) and the vanes160extend vertically in an approximately coplanar, contiguous relationship with the front and rear sheets120,140, to an open configuration (depicted inFIGS.7B-7E and8B-8E), wherein the front and rear sheets120,140are spaced apart from each other with the vanes160extending between the front and rear sheets120,140.

In contrast to conventional coverings including a front sheet, a rear sheet, and a plurality of vanes extending therebetween such as, for example, the first covering22shown inFIGS.1-4wherein in the fully deployed or extended position, the plurality of vanes extend substantially horizontally between the front and rear sheets, in accordance with one or more features of the present invention, in the fully deployed or extended position (FIGS.7E and8E), the plurality of vanes160are arranged and configured so that the vanes160are positioned substantially perpendicular to the incoming light (e.g., sunrays) L. Thus arranged, in use, a front portion or edge162of the vane160is positioned above a rear portion or edge164of the vane160. That is, a front portion or edge162of a vane160may be rotated, or over-rotated, relative to a rear portion or edge164of the vane160so that, in the fully deployed position, the front portion or edge162of the vane160is positioned vertically above the rear portion or edge164of the vane160(e.g., the front portion or edge162of the vane160is positioned closer to the rotatable member105as compared to the rear portion or edge164of the vane160) thereby enabling the vanes160to be positioned substantially perpendicular to the incoming light (e.g., sunrays) L.

More particularly, as best illustrated inFIG.9, the covering110may include a plurality of vanes160extending between the front and rear sheets120,140. As illustrated, in the open configuration, each of the vanes160define an opened cell180. For example, as illustrated, in one embodiment, each cell180defines an enclosed area without requiring any portion of the front or rear sheets120,140. Thus each cell180may be constructed by an integral sheet of material. Alternatively, each cell180may be formed by multiple sheets of material coupled together. As illustrated, in one embodiment, each vane160includes first and second layers160A,160B (e.g., top and bottom layers). In use, the front and rear edges162,164are defined by the joint, crease, coupling, etc. of the first and second layers160A,160B of the vanes160. In one embodiment, each vane160may be formed as an integral piece of material with a fold at one edge and a slit, weld, joint, coupling etc. at the other end such as, for example, a fold at the front edge162and a slit, weld, joint, coupling etc. at the rear edge164, or vice-versa. In use, the fold may also be arranged and configured to facilitate biasing of the cell180to the open configuration to provide improved aesthetics. In one embodiment, by utilizing double layers (e.g., first and second layers160A,160B) such as, for example, transparent layers, incoming light L is diffused eliminating, or at least greatly minimizing, harsh shadows (e.g., incoming light is diffused by the top layer and subsequently by the bottom layer).

With continued reference toFIG.9, in accordance with one or more features of the present disclosure, each of the vanes160may be connected to the front sheet120along a first horizontal line of attachment166(e.g., an adhesive line) and to the rear sheet140along a second horizontal line of attachment168(e.g., vane160is coupled to the front sheet120along a first horizontal line of attachment166while the vane160is coupled to the rear sheet140along a second horizontal line of attachment168). In use, placement of the first and second horizontal lines of attachment166,168ensure that the first and second layers160A,160B of each vane160are separated in the open configuration. As illustrated, when the cells are in the fully open configuration, the first horizontal line of attachment166between the vane160and the front sheet120may be vertical spaced by a height or distance D1from the second horizontal line of attachment168between the vane160and the rear sheet140. In one embodiment, the distance D1may be approximately 2.5 inches.

Moreover, as illustrated inFIG.9, in the open configuration, the front edge162of each vane160is positioned adjacent to, but separated from, the front sheet120and the rear edge164is positioned adjacent to, but separated from, the rear sheet140. In use, the first layer160A may extend downward from the first horizontal line of attachment166to the front edge162of the vane160. The second layer160B may extend upwards from the second horizontal line of attachment168to the rear edge164of the vane160. In one embodiment, the front edge162may be spaced a distance D2from or below the first horizontal line of attachment166. The rear edge164may be spaced a distance D3from or above the second horizontal line of attachment168. As such, by distancing the first and second horizontal lines of attachment166,168from the front and rear edges162,164, respectively, the connection points to the front and rear sheets120,140are positioned away from and therefore off-center from the front and rear edges162,164of the vanes160thereby facilitating movement and control of the opening and closing of the cells180. In one embodiment, distance D2and distance D3may be the same. Alternatively, distance D2and distance D3may be different. In one embodiment, distance D2and distance D3may be between ⅛″ to 3/16″, although this is but one configuration and different dimensions can be used such as, for example, between 1/16″ to ¼″, 5/16″, ⅜″, etc. In use, distance D2and distance D3can be based, in part, on a function of the flexibility of the materials used coupled with an objective aesthetic evaluation.

Thus arranged, in contrast to conventional coverings such as illustrated inFIGS.1-4, in accordance with features of the present disclosure, the covering110is arranged and configured to be over-rotated so that the first horizontal line of attachment166with the front sheet120is positioned above the second horizontal line of attachment168with the rear sheet140and with the front and rear edges162,164of the vanes160spaced a distance from the first and second horizontal line of attachments166,168, respectively. As such, in the fully deployed position, the vanes160may be positioned substantially perpendicular to the incoming light (e.g., sunrays) L.

In one embodiment, the final, fully deployed or extended position, the covering110may be supplementally rotated beyond a point at which conventional coverings are rotated. Thus, for example, when used in combination with a booster, such as, for example, an external booster as will be described in greater detail below, during the final stage of operation, the covering110may be supplementally rotated a predetermined amount (such as a final one-eighth revolution, one-quarter revolution, one-half revolution, three-quarters revolution, amounts therebetween, or other suitable amounts) as the covering110approaches the fully deployed or extended position so that the covering110is over-rotated as compared to conventional arrangements (e.g., as best illustrated by comparingFIGS.7D and8DtoFIGS.7E and8E). For example, the booster may be configured to rotate the rotatable member105and thus the covering by approximately 330 degrees, although other ranges of rotation are envisioned.

In use, depending on the material(s) used in the manufacturing of the covering110, opening and closing of the cells180may vary the light transmissivity of the covering110, as will be described in greater detail below. For example, when the cells180are closed (FIGS.7A and8A), each cell180may be substantially compressed and the plurality of vanes160may be substantially parallel with each of the front and rear sheets120,140. In some embodiments, a length or body of each of the cells180may be adjacent to each other or partially overlap so that the cells180may form a pseudo middle sheet positioned between the front and rear sheets120,140. When the cells180are open to at least some extent (FIGS.7B-7E and8B-8E), each cell180may be at least partially angled with respect to at least one of the front and rear sheets120,140. In an open configuration, the cells180may then provide an insulative aspect by trapping air in each cell180. Further, the cells180may reduce or diffuse shadows created by the structure of the covering110on one side from being as noticeable on the other side of the covering110. In other words, shadow lines caused by light encountering the covering110on the outer side thereof, whether or not at a particular angle of incidence, may be reduced as viewed from the interior side of the covering110.

In use, over-rotating the vanes160provides a “shading” attitude as the vane160is positioned more perpendicular relative to the incoming light (e.g., sunrays) L (e.g., inside-edge of the vane is tilted above horizontal). Thus, in the fully deployed position, the covering110is oriented to allow light to be admitted through the gaps or spaces between the cells180. In accordance with one or more features of the present disclosure, by enabling the covering110to over-rotate so that the vanes of the covering are orientated substantially perpendicular to the incoming light (e.g., sunrays) L, in the fully deployed position, the vanes160are arranged and configured to provide optimal positioning while avoiding, or at least minimizing, shadows below the vanes.

That is, in use, the structure of the cells180of the vanes160diffuses shadows formed from light transmitted through the covering110. In accordance with the present disclosure, shadows may be substantially prevented from being transmitted through the covering even in the open configuration of the fully extended position. This may be especially apparent in examples where the front sheet120and the rear sheet140are a transparent or sheer material, or otherwise have a high light transmissivity.

In conventional coverings, during use, as light encounters the rear sheet (e.g., if the covering is positioned over a window), the light may be transmitted through the rear sheet and the horizontal line of attachment may block part of the light. However, other light rays may pass through the rear sheet without be blocked, thus resulting in shadow lines (e.g., the light being blocked by the horizontal line of attachment may form a shadow). Thereafter, as the vane is positioned above the shadow, the shadow may be transmitted to the front sheet of the covering and may be visible on the front side or surface of the covering. In use, the shadow may appear black and/or darkened portions or spots of the front side of the covering, which may be aesthetically unpleasing. Additionally, the spots may cause the material of the front sheet to fade unevenly due to light exposure.

In contrast, in accordance with features of the present disclosure, by positioning the vanes160substantially perpendicular to the incoming light L, the covering110of the present disclosure eliminates, or at least minimizes, darkened spots due to harsh shadows.

In use, the fully deployed position of the covering may be associated with a final revolution of the rotatable member so that further rotation of the rotatable member repositions at least a portion of the covering. For example, further rotation of the rotatable member over-rotates the covering such that, for example, the front edge162of the vane160coupled to the front sheet120is rotated, or over-rotated, to a position above the rear edge164of the vane160coupled to the rear sheet140so that, in the fully deployed position, the front edge162of the vane160is positioned above the rear edge164of the vane160.

While the covering110of the present disclosure has been shown and described in the present disclosure for use with a particular architectural-structure covering, it should be appreciated that the covering110should not be limited to any particular type of architectural-structure covering. It is envisioned that the covering110according to one or more features of the present disclosure may be used in connection with other types of architectural-structure coverings. Thus, the present disclosure should not be limited to any particular type of architectural-structure covering unless specifically claimed. For example, the covering110may be used in an architectural-structure covering including dual rotatable members and dual coverings as illustrated inFIGS.1-4. Alternatively, the covering110may be used in an architectural-structure covering including a single rotatable member and covering.

The covering including the front sheet, the rear sheet, and the vanes may be manufactured from any suitable material now known or hereafter developed. For example, the covering may be constructed from natural and/or synthetic materials, including fabrics, polymers, and/or other suitable materials. Fabric materials may include woven, non-woven, knits, or other suitable fabric types. Additionally, the front sheet, rear sheet, and vanes may have varying translucent properties, varying from blackout, opaque, to partially opaque, or clear. In some instances, the front sheet and the rear sheet may have an increased light translucence as compared with the vanes, so that when the vanes are closed the light translucence of the covering may be varied. For example, the front and rear sheets may be made from a transparent or sheer material while the vanes may be manufactured from a transparent, a blackout, an opaque, or a partially opaque material.

In one embodiment, when used in combination with a second covering, the first and second coverings may have different levels of light transmissivity. For example, the first and second coverings may be constructed of transparent, translucent, and/or opaque materials to provide a desired ambience or decor in an associated room. In one embodiment, the first covering includes front and rear sheets that are transparent and/or translucent, and vanes that are translucent and/or opaque. In some examples, the second covering is made of a single sheet of material with zero light transmissivity, often referred to as a black-out shade. The second covering may include patterns or designs so that when the second covering is extended behind the first covering, the second covering creates a different aesthetic appearance than the first covering by itself.

Referring toFIGS.10A-10E, in accordance with another separate and distinct aspect of the present disclosure that may be used separately from, or in combination with, the other aspects of an architectural-structure covering disclosed herein (e.g., the separate and distinct aspect may be used in combination with the other features described herein (e.g., covering and/or external booster), or may be used with a conventional architectural-structure covering having all or some of the features disclosed herein), an improved rotatable member200for use in an architectural-structure covering is disclosed.

While features of the rotatable member will be shown and described in the present disclosure for use with an outer roller of a dual roller unit, it should be appreciated that the features of the rotatable member should not be limited to any particular type of rotatable member. For example, it is envisioned that the features of the rotatable member may be used in connection with other types of rotatable member for use with architectural-structure coverings. Thus, the present disclosure should not be limited to an outer roller of a dual roller unit unless specifically claimed.

Referring toFIGS.10A-10E, an example of an embodiment of a rotatable member200for use in an architectural-structure covering such as, for example, architectural-structure covering10, is disclosed. In one embodiment, the rotatable member200may be arranged and configured as an outer roller in a dual roller unit. Thus, in use, the rotatable member200may be arranged and configured to replace the outer roller70in dual roller unit50, and may be interchangeably referred to herein as a rotatable member200or an outer roller200.

In accordance with one or more features of the present disclosure, the outer roller200includes a scoop210arranged and configured to create a cradle or pocket220to position, maintain, hold, secure, etc. (terms used interchangeably herein without the intent to limit) the bottom rail20of the second covering24so that the bottom rail20is prevented from dropping, deploying, releasing, separately, etc. (terms used interchangeably herein without the intent to limit) from the outer roller200until the second covering24is properly positioned to be deployed. As such, in use, the scoop210is arranged and configured to prevent, or at least minimize, premature deployment, or uncontrolled or unplanned deployment, of the bottom rail20and the second covering24. For example, in one embodiment, the scoop210prevents, or at least inhibits, separation of the bottom rail20from the outer roller200and thus prevents, or at least inhibits, the bottom rail20from contacting the head rail assembly14.

In use, the scoop210enables the bottom rail20to reside within the cradle or pocket220as the outer roller200is rotated. That is, the scoop210takes up any slack in the second covering24caused by rotation of the inner roller while the outer roller remains stationary. That is, as previously discussed, in the second from last rotation of the outer roller, the first covering22is fully deployed and, as such, the bottom rail20of the second covering24is revealed (e.g., no longer wrapped by any portion of the first covering22). Thus, the bottom rail20of the second covering24can separate or deploy from the outer roller. However, deployment of the second covering24should be maintained until the bottom rail20of the second covering24reaches a predetermined, desired position. For example, in one embodiment, deployment of the second covering24, and thus of the bottom rail20, from the outer roller should not occur until the bottom rail20reaches a predetermined or desired position. In one embodiment, for rotatable members rotating in the counterclockwise position, the predetermined or desired position may be approximately 12:00 to 8:00, preferably 11:00 to 9:00 (when viewed inFIGS.6A and6Bwith the underlying architectural-structure on the left). As will be appreciated, for rotatable members rotating in the clockwise position, the predetermined or desired position may be approximately 12:00 to 4:00, preferably 1:00 to 3:00 (when viewed inFIGS.6A and6Bwith the underlying architectural-structure on the left). Thus, in use, the scoop210is arranged and configured to allow the bottom rail20of the second covering24to deploy when positioned within the predetermined or desired range of positions, but prevent, or at least inhibit, the bottom rail20of the second covering24when outside of the predetermined or desired range of position. That is, the scoop210is arranged and configured to prevent unintended, premature deployment of the bottom rail. For example, the scoop210is arranged and configured to prevent premature deployment of the bottom rail20of the second covering24, which may cause the bottom rail20to contact the head rail assembly14resulting in unwanted noise, unintended damage, or a combination thereof, as schematically shown inFIGS.6A and6B. Thus arranged, for example, the scoop210prevents the bottom rail20of the second covering24from deploying initially when the first covering22is fully deployed. In this manner, the scoop210holds the bottom rail20of the second covering24in position so that the bottom rail20of the second covering24may pass by the head rail assembly14without contacting the head rail assembly14. Thereafter, upon subsequent rotation of the outer roller200, the scoop210enables the bottom rail20to deploy.

In one embodiment, as illustrated inFIGS.10A-10E, the scoop210includes a first arm or portion230and a second arm or portion240. The first arm or portion230may extend away from the outer roller200(e.g., the first arm or portion230extends away from an outer surface202of the outer roller200). The second arm or portion240extends at an angle relative to the first arm or portion230. For example, in one embodiment, the scoop210may include an “L” or “C” shape, although this is but one configuration. Thus arranged, the scoop210defines the cradle or pocket220between the outer surface202of the outer roller200and an inner surface242of the second arm or portion240and inner surface232of the first arm or portion230. The cradle or pocket220can be arranged and configured to hold the bottom rail20in close proximity to the outer roller200so that, during rotation, the bottom rail20is prevented from premature deployment so that, for example, during rotation, the bottom rail20may pass by the head rail assembly14without contacting thereof (e.g., scoop210creates a pocket or cradle to allow slack in the second covering24while not allowing the bottom rail20to deploy from the outer roller200).

During rotation of the outer roller200, and hence the scoop210, the scoop210includes an opening222in communication with the cradle or pocket220. The opening222can be oriented in the direction of rotation of the outer roller200so that, when positioned within the predetermined or desired range, the bottom rail20of the second covering24may deploy from the cradle or pocket220via the force of gravity.

In one embodiment, the scoop210and the bottom rail20may include corresponding bumps, projections, or the like250, to maintain the bottom rail20within the cradle or pocket220. Thus arranged, during use, as illustrated inFIG.10D, when the bottom rail20is positioned outside of the predetermined or desired range, the corresponding bumps250formed on the scoop210and the bottom rail20contact, engage, etc. with each other to prevent the bottom rail20from slipping out of the cradle or pocket220. For example, as illustrated inFIG.10D, with the bottom rail20positioned at substantially 6:00 (when viewed with the underlying architectural-structure on the left and with the rotatable member rotating counterclockwise), the corresponding bumps250formed on the scoop210and the bottom rail20contact, engage, etc. with each other to prevent deployment of the bottom rail20. However, as illustrated inFIG.10E, when the bottom rail20is positioned within the predetermined or desired range, the bottom rail20aligns itself relative to the scoop210so that the corresponding bumps250do not contact, engage, etc. thereby enabling the bottom rail20to deploy from the outer roller200. For example, as illustrated inFIG.10E, with the bottom rail20positioned at substantially 9:00 (when viewed with the underlying architectural-structure on the left and with the rotatable member rotating counterclockwise), the corresponding bumps250formed on the scoop210and the bottom rail20do not contact, engage, etc. with each other to enable deployment of the bottom rail20.

In one non-limiting example embodiment, the architectural-structure covering may include a covering arranged and configured to be over-rotated so that the front portion of the vanes may be positioned above the rear portion of the vanes so that the vanes are positioned substantially perpendicular to the incoming sunrays as previously described. The architectural-structure covering may also include a booster such as, for example, an external booster as will be described in greater detail herein, to provide supplemental rotation to facilitate a fully deployed condition (e.g., over-rotation of the vanes). In use, the scoop may be positioned and timed with the booster to pick up any slack in the second covering. That is, during deployment of the first covering, the inner and outer rollers rotate in unison. However, with the first covering fully extended but prior to firing or activation of the booster, a brief time delay may occur when the inner roller continues to rotate but before the booster fires to rotate the outer roller (e.g., milli-seconds), which may result in movement of the inner roller relative to the outer roller (e.g., approximately 1/16″ or more of rotation) causing the second covering to begin deploying from the inner roller. Generally speaking, this may cause slack in the second covering, which may cause the bottom rail of the second covering to separate from the outer roller and thus contact the head rail assembly. However, by properly positioning the scoop on the outer roller and timing the position of the scoop with the firing of the booster, the scoop is arranged and configured to maintain the position of the bottom rail of the second covering accommodating for the slack in the second covering so that the bottom rail of the second covering may pass through the head rail assembly. Thereafter, the bottom rail may slip from the scoop and deploy.

Referring toFIGS.11-17B, in accordance with another separate and distinct aspect of the present disclosure that may be used separately from, or in combination with, the other aspects of an architectural-structure covering disclosed herein (e.g., the separate and distinct aspect may be used in combination with the other features described herein (e.g., covering and/or scoop), or may be used with a conventional architectural-structure covering having all or some of the features disclosed herein), an external booster for use in an architectural-structure covering is disclosed.

As will be described in greater detail below, an external booster according to the present disclosure may be arranged and configured to operatively engage the covering of an architectural-structure covering. For example, the external booster may be coupled via one or more gears to an end of a rotatable member associated with the covering. In use, the external booster may be arranged and configured to transition from a first configuration to a second configuration. In the first configuration, the external booster may be arranged and configured to store potential energy. In the second configuration, the external booster may be arranged and configured to release the stored potential energy in the form of kinetic energy. The external booster may be arranged and configured to transition from the first configuration to the second configuration at a predetermined covering position during extension or deployment of the covering. In use, the kinetic energy may be utilized to rotate the rotatable member in a specific direction to effect full extension or deployment of the covering.

Referring toFIG.11, an example of an embodiment of an architectural-structure covering such as, for example, architectural-structure covering10, including an external booster300in accordance with one or more aspects of the present disclosure is shown. As shown and described herein, the external booster300is arranged and configured to work in conjunction with an architectural-structure covering10. In particular, certain aspects of the external booster300have been arranged and configured so that the external booster300may be used in connection with a dual roller unit for operatively moving first and second coverings such as, for example, first and second coverings22,24. In particular, the covering, such as, for example, the first covering22, may include a front sheet30, a rear sheet34, and a plurality of vanes38extending between the front and rear sheets30,34, as previously described. As previously mentioned, in the fully deployed or extended position, the first covering22is movable from a closed configuration (depicted inFIG.1) wherein the front and rear sheets30,34of the first covering22are relatively close together (e.g., the front and rear sheets30,34are positioned directly adjacent to each other) and the vanes38extend vertically in an approximately coplanar, contiguous relationship with the front and rear sheets30,34, to an open configuration (depicted inFIG.2), wherein the front and rear sheets30,34are horizontally spaced apart from each other with the vanes38extending substantially horizontally therebetween. In one embodiment, the external booster300may be used with a covering arranged and configured to over-rotate as previously described herein in connection withFIGS.7A-9.

In use, movement of the first covering22from the retracted position to a partially extended position to the fully extended position, wherein the first covering22is transitioned from the closed configuration to the open configuration, may occur, for example, via gravity. As such, the motion of the covering22may not be controlled or driven. In such instances, variations due to the size and weight of the covering22may exist, which may adversely affect the appearance of the architectural-structure covering10. In addition, in one or more embodiments, over-rotation of the covering22in the open configuration may be desired. For example, in one or more embodiments, it may be aesthetically desirable to have a front edge of a vane coupled to the front sheet rotated, or over-rotated, to a position above a rear edge of the vane coupled to the rear sheet so that, in the fully deployed position, the front edge of the vane is positioned above the rear edge of the vane rotate as previously described herein in connection withFIGS.7A-9. In either event, the external booster300may be utilized to operatively couple to the covering22such as, for example, the rotatable member50(e.g., the outer roller70of a dual roller unit50) of the covering22to apply an additional torque or rotation to the rotatable member50to move, rotate, etc. the rotatable member50so that the covering22reaches its fully deployed position (e.g., the external booster300applies an additional torque to the rotatable member50to provide additional rotation to the rotatable member50to ensure that the covering22opens and travels to a limit stop as desired).

While the external booster300is shown and described in the present disclosure for use with a particular covering, it should be appreciated that the external booster300should not be limited to any particular type of architectural-structure covering. It is envisioned that the external booster300according to one or more aspects of the present disclosure may be used in connection with other types of architectural-structure coverings. Thus, the present disclosure should not be limited to any particular type of architectural-structure covering unless specifically claimed.

Referring toFIGS.11-15, as will be described in greater detail herein, the external booster300may include an anchoring and/or coupling mechanism320, a biasing mechanism350, and a retention mechanism400.

As will be described in greater detail, in use, the anchoring or coupling mechanism320is arranged and configured to secure the external booster300to the architectural-structure covering10. For example, the anchoring or coupling mechanism320may include a shaft322for engaging one of the end caps26of the architectural-structure covering10. By engaging the end cap26of the architectural-structure covering10, the external booster300is arranged and configured to be positioned outside or exterior to the rotatable member50. Thus arranged, the external booster300also includes one or more coupling mechanisms330for rotatably engaging the rotatable member50. For example, the external booster300may include one or more gears332for engaging a gear52associated with the rotatable member50.

The biasing mechanism350may be preloaded with a resilient force and may remain in a preloaded state until the covering22reaches a predetermined extended position (e.g., the fully deployed position). That is, the biasing mechanism350may be arranged and configured so that when the external booster300is in the first configuration, the biasing mechanism350is preloaded with a resilient force. Thereafter, when the external booster300is transitioned to the second configuration, the biasing mechanism350is arranged and configured to release its preloaded resilient force, which in turn causes the retention mechanism400to rotate, which causes the rotatable member50, and hence the covering22associated therewith, to rotate.

The biasing mechanism350may include a biasing member352(such as a compression spring, an extension spring, a torsion spring, etc.) or any other suitable energy storage member, thus the biasing member352may be interchangeably referred to herein as a spring352. In use, the predetermined extended position of the covering22(e.g., the point at which the external booster300may be configured to transition from the first configuration to the second configuration) may be associated with a final revolution of the rotatable member50so that further rotation of the rotatable member50repositions at least a portion of the covering22. For example, further rotation of the rotatable member50may laterally separate a Silhouette® shade (e.g., cause the covering22to move from the closed configuration to the open configuration as previously described in connection withFIGS.1and2). Alternatively, for example, further rotation of the rotatable member50may over-rotate the covering22such that, for example, the front edge of the vane coupled to the front sheet is rotated, or over-rotated, to a position above the rear edge of the vane coupled to the rear sheet so that, in the fully deployed position, the front edge of the vane is positioned above the rear edge of the vane (e.g., over-rotating the vanes provides a “shading” attitude as the vane is positioned more perpendicular relative to the sun (inside-edge of the vane is tilted above horizontal)), as previously described herein in connection withFIGS.7A-9. In one embodiment, the biasing member352may be preloaded by rotating a first end of the biasing member352relative to a second end of the biasing member352, thereby imparting a preload on the biasing member352. The preloaded biasing member352may be biased in the extension direction.

The retention mechanism400may be configured to retain the potential energy or preload in the biasing mechanism350until the covering22reaches the predetermined extended position. The retention mechanism400may be selectively associated with the anchoring mechanism320to either restrict or permit movement of the biasing mechanism350. When associated with the anchoring mechanism320(e.g., when the external booster300is in the first configuration), the retention mechanism400may restrict movement of the biasing mechanism350, thereby maintaining the preload in the biasing mechanism350. When not associated with the anchoring mechanism320(e.g., when the external booster300is in the second configuration), the retention mechanism400may permit movement of the biasing mechanism350, thereby enabling conversion of the stored potential energy into kinetic energy, which may affect rotation of the rotatable member50and further movement (e.g., extension) of the covering22to the fully deployed position.

During use, at least a portion or an element of the retention mechanism400may be movable between a first position and a second position. For example, the retention mechanism400, or at least a portion or element thereof, may be slidable, pivotable, and/or rotatable between the first and second positions. Movement of the retention mechanism400, or at least a portion or element thereof, into the first position may couple the biasing mechanism350and the anchoring mechanism320(e.g., positioning the external booster300in the first configuration). Movement of the retention mechanism400, or at least a portion or element thereof, into the second position may disconnect the biasing mechanism350from the anchoring mechanism320(e.g., positioning the external booster300in the second configuration). The first and second positions of the retention mechanism400may be axially spaced, circumferentially spaced, radially spaced, or any combination thereof.

Once released, the potential energy or preload of the biasing mechanism350may be restored during normal covering operation. For example, during retraction of the covering22, reverse rotation of the rotatable member50may affect movement of the retention mechanism400, which in turn may affect movement of the biasing mechanism350in a preloading direction. Once a desired preload is achieved, the retention mechanism400may move into the first position (e.g., positioning the external booster300in the first configuration) to maintain the preload in the biasing mechanism350for use during the next covering operating cycle. When in the first position, the retention mechanism400may be positioned so as to not interfere with covering operation. As arranged, an architecture-structure covering10is provided that includes a covering22that may be repeatedly lowered via gravity into a fully operational position in a continuous, uninterrupted, smooth action without operator intervention.

With continued reference toFIGS.11-15, the architectural-structure covering10may include an external booster300. The external booster300may be assembled as a single, modular unit that couples to one end of the head rail assembly14and rotatably couples with an end of the rotatable member50. The external booster300(which may be referred to as a module, system, or unit) may be pre-assembled and thus simplify on-site installation of the architectural-structure covering10. The external booster300may be incorporated into a new architectural-structure covering10or added to an existing or installed, architectural-structure covering10(i.e., retrofit applications).

With continued reference toFIGS.11-13and15, the external booster300is shown in an assembled configuration. As illustrated, given the nature and space constraints of certain rotatable members50such as, for example, a dual roller unit including an inner roller positioned within an outer roller, as previously described herein, the external booster300is arranged and configured to be positioned exterior to the rotatable member50. As such, as previously mentioned, the external booster300may include an anchoring mechanism320. For example, in one embodiment, the external booster300includes a shaft322arranged and configured to couple to one of the end caps26of the head rail assembly14of the architectural-structure covering10, although it is envisioned that the external booster300may be mounted to the architectural-structure covering10in other ways. For example, the shaft322may include an enlarged, first end portion324arranged and configured to attach to an end cap26. For example, the enlarged, first end portion324may include axially extending splines or projections325configured to engage a corresponding recess, opening, or the like formed in the end cap26. Alternatively, the shaft322may be coupled to the end caps26by any other now known or hereinafter developed mechanism such as, for example, a snap-fit connection, a press-fit connection, fasteners, etc. The external booster300may extend parallel with a central axis of the rotatable member50. In use, in one embodiment, the shaft322is non-rotatably coupled to the end cap26of the head rail assembly14. As such, the shaft322may be interchangeably referred to herein as a non-rotatable shaft322. For example, the shaft322may be keyed to the end cap26, although other mechanisms for preventing relative rotation between the shaft322and the end cap26may be utilized.

In addition, as illustrated, the external booster300is arranged and configured to couple to the rotatable member50such as, for example, the outer roller of a dual roller unit so that rotation from the external booster300is transferred to the outer roller, and vice versa. In use, the external booster300may be arranged and configured to rotatably couple to the rotatable member50(e.g., outer roller) by any suitable mechanism now known or hereafter developed. For example, as shown, the external booster300includes one or more gears332to couple the external booster300to the rotatable member50. That is, for example, the rotatable member50may include a first gear52arranged and configured to rotate in unison with the rotatable member50, and thus with the covering22. The external booster300may also include a second gear332arranged and configured to rotate in unison with the external booster300. One or more intermediate or idler gears334may be positioned between the first gear52of the rotatable member50and the second gear332of the external booster300. Thus arranged, in use, rotation of the first gear52is transferred to the second gear332via the intermediate or idler gear334, and vice-versa. Alternatively, in use, if reverse torque is necessary such as, for example, if the external booster300is mounted to the opposite, end cap26of the head rail assembly14of the architectural-structure covering10, an additional, second idle gear may be provided.

In use, the external booster300may be configured to rotate the rotatable member50a specific amount (such as a final one-eighth revolution, one-quarter revolution, one-half revolution, three-quarters revolution, amounts therebetween, or other suitable amounts) as the covering22approaches a fully extended position. In one embodiment, the external booster300is configured to rotate approximately 330 degrees, as will be appreciated by one of ordinary skill in the art, the amount of rotation to the rotatable member50can be altered based on the gear ratios of gears52,332,334.

Referring toFIGS.14and15, in one embodiment, the biasing mechanism350of the external booster300may include a spring guide360, a spring cap370, and a biasing member (e.g., a spring)352. As illustrated, the spring guide360includes a first end portion362, a second end portion364, and a central portion366positioned between the first and second end portions362,364. In addition, the spring guide360includes a bore368extending from the first end portion362to the second end portion364, the bore368being sized and configured to enable the shaft322to pass therethrough. As illustrated, the first end portion362may be enlarged relative to the second end portion364. In use, as will be described in greater detail below, the spring guide360is keyed to a bolt410of the retention mechanism400so that in use, rotation of the spring guide360rotates the bolt410.

Referring toFIGS.14and15, in one embodiment, the spring cap370includes a first end portion372, a second end portion374, and a central portion376positioned between the first and second end portions372,374. In addition, the spring cap370includes an interior cavity378for enclosing at least a portion of the spring guide360and the spring352. In addition, as illustrated, the spring cap370includes a bore380sized and configured to enable the shaft322to pass therethrough. In use, the spring cap370is keyed to the shaft322so that in use, rotation of the spring cap370is inhibited.

With continued reference toFIGS.14and15, in one embodiment, as previously mentioned, the biasing member352may be in the form of a spring such as, for example, a compression spring, an extension spring, a torsion spring, etc. Alternatively, it is envisioned that the biasing member may be in the form of any other suitable energy storage member. Thus, as used herein, biasing member and spring are used interchangeably without the intent to limit. As illustrated, the spring352includes a first end portion354and a second end portion356. In addition, the spring352includes an interior cavity358arranged and configured to enable the spring guide360and the shaft322to pass therethrough. Thus, as illustrated, the spring352may be positioned about the central portion366of the spring guide360. In use, the first end portion354of the spring352is coupled, contacts, etc. the first end portion362of the spring guide360such as, for example, a backside of the enlarged first end portion362. Similarly, the second end portion356of the spring352may be coupled to the second end portion374of the spring cap370. For example, a tang formed on the first end portion354of the spring352may be received within a channel formed in the spring guide360. Similarly, a tang formed on the second end portion356of the spring352may be received within a channel formed in the spring cap370, although any other suitable coupling structures may be used. In use, the second end portion356of the spring352is rotatably fixed to the spring cap370.

Thus arranged, with the external booster300in the first configuration, the spring352may be preloaded to apply a force to the spring guide360. However, because the spring guide360is inhibited from rotating (e.g., as will be described in greater detail herein, the spring guide360is keyed to a bolt410of the retention mechanism400, which in the first configuration is coupled to the non-rotatable shaft322), the spring352remains in the preloaded state. That is, in use, as will be described in greater detail herein, with the covering22in the retracted position (e.g., with the external booster300in the first configuration), the spring352is preloaded (e.g., the spring352is arranged and configured to apply a torque to the spring guide360however, because the spring guide360is prevented from rotating, the spring352remains preloaded).

Thereafter, when the external booster300is transitioned to the second configuration, the spring352applies a force (e.g., torque) to the spring guide360, which is turn causes the retention mechanism400to rotate, which rotates the rotatable member50and the covering22(e.g., as will be described in greater detail below, when the external booster300is in the second configuration, the bolt410of the retention mechanism400is decoupled from the non-rotatable shaft322thereby enabling the spring guide360and the bolt410to rotate, which rotates a nut430and a drive sleeve450of the retention mechanism400).

Referring toFIGS.14and15, in one embodiment and as previously noted, the retention mechanism400of the external booster300may include a bolt410, a traveling nut430, and a drive sleeve450. The retention mechanism400may also include a pawl470. As illustrated, the bolt410includes a first end portion412, a second end portion414, and a central portion416positioned between the first and second end portions412,414. As illustrated, the bolt410also includes an externally threaded section418(e.g., external threads extend across a majority of the length of the central portion416, as such the bolt410may also be referred to as an externally threaded bolt). In use, as will be described in greater detail below, the external threads formed on the bolt410are arranged and configured to threadably engage the traveling nut430. In addition, the bolt410includes a bore420extending from the first end portion412to the second end portion414, the bore420being sized and configured to enable the shaft322to pass therethrough. As illustrated, the first end portion412may be enlarged relative to the second end portion414. In use, as will be described in greater detail below, with the external booster300in the first configuration, the bolt410is inhibited from rotating, however when the external booster300is transitioned from the first configuration to the second configuration, the bolt410is permitted to rotate.

With continued reference toFIGS.14and15, the drive sleeve450is rotatably coupled to the rotatable member50of the architectural-structure covering10via, for example, one or more gears52,332,334. As such, in use, rotation of the drive sleeve450rotates the rotatable member50, and vice-versa. As illustrated, in one embodiment, the drive sleeve450includes a first end portion452, a second end portion454, and a central portion456positioned between the first and second end portions452,454. The first end portion452can include the gear332. In addition, the drive sleeve450can include an interior cavity458for enclosing at least a portion of the shaft322, the bolt410, and the traveling nut430.

The traveling nut430may be threadably engaged to the bolt410. For example, the traveling nut430may be threadably mounted onto the threaded section418of the bolt410. In use, rotation of the traveling nut430relative to the bolt410causes the traveling nut430to axially translate along a longitudinal length of the bolt410. In addition, the traveling nut430is keyed to the drive sleeve450so that the nut430and the drive sleeve450rotate in unison. Thus arranged, during retraction of the covering22, rotation of the rotatable member50rotates the drive sleeve450, which causes the nut430to axially translate toward the second end portion414of the bolt410(e.g., to the right inFIG.15). During extension of the covering22, the traveling nut430axially translates towards the first end portion412of the bolt410(e.g., to the left inFIG.15). As will be appreciated by one of ordinary skill in the art, these movements could be reversed.

As will be described in greater detail below, movement of the covering22from the retracted position to the extended position causes the traveling nut430to axially translate toward the first end portion412of the bolt410causing the traveling nut430to contact the pawl470, which causes the pawl470to move from a first or engaged position to a second or disengaged position.

In the first position, the pawl470is in engagement with the non-rotatable shaft322and as a result, rotation of the bolt410relative to the non-rotatable shaft322is prevented. In the second position, the pawl470is decoupled from the non-rotatable shaft322. As such, rotation of the bolt410relative to the non-rotatable shaft322is enabled. Movement of the pawl470from the first position to the second position causes the external booster300to transition from the first configuration to the second configuration. Thus, movement of the covering22from the retracted position to the extended position causes the traveling nut430to contact the pawl470, which causes the pawl470to release the non-rotatable shaft322, thus enabling the bolt410to rotate due to the preloaded torque built up in the spring352. As such, with the pawl470in the second position, released from the non-rotatable shaft322, the spring352biases and rotates the spring guide360causing the spring guide360and the bolt410to rotate, which in turn rotates the nut430and the drive sleeve450. Rotation of the drive sleeve450rotates the rotatable member50, and hence the covering22, of the architectural-structure covering10to further rotate the covering22to the fully deployed position.

Similarly, movement of the covering22from the fully deployed position to the retracted position, causes the traveling nut430to axially translate towards the second end portion414of the bolt410and away from the first end portion412of the bolt410causing the traveling nut430to rotate in the opposite direction, which causes the pawl470to move from the second position to the first position. As such, movement of the covering22from the fully deployed position to the retracted position causes the pawl470to reengage the non-rotatable shaft322thus preventing the bolt410, and hence the spring guide360from rotating. Thus arranged, the external booster300can be transitioned from the second configuration to the first configuration. In addition, initial movement of the covering22from the fully deployed position to the retracted position causes the bolt410and the spring guide360to rotate in the opposite direction thereby compressing the spring352, preloading the spring352for the next operating cycle (e.g., initial rotation of the pawl470and the nut430before the pawl470reengages the non-rotatable shaft322compresses and preloads the springs352). As such, with the pawl470in the first position, coupled to the non-rotatable shaft322, the spring352is once again preloaded.

Referring toFIGS.16A-16H, an example embodiment of a locking mechanism for coupling and disconnecting the bolt410and the non-rotatable shaft322is illustrated. As previously mentioned, in the first configuration of the external booster300, the spring352is preloaded. Since the bolt410is rotationally coupled to the non-rotatable shaft322, however, the bolt410is prevented from rotating, which prevents the spring guide360from moving. In the second configuration of the external booster300, the bolt410is decoupled from the shaft322so that the bolt410can rotate relative to the non-rotatable shaft322. Thus arranged, in the second configuration of the external booster300, the spring352biases the spring guide360, which rotates the bolt410, the traveling nut430, and the drive sleeve450to rotate, which in turn rotates the rotatable member50and the covering22.

In use, the locking mechanism may be any suitable mechanism for rotationally engaging and disengaging the bolt410from the shaft322. For example, as illustrated and as previously mentioned, the locking mechanism may be a pawl470. In use, the pawl470may be movable such as, for example, pivotable from a first or engaged position to a second or disengaged position. With reference toFIGS.16A-16H, various views illustrating movement of the pawl470from the first or engaged position to the second or disengaged position are shown. As illustrated, the pawl470may include a head portion480. In the first position, the head portion480of the pawl470may be received within a pocket500formed in the non-rotatable shaft322. In this position, the pawl470is rotationally coupled to the non-rotatable shaft322so that relative rotation between the bolt410and the non-rotatable shaft322is prevented.

Referring toFIG.16I, in one embodiment, the nut530may include a bumper575located in the pocket510thereof. In use, as the pawl470moves outwards, and the spring charge is released, the pawl470contacts the bumper575causing the bumper575to compress, absorbing some of the impact or shock. In use, the bumper575may be manufactured from any suitable material such as, for example, a softer durometer material. Thus arranged, in use, the bumper575is arranged and configured to reduce noise when the booster fires.

Referring toFIGS.17A and17B, as illustrated, the pawl470may include a projection, a pin, etc.475extending from a rear surface474of the pawl470. In use, the traveling nut430includes a contacting surface432having a pathway, a groove, a recess, or the like434formed therein (terms used interchangeably herein without the intent to limit). As the contacting surface432of the traveling nut430contacts the rear surface474of the pawl470, the pathway434interacts with the pin475extending from the rear surface474of the pawl470. This interaction between the pin475and the pathway434guides movement of the pawl470as the traveling nut430continues to rotate so that the head portion480of the pawl470moves out of the pocket500formed in the shaft322, as illustrated in, for example,FIG.16E(e.g., the pin475is arranged and configured to ride along the pathway434formed in the contacting surface432of the traveling nut430). Once the pawl470is moves out of the pocket500, the bolt410and the non-rotatable shaft322are rotatably decoupled. As such, the preload force in the spring352is released, which causes the spring guide360, the bolt410, the traveling nut430, and the drive sleeve450to rotate, which causes the rotatable member50to rotate via the interconnecting gears such as, for example, gears52,332,334, or flexible gears600as will be described in greater detail below. As will be appreciated, this results in additional rotation being transmitted to the covering22to ensure that the covering22is in the fully deployed position. That is, in operation, as the covering22approaches a predetermined extended position, the traveling nut430axially translates along the threaded section418of the bolt410toward the pawl470. The external booster300is mechanically toleranced and timed so that as the covering22reaches a predetermined covering position, the pathway434contacts the pin475and pivots the pawl470from the first or engaged position to the second or disengaged position, thereby disengaging the pawl470from the pocket500formed in the non-rotatable shaft322. In one embodiment, the predetermined covering position (e.g., limit stop) can be changed for different products (e.g., different limit stops can be provided or adjusted) by adjusting the rotatable member50to the desired limit stop position prior to attaching the external booster300to the end cap26.

In use, and as best illustrated inFIG.16H, the traveling nut430and pawl470are arranged and configured to rotate until reaching a limit stop, which prevents the pawl470from reengaging the pocket500when rotating in the extension direction. As previously mentioned, and as illustrated inFIGS.16A-16H, once released, the traveling nut430and the pawl470are arranged and configured to rotate approximately 330 degrees, although other ranges of rotation are envisioned.

Subsequent rotation of the covering22from the fully deployed position to the retracted position causes the rotatable member50and hence the drive sleeve450and the traveling nut430to rotate in the opposite direction (e.g., clockwise direction as viewed inFIGS.16A-16H). When rotated in the clockwise direction, an abutment surface512of an opposing pocket510formed in the contacting surface432of the traveling nut430contacts a segment, a leg, a projection, or the like476(terms used interchangeably herein without the intent to limit) formed on the pawl470thereby rotating the pawl470in the clockwise direction until the head portion480of the pawl470is aligned with the pocket500formed in the non-rotatable shaft322. Thereafter, via continued rotation of the traveling nut430and the interacting arcuate or curved surfaces between the pawl470and the non-rotatable shaft322, the head portion480of the pawl470is received once again within the pocket500formed in the non-rotatable shaft322. Thus arranged, the bolt410is once again rotationally coupled to the non-rotatable shaft322. In addition, rotation of the traveling nut430and the pawl470in the clockwise direction causes the bolt410, the spring guide360, and the spring352to rotate, which preloads the spring352once again.

More specifically, with continued reference toFIGS.16A-16H, the pawl470may be pivotably seated in the pocket500formed in the non-rotatable shaft322. The pawl470may include a seat portion472for pivotably coupling the pawl470relative to the traveling nut430, the head portion480, and intermediate portion473located therebetween. As illustrated, the head portion480may have an arcuate or curved outer surface corresponding to the shape of the pocket500. The seat portion472may serve as the pivot axis of the pawl470, which may be substantially parallel to a longitudinal axis or centerline of the rotatable member50and/or the external booster300. As such, the head portion480may be movable between a radially-inward position (e.g., the first or engaged position) and a radially-outward position (e.g., the second or disengaged position). The head portion480of the pawl470may be arranged and configured to be received within the pocket500formed in the non-rotatable shaft322to restrain rotation of the bolt410. As illustrated, in one embodiment, the head portion480may include a proximal face480a, a distal face480b, and an intermediate face480cextending between the proximal and distal faces480a,480b. The proximal and distal faces480a,480bmay be arcuate or curved. The intermediate face480cmay be arcuate or curved and have a radius. In use, the leg476is positioned on a same side of the head portion480as the proximal face480aof the head portion480and opposite that of the distal face480bof the head portion480.

As described herein, the external booster300is arranged and configured to provide supplemental rotation of the rotatable member50, and hence the covering22. For example, the external booster300may be arranged and configured to provide supplemental rotation to ensure that the covering22is moved to an open configuration. Alternatively, the external booster300may be arranged and configured to over-rotate the front sheet30relative to the rear sheet34.

That is, according to one or more aspects of the present disclosure, with the external booster300in the first configuration, the pawl470is in the first or engaged position (e.g., the head portion480of the pawl470is positioned within the pocket500formed in the non-rotatable shaft322). In one embodiment, the head portion480of the pawl470may extend into the pocket500of the non-rotatable shaft322and the intermediate face480cmay abut or contact an arcuate or curved base wall502of the pocket500. Thus arranged, the pawl470may be rotationally constrained to the non-rotatable shaft322, thereby rotationally constraining the bolt410. In other words, the external booster300may be rotationally constrained in a static, preloaded configuration during a majority of the covering22movement. In this configuration, the external booster300may not interfere with the operation of the covering22.

During rotation of the rotatable member50, and hence the covering22, in the extension direction, with the external booster300in the first configuration (e.g., with the spring352preloaded and the bolt410coupled to the non-rotatable shaft322), the traveling nut430rotates in unison with the rotatable member50and axially translates along the length of the bolt410toward the pawl470. As the covering22approaches the predetermined extended position (for example, as the covering22approaches the extended or deployed position depictedFIG.1), the contacting surface432of the nut430approaches the rear surface474of the pawl470. As the rotatable member50, and thus the nut430, continue to rotate in the extension direction under the influence of gravity, the pin475extending from the rear surface474of the pawl470approaches and interacts with the pathway434formed in the contacting surface432of the nut430. Continued rotation of the rotatable member50, causes the pawl470to become disengaged or lifted from the pocket500formed in the non-rotatable shaft322via the interaction between the pin475and pathway434thus permitting rotation of the spring guide360, the bolt410, the nut430, and the drive sleeve450under the influence of the spring352. This additional rotation via the spring352enables the covering22to extend to the fully deployed position such as, for example, depicted inFIG.2.

After the pawl470is rotationally disengaged from the non-rotatable shaft322, the pawl470contacts or engages the abutment surface512of the traveling nut430. The initial contact or engagement between the pawl470and the nut430may occur as the rotatable member50begins a final or nearly final revolution in the extension direction. Once in contact or engagement, the pawl470may rotate the rotatable member50in the extension direction to fully extend the covering22(FIG.2). That is, with the pawl470disengaged from the non-rotatable shaft322, the spring352applies a rotation force to cause the spring guide360, the bolt410, the traveling nut430, and the drive sleeve450to rotate, which in turns causes the rotatable member50, and hence the covering22, to rotate in the extension direction.

Generally speaking, in use, the external booster300may be configured to supplementally rotate the rotatable member50any desired rotational amount after the covering22reaches a desired extended position, such as a final revolution of the rotatable member50associated with a fully extended covering position. That is, as described herein, the external booster300may drive or rotate the rotatable member50in the extension direction toward an open configuration in which the front and rear sheets30,34are laterally spaced from one another and the vanes38are substantially horizontal (FIG.2). In this fully deployed position, a limit stop may inhibit further rotation of the rotatable member50under the bias of the spring352. As such, in one implementation, the external booster300may supplementally rotate the rotatable member50once the covering22has reached a fully extended, closed position to reconfigure the covering22from an extended and closed-vane position (seeFIG.1, for example) to an extended and open-vane position (seeFIG.2, for example).

After rotating the rotatable member50, the pawl470may be reset into the first or engaged position during normal operation of the architectural-structure covering10. For example, during rotation of the rotatable member50in the retraction direction, the nut430and the pawl470may rotate in the opposite direction (e.g., in the clockwise direction as illustrated inFIGS.16A-16H). In addition, the external booster300, or at least portions thereof such as, for example, the bolt410and the spring guide360may rotate in the retraction direction against the bias of the spring352, thereby preloading the spring352. Once the head portion480of the pawl470is rotatably aligned with the pocket500, the interaction between the corresponding arcuate surfaces causes the pawl470to pivot back to its first or engaged position with the head portion480located within the pocket500of the non-rotatable shaft322. In this position, the pawl470prevents rotation of the bolt410, thereby maintaining the preload in the spring352for the next lowering cycle. Upon the pawl470moving into the first or engaged position in the pocket500, the pawl470may not interfere with rotation of the rotatable member50and thus further retraction of the covering22may occur nominally. As provided herein, the external booster300is transitioned back to its first configuration under normal retraction of the covering22.

In accordance with another separate and distinct aspect of the present disclosure that may be used separately from, or in combination with, the other aspects of an architectural-structure covering disclosed herein, the one or more gears such as, for example, gear52,332,334may be in the form of a flexible, compressible, or spring-loaded gear (terms used interchangeably herein without the intent to limit). In use, the one or more flexible gears are arranged and configured to enable compression between adjoining gears to provide, for example, a friction fit type meshing with corresponding gears to ensure constant contact between the gears during operation to prevent, or at least reduce, unwanted backlash and/or unwanted clearance.

It should be appreciated that while the flexible gears may be described and illustrated herein in connection with an architectural-structure covering and more particularly for use with coupling the external booster300to the rotatable member50(as illustrated inFIGS.20A-20C), the flexible gears should not be so limited. That is, the flexible gears may have application outside of architectural-structure coverings and may be used in place of traditional gears. As such, the flexible gears should not be limited for use in architectural-structure coverings unless explicitly claimed.

Referring toFIG.18, an example embodiment of a flexible gear600is illustrated. As illustrated, in one embodiment, the flexible gear600may include an outer circumference602having a plurality of teeth604for meshing with mating gears as conventionally known. However, in accordance with features of the present disclosure, the flexible gear600may also include a plurality of spiral cutouts610formed adjacent to the plurality of teeth604(e.g., spiral cutouts610are positioned between the outer circumference602and teeth604and center bore or axis of the gear600). In use, the spiral cutouts610enable the flexible gear600to compress or flex inwardly by a predetermined amount when a radial force is applied to the flexible gear600.

That is, referring toFIGS.19A and19B, and as will be readily appreciated by one of ordinary skill in the art, conventional gears G include a pitch diameter PD.FIG.19Aillustrates a conventional gear G shown in a nominal position with gear teeth/pitch diameters PDperfectly matching.FIG.19Billustrates a conventional gear G including a center-to-center offset in the gears G designed and configured to compensate for variances in materials and/or tolerances to avoid interference between corresponding meshed teeth. That is, generally speaking, the pitch diameters PDof parallel shaft gears G can be determined by measuring the diameter from a center point or distance of the gear G to the circumferentially disposed teeth. Generally speaking, in connection with conventional gears G, the pitch diameters PDof interconnecting gears G may be designed to exactly mesh (FIG.19A). More commonly, however, interconnecting gears G may be designed and/or arranged and configured with a slightly reduced pitch diameters PDand/or offsets to prevent, for example, binding between interconnecting gears G (FIG.19B). However, one disadvantage with such traditional gears G is that backlash (or slop) between adjacent gears G may be introduced. When used in connection with an architectural-structure covering and, more particularly, when used to couple an external booster to the rotatable member, this unwanted backlash may result in unwanted clearance when the external booster operates to, for example, over-rotate the covering.

In contrast, referring toFIGS.19C and19D, by utilizing a flexible gear600, the pitch diameter PDbetween interconnecting gears600, G may be designed so that the pitch diameters PDof the interconnecting gears600, G overlap (e.g., the diameter of the flexible gear600is arranged and configured to be slightly larger than the actual diameter between the interconnecting gears). For example,FIG.19Cillustrates a flexible gear600(although one or more flexible gears600could be utilized as needed) incorporating interfering gear teeth/pitch diameters PDin accordance with one or more features of the present disclosure.FIG.19Dillustrates a flexible gear600incorporating an offset center arranged and configured to slightly change or adjust as the flexible gear600rotate to compensate for gear roundness error. In use, the gear teeth602remain fully engaged to eliminate backlash between gear sets.

Thus arranged, in use, when a radially-inwardly directed force CFis applied to the flexible gear600(e.g., by meshing with an adjacent interconnecting gear) the pitch diameter PDof the flexible gear600may compress thereby introducing or creating radially-inwardly directed compression or pressure CF(FIG.20C) between intermeshing gears (e.g., intermeshing teeth apply a perpendicular or compression force onto the outer circumference of the flexible gear600). As such, a frictional or compression force between intercoupling meshed gears may be created, which eliminates, or at least reduces, backlash and thus any unwanted clearance.

In one embodiment, it is envisioned that the flexible gears600may be arranged and configured with 3 to 5-thousandths overlap between adjacent pitch diameters PD. This is in contrast to known, traditional gears G, which may be designed with 3 to 5-thousandths clearance to prevent binding between meshing gears.

Referring toFIG.18, in one embodiment, each spiral may include a bump612formed thereon. In use, the bump612may serve as limit stops to prevent excess deflection of the gear600(e.g., bumps612could be arranged and configured to bottom out at a certain deflection/gear load).

It should be appreciated that while the flexible gears600are shown with spiral shaped cutouts610, flexibility could be introduced into the gears600by any suitable method now known of hereafter developed. For example, alternate shaped cutouts could be utilized such as, for example, slits, circumferential cutouts, etc. Preferably, the cutouts are arranged and configured to provide a substantially uniform pressure around the gear Alternatively, it is envisioned that that flexible gears could be manufactured with alternate materials having different durometers. Combinations of cutouts (e.g., spirals, slits, circumferential cutouts) and material selection (e.g., durometer) in a single flexible gear600are also contemplated.

The foregoing has many advantages. For instance, as described, the external booster300may be automatically actuated or triggered during normal extension of a covering22to complete or finish a covering extension operation, which may work against gravitational forces, without requiring additional steps by an operator. Further, the external booster300may be automatically reset during normal retraction of the covering22from an extended position. Moreover, the external booster300may be scalable to accommodate different covering sizes. For instance, the size of the spring (e.g., the length and/or wire diameter) may be varied depending upon the weight of the covering22. In addition, and/or alternatively, different rotational limits can be accommodated (e.g., less total rotation could be provided, if desired). For example, in one embodiment, the non-rotatable shaft322and pocket500could be designed and configured in different relative positions with respect to the traveling nut430so that rotation could limit the travel of the booster assembly. For example, the external booster could be arranged and configured to provide a total rotation of 120 degrees or the like, if required for a product.

The foregoing description has broad application. While the provided examples describe a silhouette-type covering, it should be appreciated that the concepts disclosed herein may equally apply to any type of covering that may selectively use supplemental energy to actuate, extend, and/or open a covering. For instance, the external booster300may be used to actuate operable vanes attached to a support sheet. Further, while the provided examples describe the external booster300as assisting in an extension of a covering, the external booster300may be configured to assist in raising or retracting a covering. Accordingly, the discussion of any embodiment is meant only to be explanatory and is not intended to suggest that the scope of the disclosure, including the claims, is limited to these embodiments. In other words, while illustrative embodiments of the disclosure have been described in detail herein, it is to be understood that the inventive concepts may be otherwise variously embodied and employed, and that the appended claims are intended to be construed to include such variations, except as limited by the prior art.

The foregoing discussion has been presented for purposes of illustration and description and is not intended to limit the disclosure to the form or forms disclosed herein. For example, various features of the disclosure are grouped together in one or more aspects, embodiments, or configurations for the purpose of streamlining the disclosure. However, it should be understood that various features of the certain aspects, embodiments, or configurations of the disclosure may be combined in alternate aspects, embodiments, or configurations. Moreover, the following claims are hereby incorporated into this Detailed Description by this reference, with each claim standing on its own as a separate embodiment of the present disclosure.

The phrases “at least one”, “one or more”, and “and/or”, as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural elements or steps, unless such exclusion is explicitly recited.

Connection references (e.g., engaged, attached, coupled, connected, and joined) are to be construed broadly and may include intermediate members between a collection of elements and relative to movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other. Identification references (e.g., primary, secondary, first, second, third, fourth, etc.) are not intended to connote importance or priority, but are used to distinguish one feature from another. The drawings are for purposes of illustration only and the dimensions, positions, order and relative to sizes reflected in the drawings attached hereto may vary.

The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof are open-ended expressions and can be used interchangeably herein.

All directional references (e.g., proximal, distal, upper, lower, upward, downward, left, right, lateral, longitudinal, front, back, top, bottom, above, below, vertical, horizontal, radial, axial, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of this disclosure.

While the present disclosure refers to certain embodiments, numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of the present disclosure, as defined in the appended claim(s). Accordingly, it is intended that the present disclosure not be limited to the described embodiments, but that it has the full scope defined by the language of the following claims, and equivalents thereof.

It should be understood that, as described herein, an “embodiment” (such as illustrated in the accompanying Figures) may refer to an illustrative representation of an environment or article or component in which a disclosed concept or feature may be provided or embodied, or to the representation of a manner in which just the concept or feature may be provided or embodied. However, such illustrated embodiments are to be understood as examples (unless otherwise stated), and other manners of embodying the described concepts or features, such as may be understood by one of ordinary skill in the art upon learning the concepts or features from the present disclosure, are within the scope of the disclosure. In addition, it will be appreciated that while the Figures may show one or more embodiments of concepts or features together in a single embodiment of an environment, article, or component incorporating such concepts or features, such concepts or features are to be understood (unless otherwise specified) as independent of and separate from one another and are shown together for the sake of convenience and without intent to limit to being present or used together. For instance, features illustrated or described as part of one embodiment can be used separately, or with another embodiment to yield a still further embodiment. Thus, it is intended that the present subject matter covers such modifications and variations as come within the scope of the appended claims and their equivalents.