Note: Descriptions are shown in the official language in which they were submitted.
CA 02426760 2003-04-16
APPARATUS AND METHOD FOR THE PRODUC7CION OF
ROLLER DL)~TDS
The present invention relates to a new apparatus for the production of roller
blinds
and to a method of producing roller blinds employing the apparatus.
Roller blinds are well known and generally comprise a trzbe or cylinder around
which
a body of fabric is wound. The tube carrying the fabric is mounted in a window
casement so that the tube can rotate, generally against a spring bias, to
unroll the
1o fabric and so cover the window.
Mounting of the fabric on the roller blind tube during manufacture presents a
number
of problems. Clearly a roller blind must be manufactured in a size which
corresponds to the size of the window in which the blind is to be mounted.
This in
I5 turn means that the fabric must be cut to size in terms of both of its
length and its
width before it can be mounted on the roller blind tube. After the fabric has
been cut
to size, if must be mounted in the correct orientation on the roller blind
tube.
Conventionally, the fabric is cut on a large cutting table 'which must be at
least as
large as the largest piece of fabric to be used in blind manufacture when laid
out flat.
20 Each side of the fabric is cut individually, for example using a guillotine-
type roller
cutter and great care and attention is required to ensure that the sides are
cut straight
and that adjacent sides are perpendicular (and opposite sides are parallel) so
that a
perfectly rectangular piece of fabric is formed. This is tune consuming and
subject
to inaccuracies.
The cut fabric is conventionally mounted manually on t1: a roller, blind tube,
with the
correct alignment being judged by eye. This requires considerable skill as
only a
small misalignment can result in an unsatisfactory blind. The fabric then has
to be
rolled onto the tube evenly to ensure the edges are perpendicular to the tube
and do
3o not cone to one side. Where such coning occurs, small strips of fabric may
need to
be inserted at the edge of the fabric as it is rolled to correct the coning.
The depth of
insertion of these fabric corrector strips must be judged and adjusted to
provide the
1
CA 02426760 2003-04-16
correct degree of coning correction. The fabric als~ has to be rolled at,the
correct
tension to avoid coning problems when the blind is operated.
The present invention seeks to overcome all the above p~roblem.s and provides
aw
apparatus for cutting fabric and mounting the cut fabric on a roller blind
tube such
that the fabric is cut automatically to the correct size and is automatically
mounted
on the roller blznd tube in the correct alignment. The apparatus of the
invention
produces correctly cut, tensioned and aligned fabric on a roller blind tube in
approximately 25% of the time of the conventional method, and requiring
approximately 25% of the space. In variations of the invention, the apparatus
can be
modified to accommodate more than oxie roller blind tube so that a plurality
of roller
blinds can be manufactured at the same time.
According to a first aspect of the present invention there is provided an
apparatus for
Zs use in the manufacture of a roller blind comprising:
(l) drive means for feeding a web of fabric through the apparatus parallel to
a
first direction;
(ii) alignment means for aligning the web of fabric with respect to the first
direction;
(iii) first and second roller blind tube mounting means for mounting a roller
blind tube on the apparatus by its respective ends such that the
longitudinal axis of the tube lies in a second direction perpendicular to the
first direction, wherein at least one of the mounting means is adjustable in
2~ the second direction in order to nmur~i ~-~iiier Mind tubes of different
lengths;
(iv) roller blind tube drive means for driving one of the mounting means to
rotate.the roller blind tube about its longitudinal axis;.
(v) width cutting means for cutting the web of fabric to a desired yvidth in
accordance with the length of the roller blind tube
wherein the alignment rr3eans, mounting means and cutting means are
mounted in fixed angular relation with respect to one another.
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CA 02426760 2003-04-16
Most preferably, in this apparatus the width cutting means comprise at least a
first
width cutting means which is adjustable in the seco-nd direction and is
mounted in
fixed angular relation to the alignment means and the mouating means. 1n a
particularly preferred embodiment, the adjustable width cutting means is
mounted in
fixed relation to the adjustable mounting means, for movement therewith.
In an especially advantageous arrangement of the apparatus the adjustable
mounting
means and the adjustable width cutting means are mounted on a common bracket,
1o which bracket is mounted for slideable movement parallel to the second
direction.
Preferably means are provided for locking the common bracket in a desired
location
after adjustment.
According to a second aspect of the present invention there is provided
apparatus for
use in the manufacture of roller blinds comprising:
(i) drive means for feeding a web of fabric through the apparatus parallel to
a
first direction;
(ii) alignment means for aligning the web of fabric with respect to the first
direction;
(iii) mounting components for mounting n roller blind tubes, where n is an
integer greater than l, such that the Longitudinal axis of each roller blind
tube lies in a second direction perpendicular to. the first direction, said
mounting components comprising first mounting means for mounting a
LJ plVxlillaL end. of a ~rsi roller blind t~i..'C7e, ~C~OfS.CL TnOtIntIng
Lt2eanS IOr
mounting a distal end of a final roller blind tube and n-I intermediate
mounting means for mounting adjacent respective proximal and distal
ends of intermediate roller blind tubes, or, where n=2 for mounting the
distal end of the first roller blind tube and the adjacent proximal end of
the second roller blind tube, the second and intermediate mounting means
being adjustable in the second direction ixE order to mount roller blind
tubes of different lengths;
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CA 02426760 2003-04-16
(iv) roller blind tube drive means for driving one of the mounting means to
rotate the roller blind tubes about the longiW dinal axis and;
(v) a plurality of width cutting means for cutting fhe web of fabric to a
desired widths in accordance with the re:>pective lengths of the roller
blind tubes
wherein the alignment means, mounting means and cutting means are
mounted in fixed angular relation with respect to one another.
Most preferably, in this apparatus at Ieast n of the width cutting means are
adjustable
Io in the second direction and are mounted in fixed angular relation to the
alignment
means and the mounting means. . In a particularly preferred embodiment, the
adjustable width cutting means are mounted in fixed relation to respective
adjustable
mounting means, for movement therewith.
Yn an especially advantageous arrangement of the: apparatus each respective
adjustable mounting means and adjustable width cut~:ing means is mounted on a
common bracket, which brackets are mounted for slideable movement parallel to
the
second direction. Preferably means are provided on each common bracket for
locking the bracket in a desired Location after adjustment.
in another preferred embodiment of these aspects of the invention the dri-we
means
comprise a pair of pinch rollers mounted with their ass;es of rotation
parallel to the
second direction and perpendicular to the first direction.
c~.~ Pr°vf°vrablj' ths°i a"Ypaial~',ua 6.IliFtGd
liU~tipld°.!'GS C't ~)iaYlaT s~l7p~rC SurIaCe OVer wb2C11 the
web of fahric is passed prior to the drive means.
In another preferred arrangement the alignment means; comprises a planar
surface
disposed at one side of the support surface, said planar surface having a
component
3a parallel to the first direction and perpendicular to the second direction,
and along
which in use, the edge of the fabric makes nmning contact. Preferably also the
planar support surface comprises a cutting guide for ensuring accurate cutting
of the
4
CA 02426760 2003-04-16
trailing end of the fabric. In a preferred form, the cutting guide comprises a
linear
groove disposed in the planar support surface. In order to hold the fabric in
place
during cutting, preferably the apparatus also comprises clamping means
operable to
hold the fabric against the planar surface during cutting of the trailing end
of the
s fabric.
In. another advantageous embodiment, the roller blind tube drive means
includes a
slipping clutch operative to maintain a desired tension in the web of fabric.
1o To assist in accurate cutting of the trailing end of tlae fabric, the
apparatus preferably
further comprises a brake operable to act on the roller blind tube drive
means.
Preferably the apparatus of the invention farther comprises means of
introducing
back tension to the web of fabric, also the apparatus preferably comprises
electronic
z5 control means operative to start and stop the respective: drive means. In
preferred
forms of the invention, the control means is operative to stop the respective
drive
means at a predetermined point for cutting of the trailing end of the fabric.
The
control means may calculate the predetermined point in accordance with an
operator
input of a desired blind length.
Where the apparatus is provided with a brake, the control means is preferably
operative to apply the brake as the trailing end of the fabric approaches the
cutting
means.
according to a 'irurd aspect of the invention there is provided a roiier blind
rube for
use on the apparatus of the fixst and second aspects of the invention,
comprising a
hollow metal tube and a cutting guide for guiding cutting of the leading end
of the
fabric. Preferably, the cutting guide ' comprises a linear groove disposed in
the
external surface of the roller blind tube, and parallel to the longitudinal
axis of the
3o tube.
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CA 02426760 2003-04-16
In one variation the roller blind tube 25 includes a formation, operative to
co-operate
with a corresponding formation on the driven roller blind tube mounting
'means,
whereby the roller blind tube is mountable on the apparatus only in a
predetermined
rotational orientation.
In a fourth aspect of the invention there is provided an apparatus as defined
in first or
second aspects of the invention further comprising a rcsller blind tube as
defined in
the third aspect of the invention.
1o A fifth aspect of the invention provides an assembly for use in the
manufacture of a
roller blind comprising a roller blind tube as defined in the third aspect of
the
invention and a body of fabric wound around the roller blind tube. In
preferred such
assemblies, the edges of the body of fabric are parallel to the respective
ends of the
roller blind tube and/or the trailing end of the body of fabric is parallel to
the
1s longitudinal axis of the roller blind tube.
A sixth aspect of the invention provides a roller blind including a roller
blind tube as
defined in the fourth aspect of the invention or including an assembly as
defined in
the fifth aspect of the invention..
According to a seventh aspect of the invention there is provided a method of
producing an assembly for use in the manufacture of a roller blind, said
assembly
comprising a roller blind tube with a body of fabric wound thereupon, the
method
comprising the steps of
(l) providing an apparatus as claimed in claim 1;
(ii} providing a roller blind tube;
(iii) mounting a first end of the roller blind tube on the driven roller blind
tube
mounting means;
(iv} adjusting the location of the adjustable roller blind tube mounting means
and mounting the second end of the roller blind tube on said adjustable
roller blind tube mounting means;
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CA 02426760 2003-04-16
(v) adjusting the location of the width cutting means at at least one side of
the
apparatus in accordance with the desired widlth of the body of fabric.
{vi) aligning a web of fabric with the alignment means;
(vii) driving the respective driving means to dnrJe the web of fabric thrbugh
the apparatus via the width cutting means until the leading end reaches
the roller blind tube;
{viii) stopping the drive means and mounting the leading end of the web of
fabric on the roller blind tube;
(ix) re-starting the respective drive means anal driving a predetermined
length
to of fabric through the apparatus via the width cutting means;
(x) stopping the respective driving means;
(xi) cutting the trailing end of the fabric along a Line perpendicular to the
adjacent means;
(xii) re-starting the respective driving means; and
is {xiii) optionally, applying a brake to the driving means of the roller
blind tube
mounting means to slow said means as the trailing end of the web of
fabric is cut by the width cutting means.
In a preferred embodiment of this seventh aspect of the invention, the
adjustable
2o roller blind tube mounting means and the adjustable; width cutting means
are
mounted in fixed relation to each other whereby steps (iv) and (v) are
performed in a ''
single operation.
A preferred variation of this aspect of the invention includes, after step
(viii), the step
25 of {viii)a) cutting the leading edge of the web of fabric so that it is
parallel to the
longitudinal axis of the roller blind tube. Preferably, the roller blind tube
includes a
cutting guide in its external surface in the farm of a linear groove parallel
to the
longitudinal axis of the roller blind. tube, and said step (vill)a) comprises
cutting said
leading edge with a knife by guiding the knife blade in said groove.
7
CA 02426760 2003-04-16
Tn another preferred embodiment of this aspect of the invention, the method
further
comprises providing a slipping clutch for the roller blind tube driving means
and
maintaining a desired tension in the web of fabric by' in~eans of said
slipping clutch_
In another preferred variation of this aspect of the invention the method
further
comprises, in step (xi}, providing a planar support surface having a cutting
guide in
the form of a linear groove perpendicular to the alignment means and cutting
said
trailing end by guiding a cutting knife along said groove.
to A further preferred variation of this aspect of the invention further
comprises the step
of providing clamping means and clamping the web of fabric against a support
surface and in step (xi) cutting the trailing end of the web of fabric
proximate said
clamping means.
Preferably, the method of this aspect of the invention further comprises the
step of
introducing back tension into the web of fabric.
For a better understanding of the invention and to show how the same may be
carried
into effect, reference will now be made, by way of example only, to the
following
2o drawings, in whiche
Figure 1 is a general perspective view of the apparatus according to the
invention;
Figure 2 is a perspective view of the apparatus according to the invention
showing
initial stages of-feeding the fabric through the apparatus;
Figure 3 is a perspective view of the apparatus according to the invention
showing a
later stage of feeding the fabric through the apparatus;
Figures 4 and 5 show the mounting of the roller blind tube; on driven end
mounting
means according to the invention;
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CA 02426760 2003-04-16
Figures 6 and 7 show the mounting of the roller blind tube on idle end
mounting
means according to the invention;
Figures 8 and 9 show details of the locking means for idle end mounting means
in
respective unlocked and locked positions;
Figure I O shows the attaching of the fabric to the roller blind tube;
Figure 1 Ia is a schematic perspective view of an alternative roller blind
tube and
1o Figure I Ib shows a detail of the attachment of the fabric to the .roller
blind tube of
Figure 11 a;
Figure 12 illustrates in more detail the width cutting of the fabric;
15 Figures I3 and 14 show the operation of the back tensioning means in the
apparatus
according to the invention;
Figure 15 shows the cutting of the trailing end of the fabric;
2o Referring now to the drawings, the apparatus (10) comprises fabric holding
means
(1) to support a body of fabric {3a) such as a roll of .fabric prior to
cutting to form a
blind, a support surface (5) over which the web of fabric (3) passes in use,
drove
means ('~ for moving the web of fabric {3) through the apparatus (I O) and
mounting
means (9a, 9b) for a roller blind tube (l I) onto which tube (I I) the web
offabric (3)
LJ is rolled in order io form the roiier b'cind. r~.s the we'o of fabric (3)
passes through t ie
apparatus (10), one or more width cutting means (13a, 13b) are provided to cut
the
web of fabric (3) to a desired width. Further means (15) are preferably
provided to
cut, or assist in cutting, the leading and/or trailing ends of the fabric (3),
so that the
fabric is cut to a desired length. To ensure that the web of fabric (3) is
aligned in the
so desired orientation in the apparatus, alignment means (I7a, I7b) are
provided.
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CA 02426760 2003-04-16
The web of fabric {3) may initially be folded or may be in the form of a bolt
or roll.
The fabric holding means (1) may take any suitable form, provided that the web
of .
fabric (3) may be fed from said holding means without vzndue restriction. A
simple
fabric holding cradle (1) as illustrated in Figure 1 is normally sufficient. '
From the fabric holding means (1), the web of fabric (3) passes over the
support
surface (5) in which a cutting guide {IS) may be disposed, as will be
described
below. From the support surface (S), the web of fabric (3) passes on to fabric
drive
means (7~ such as, for example, a pair of pinch rollers, v~rhich assist in
moving the
zo web of fabric (3) through the apparatus. The support surface (S) includes
alignment
means (i 7a) to ensure that the web of fabric (3) is correctly aligned in the
apparatus
(10), and that the alignment is maintained as the web of :fabric(3) continues
to pass
through the apparatus (10). The alignment means (17a} preferably comprise a
formation disposed at one side of the support surface (5), which formation
includes a
z5 generally upright planar surface. The web of fabric (3) should pass through
the
apparatus (I0} of the invention in a first direction indicated generally by
arrow A and
the plane of said generally upright planar surface includes at least a first
component
which is disposed exactly parallel to said first direction. Thus, alignment of
the web
of fabric (3) is achieved by ensuring that the side edge of the fabric (3)
maintains a
2o running contact with the generally upright planar surface., Preferably, the
upright
planar surface will be vertical, but some deviation from vertical is
acceptable.
Where, as in the preferred embodiment, the fabric drive paeans (7) comprise
pinch
rollers (7a, 7b (7b not shown)), the rollers (7a, 76) are arranged such that
the
~5 alignment of the web of fabric (s) achieved by th.e alignn~.ent means is
rnaintaincd
and is not disrupted. Specifically the pinch rollers {7a, 7b) are arranged so
that their
axes Iie perpendicular to the first direction A and perpendicular to the plane
of the
planar surface of the alignment means {I?a).
3o In the illustrated embodiment, the web of fabric {3) passes around the
upper pinch
roller (7a) (see Figure 3) and on to the roller blind tube {1:l), around which
it is rolled
by the apparatus (10} of the invention. The roller blind tuhe {l I ) as a
sub5tantialiy
CA 02426760 2003-04-16
rigid tube, preferably of nnetal but possibly of plastic or other suitable
material.
Cardboard tube may be used in some cases. The web of fabric (3) is roiled
around
the tube and, in further manufacturing stages not part' of this invention, the
tube (11)
is provided with suitable fixings such as end caps and brackets to form a
blind which
may be mounted in a window. Tt is also possible that the roller blind tube
(11) may
take the form of a solid rod, such as of wood, but this is less preferred.
The roller blind tube (11) is mounted on the apparatus (10) of the invention
by
suitable mounting means (9a, 9b) at its respective ends. One or both of the
mounting
means (9a, 9b) is driven to cause it to rotate, and thereby to rotate the
roller blind
tube (I I ) when mounted thereon. Preferably, only one of the mounting means
is
driven (hereinafter the "driven end mounting means" (9b)), the other
{hereinafter the
"idle end mounting means" (9a)) being able to rotate freely. Thus, when the
roller
blind tube (11) is mounted on the mounting means {9a; ab), the roller blind
tube
(I 1)is rotatably driven so that, after the leading end of the web of fabric
(3} has been
attached to the roller blind tube (I 1), the fabric may be taken up onto the
roller blind
tube (l I).
The particular form of the mounting means (9a, 9b) may be selected as desired
2o provided that rotational drive is effectively transferred from suitable
drive means
(19) via the mounting means (9b) to the roller blind tube {1 I)and provided
also that
the mounting means {9a, 9b) maintain the roller blind tube (I I) in a correct
alignment. Specifically, the roller blind tube (I I) must be maintained so
that its axis
of rotation {i.e. the longitudinal axis) is parallel to the axes of the pinch
rollers (7a,
7~ ,7b} an_d _m__ore p~rti_E~plarly ~c~ that sgid axis ~~ _rc~t~,~ie~n ~~
~erpendt_Gi~Ia_,r to tl2e first
direction A and to said first component of the plane of the planar surface of
the
alignment means (i 7a). Generally, the mounting means {9b) will be such that
drive
is transferred to the roller. blind tube (1 I) by frictional engagement of the
mounting
means (9b) with the inside surface of the roller blind tube (1 I). It may be
desirable
3o to provide co-operating features on the mounting means (Rb) and the roller
bfind tube
(I i} to assist in the transfer of drive but this is not normally necessary.
Such features
may also be useful in ensuring that the roller blind tube {11) may be mounted
on the
II
CA 02426760 2003-04-16
mounting means (9b) only in one particular rotational orientation. For
example, the
roller blind tube (I 1 ) may be provided with a pxofitvding formation on its
inner
surface which co-operates with a groove in the mounting means (9b) so that the
roller blind tube (I1) may be mounted on the mounting z~neans (9b) only wben
the
protrusion is aligned with the groove.
It is a particular feature of the present invention that the apparatus (10) is
suitable for
manufacturing roller blinds of various widfhs, to accommodate different window
sizes, for example. Usually, it is desired that the width of the web fabric
mounted on
a roller blind tube (1 I) is exactly fhe same as the length of the roller
blind tube, or
only a few millimetres greater or smaller to suit the particular roiled blind
mechanism
being used. Thus, the apparatus (10) of the invention accommodates roller
blind
tubes (1 I) of various lengths by providing :hat one or both of the roller
blind tube
mounting means (9a, 9b) is adjustable in a second direction parallel to the
axis of
rotation of the roller blind tube (1I) (and therefore perpendicular to the
first direction
A and to said first component of the plane of the planar surface of the
alignment
means (17a)). Preferably, the driven end mounting means (9f) is fixed and the
idle
end mounting means (9a) is adjustable. Thus, in order to mo~ertt a roller
blind tube
(1I) on the apparatus of the invention, the position of the idle end mounting
means
(9a) may be adjusted so that, initially, the distance between the respective
mounting
means (9a, 9b) is greater than the length of the particular roller blind tube
(1 I ) to be
used. One end of the roller blind tube (1 I) is then engaged with the driven
end
mounting means (9b) (see Figures 4 and 5) and the position of the idle end
anounting
means (9a) is re-adjusted so that it engages the other end of tl~e roller
blind tube (I 1)
75 (fee Fig~_res ~ an_cj 7), The 1C~~P Pnd r_vko~n-tang means (9a) r__n_ay
then he ~_x_ed pr
locked in position by suitable means (21), such that the roller blind tube
(11) is
retained in its use position by the mounting means (9a, 9b).
Preferably, the idle end mounting means (9a) is disposed on a bra~cl~et (23)
or the like
3o which is slideably mounted on a bar or rail {25). The bar or rail (25) is
arranged to
be parallel to the desired axis of rotation of the roller blind tube (1 I), so
that the
bracket (23) for the idle end mounting means (9a) slides parallel to said
axis. The
Iz
CA 02426760 2003-04-16
means (21} far locking the idle end mounting means (9a} in position may
comprise
means for bringing a component of said bracket (23) into frictional engagement
with
the bar or rail (25). Suitable means (2I) can be seen x~iost clearly in
Figures 8 and 9 ,
in the form of a toggle clamp {22). In Fi~~ 8, the toggle clamp (22) is in its
released position so that the bracket (23) can slide on the rail (25) and in
Figure 9 the
toggle clamp (22) is in its locking position so that the bracket (23) is fixed
with
respect to the rail (25).
In one variation of the invention, the apparatus of the invention is adapted
for the
to simultaneous manufacture of a plurality of roller blind tubes. In this
variation, a first
roller bfind tube (I 1') is mounted on the driven end mounting means {9b) as
described above, The idle end mounting means {9a) is modified (ga')to mount
two
roller blind tubes (11', 11 ") along the same axis of rotation, that is, so
that the two
roller blind tubes are mounted "end to end". Thus, the modified idle end
mounting
15 means {9a'} is adjusted in the same manner as described above with
reference to
means (9a) so that it engages the second end ofthe first roller blind tube
(11'). A
first end of the second roller blind tube (11 ") is then mounted on the other
side of the
modified idle end mounting means (9a'). A further idle end mounting means
{9a")
which is adjustable, preferably in the same manner. as idle end mounting means
(9a),
2o is provided to mount the second end of the second roller blind tube (11 ").
Thus,
rotational drive is transferred from the drive means (I9) to the driven end
mounting
means (9b) which transfers strive to the first roller blind tube (3.1') which
in turn
transfers drive to the modified idle end mounting means. (9a') which transfers
drive
to the second roller blind tube (1 I "). Further additional roller blind tubes
may be
25 added by 't7odify~ng the appa~t,~ t~ iprltrri~ fi,"~i-tiler a"~i~4~;~:''~al
n:~d:.'~'.Sd idle end
InOUntIIlg rneanS.
After having passed around 'the upper pinch roller (7a} inn the embodiment
illustrated,
the leading edge of the web of fabric {3) must be attached to the roller blind
tube (1 I)
3o to allow the fabric {3) to be taken up onto the roller blind tube (1 I}.
This can be
achieved by any suitable means but a preferred embodiment of the present
invention
is particularly convenient. In this embodiment, the outer surface of the
roller blind
13
CA 02426760 2003-04-16
tube is provided with one or more adhesive zones 27 such as one or more pieces
of
double-sided sticky tape. Most preferably, a single stri,~ of such tape is
provided
running generally parallel to the longitudinal axis of the; roller blind tube
(I1) and
extending for substantially the whole Iengtl~ of the roller blind tube (l l).
In this way,
the leading edge of the web of fabric (3) can be placed over the double sided
sticky
tape and firmly attached by means of a gentle pressure applied by, say, an
operator's
hand.
The present invention also provides means 3 or ensuring that the leading edge
of the
iD web of fabric (3), when mounted on the roller blind tube (I1), is cut
straight and true,
that is, that the leading edge is cut parallel to the second direct~~on and
the
longitudinal axis of the roller blind tube (I 1 ) and perpendicular to the
first direction
(A} and to the first component of the plane of the planar surface of the
alignment
means (17a}. The means for ensuring that the leading edge is rut straight and
true
comprise a cutting guide (29) which is in the appropriate aligrunent. In a
preferred
embodiment of the invention, the cutting guide (29) siynply comprises a groove
extending in the outer surface of the roller blind tube (I 1} exactly parallel
to the
longitudinal axis of the ttabe (11). Thus, when the rollen~ blind tube (I l)
is rrgounted
on the mounting means (9a, 9b), cutting the leading edge of the fabric with
the
2o guidance of the groove provides that the leading edge has the desired
alignment as
set out above. The apparatus of the invention may be.provided with integral
cutting
means, but manual cutting of the leading edge of the web of fabric (3) with a
craft
Imife is simple and effective. In use, the means (27) for attaching the
leading edge of
the web of fabric to the roller blind tube (such as the dovuble-sided sticky
tape) i5
7S lBICpI~CPC~ bPl'bt1'id ~~e ryt~»g wide (20) (ryi+~ rvsp°va".t to the
dirv.~. ivit of rotai vu of thi.
roller blind tube (1 I)). The leading edge of the fabric (~~) is applied to
the means for
attaching the fabric (27) with an overlap sufficient to ensure that the
portion ofthe
leading edge in front of the means for attaching the fabric (27) overlies the
cutting
guide (29). After the leading edge has been attached, the fabric; (3) is cut
along the
30 cutting guide (29) and the waste fabric is disposed of.
14
CA 02426760 2003-04-16
An alternative arrangement for attaching the fabric (3) tc~ the roller blind
tube (1 Ia) is
illustrated in Figures 11 a and l 1b. The roller blindtube (1 I a} in these
figures
includes a relatively wide longitudinal slot (31) with opposed retaining lips
(33a,
33b}. A strip (35) of resilient material such as of plastic is held in the
slot (31) by the
lips (33). As can be seen from Figure 1 1b, the leading edge of the fabric (3}
is
retained in the slot (31) around the strip (35) without the use of any
adhesive means.
A particular feature of the apparatus and method according to the present
invention is
that the web of fabric (3) is cut by the apparatus to a desired width
(normally in
1o accordance with the length of a particular roller blind tube (I I)) and
that the resulting
side edges of the fabric are straight and true. That is, the side edges are
exactly
parallel to each other and perpendicular to the leading edge, a$er the leading
edge
has been cut with the aid ofthe cutting guide. The appaa~atus of'the invention
is
provided with one or a plurality of width cutting means (I3a, I3b) (depending
on the
number of blinds being manufactured simultaneously) to cut the side edges of
the
web of fabric (3). At least one of the width cutting rnear~s (23a') is
adjustable to
accommodate different desired widths of the final roller blind. Most
preferably, for
the manufacture of a single blind, two width cutting means are provided, one
of
which (I3a) is fixed and the other of which (13b) is adjustable. For the
simultaneous
2o manufacture of more than one xnller blind, preferably one additional
adjustable width
cutting means (I3a) is provided per additional blind. Both or all the width
cutting -
means (I3} are mounted on the apparatus so .hat their direction of cutting is
exactly
parallel to the first direction and to the plane of the planar surface of the
alignment
means (17) and exactly perpendicular to the second direc~tionyand to the
longitudinal
7S a~ic afthP rpllPr lol~nri f-ybe (11 ). The o.T eaCh ad3',:Stw,1'le ~: ~rith
~;,wl~-t'~r g ~m8.a..T'a (1 32) i~
most preferably moveable in a direction parallel to the second direction and
may be
moveable independently of other components of the apparatus. However, in one
particularly advantageous embodiment, the moveable width cutting means (I3a)
is
mounted in fixed relation to the adjustable roller blind tube mounting means
(9a). In
3o the case of simultaneous manufacture of a plurality of blinds, each
adjustable width
cutting means (13a) is mounted in fixed relation to a corresponding adjustable
roller
blind tube mounting means (~a',9a"}. In a preferred embodiment of the
invention,
IS
CA 02426760 2003-04-16
the adjustable roller blind mounting means (9a, 9a', 9a") and the adjustable
width
cutting means (I3a) are mounted on a respective common brac:~et (23). As
discussed
above in relation to the adjustable roller blind mounting means, the or each
bracket
(23) is slideably mounted on a rail or bar (2S). Any suitable fabric cutting
means
(I3) may, in principle, be used in the present invention, including electric
or
pneumatic rotary scissors, but a particularly preferred cutting means
comprises a
crush cutter in the faxm of a suitable blade or wheel (37;1 having a cutting
edge
bearing on one of the pinch rollers (preferably the upper pinch roller) (see
Figures ~
to 9). The respective cutting means {13) are ideally provided v~rith scrap
fabric
l0 guides (39) (Figure 12) to direct the cut excess fabric array from the web
of fabric
which is to be taken up on the roller blind tube (I1).
Following cutting of the fabric, the web of fabric (3) moat be attached to a
roller
blind tube (1 I) and subsequently rolled up on the tube (I I). It is essential
that the
i5 fabric (3) is mounted on the roller blind tube {~ I ) in exactly the
correct alignment.
That is, the side edges of the fabric (3) must be maintained exactly
perpendicular to
the axis of rotafion of the roller blind tube (I 1). If this is not done, the
edges of the
fabric (3) become gradually offset from their proper location as the fabric is
wound
on to the tube (11). In the prior art method, the alignment of the fabric on
the tube is
20 judged largely by eye and involves aligning the leading edge of the fabric
parallel to
the axis of the roller blind tube. This requires considerable practice and
skill and can
be a significant cause of error since only a small mis-alignment can result in
a
significant off setting of the fabric when wound onto the roller blind tube
(i.e.
"coning" of the fabric). in the present invention the or each adjustable width
cutting
meana {1_3a) is mn int~t_3 ov, r_t,e bracket l~3) .o the line of action along
which it cuts
{and hence the side edge of the fabric (3) when cut) is in alignment with the
edge of
the end of the roller blind tube (1 l, Z I', 11 ") which is mounted on the
idle end
mounting means (9a, 9a'; 9a"), or is spaced a set distance from that end edge,
normally not more than a few millimetres. Where, as is preferred, the driven
end
3o mounting means (9b) is fixed, the corresponding width cutting means (13b)
is also
fixed (non-adjustable). The fixed width cutting means (13b) is mounted on the
apparatus so that the line of action along which it cuts (and hence the side
edge of the
16
CA 02426760 2003-04-16
fabric (3) when cut) is in alignment with the edge of the end of the roller
blind tube
(11) which is mounted on the driven end mounting mead's {9b), or is spaced a
set
distance from that end edge. The significant operational advantage which
derives
from the constructions where the adjustable width cutting means {13a) is in
fixed
relation to the adjustable mounting means (~a, 9a', 9a"), is that the:operator
does not
need to make a separate adjustment of the adjustable width cutting means (13a)
in
order to accommodate roller blind tubes {1 l;~ of different Iengtlas requiring
correspondingly different widths for the fabric web (3). This advantage
applies
equally to the manufacture of a single blind or to the sirrmltaneous
manufacture of
In more than one blind. This means that, for example, it is not necessary for
the
operator to calculate the correct location of the or each moveable width
cutting
means (13a) and adjust it accordingly to achieve a desired width of cut
fabric.
Rather, the simple act of mounting the roller blind tube or tubes (11) on the
roller
blind tube mounting means (~a, 9a', 9a", 9b) automatically sets the moveable
width
t5 cutting means (13a) in the correct location to achieve the. desired width
of fabric (3).
Furthermore, the alignment means (I7), and the fact that the roller blind
tubes) {11)
is {are) mounted in fixed angular relation to the alignment means (17),
provides that
the fabric {3) ~S automatzcally in the correct alignment for mounting on the
roller
blind tubes) {T 1), with no operator adjustment of the coarect alignment being
2o required.
It is advantageous for ensuring accurate cutting of the fabric {3) to provide
a degree
of tension in the fabric (3) and the apparatus of the invention provides the
required
tension automatically by irate~° aliu controlling the drive means
(pinch rollers 7a, °7b)
~5 for the web of fabric and also those {19) for the driven end r_no~,~ti_n_g
means.
particular, the apparatus of the invention provides a required degree of back
tension.
To this end, the apparatus is provided with back tensioning means (41). ~ne
example of a suitable back tensioning means {41) is lmown in the art as a
twitch bar
and is illustrated in Figures 1 ~ and 14. The twitch bar (4l_) comprises a
pair of
3o parallel bars (43; 45) mounted for rotation about an axis parallel to and
located
between the respective bars {43, 45). Preferably the axes of the bars (43, 45)
and the
axis of rotation lie in the same plane. The twitch bar (4I) is preferably
disposed
1'?
CA 02426760 2003-04-16
between the fabric cradle (1) and the support surface (5}. In use, with the
parallel
bars {43, 45) in an approximately horizontal orientation (i.e. with both their
longitudinal axes lying approximately in the same substantially horizontal
plane), the
web of fabric (3) is fed between the bars and on to the support surface (5),
so that the
web of fabric (3) is fed over the support surface (5) in the first direction.
The twitch
bar (4I) is then rotated through an appropriate angle, foal example about
135°,
whereby one of the parallel bars (43) displaces the fabric web {3) rearwardly
(with
respect to the first direction) and the other of the parallel bars (45)
displaces the
fabric web (3) forwardly. The fabric web (3} then follows a convoluted path
around
i0 the parallel bars (43, 45), preferably passing first around the fai-wardly
arranged bar
(45) and passing in a generally rearward direction (with :respect to the first
direction)
and then around the rearwardIy arranged bar (43) so that the fabric (3) then
moves in
generally the first direction. ~n a particularly preferred arrangement, the
back
tensioning means (41) is provided with alignment means {17b) for the fabric
(3).
The alignment means (17b) of the back tensioning means {4I} are disposed in
exact
alignment with the alignment means (17a) of the support surface (S) and again
preferably comprises a planar surface disposed at one side of the back
tensioning
means (4I), the plane of said planar surface including at least a component
which is
disposed exactly parallel to the first direction. In order to guarantee the.
correct
2o alignment of the fabric web (3), the parallel bars (43, 45} of the twitch
bar (41)
should be mounted with their longitudinal axes perpendicular to the first
direction
and to the first component of the plane of the alignment n:~eans (17a)of the
support
surface (5}.
z5 In order to maintain a desired tension in the fabric (3) during cutting and
rolling onto
the roller blind tube (11), and especially in order to maintain a desired
substantially
constant tension, the drive means (19) for the roller blind tube (l l) is
provided with a
slipping clutch (4.'.7). Thus, if for some reason the tension in the web of
fabric (3)
provided from the drive means (I9, 7a, 7b) for the fabric exceeds a certain
desired
30 value, the slipping clutch (47) will begin to slip, so that the tension in
the fabric (3) is
maintained essentially at the desired value. Rolling the fabric onto the
roller blind
18
CA 02426760 2003-04-16
tube (11) at the correct tension is important in preventing coning of the
fabric when
the finally produced blind is in use.
As mentioned above, the support surface is also preferably provided with a
cutting
guide (15). This cutting guide (15} is used to ensure accurate cutting of the
fabric
web (3) to form the trailing edge of the fabric. The cutting guide (15) may
also be
used, as an alternative to the cutting guide (~9) on the roller blind tube, to
ensure
accurate cutting of the fabric web (3) to form the leadin~; edge of the
fabric. In a
preferred and advantageously simple arrangement, the cutting guide (15)
comprises a
to groove formed in the support surface (5). The groove is arranged to be
straight and
exactly parallel to the axis of rotation of the roller blind tube (11), hence
also
perpendicular to the first direction and to the first component of the plane
of the
alignment means (i7a, 176). In this way the trailing edge of the fabric (3)
can be cut
straight and true. Specific trailing end cutting means may be mounted on the
apparatus of the invention to co-operate with the cutting guide, 'but this is
not
necessary. Where the cutting guide (15) is the groove as discussed above, the
fabric
(3) can simply be cut by using a suitable craft knife which is guided by the
groove.
Preferably means are provided to hold the fabric (3) firmly in position while
the
trailing end is being cut. Such means may be a clamping bar (49) aligned
generally
2o parallel to and close to the Brie along which the trailing edge is to be
cut. The
clamping bar (49) may, for example, be pneumatically operated.
The driving means for the roller blind tube mounting means (19) may preferably
be
provided with a brake 51 which is used towards the end of the process of
rolling the
2.'s vJeb Gf i biav (~) viiic'5 the rUllGr b111ad t6lUe (11), ila c3rdC r tU
iFilpravG tSiG 131~lytstl Ul the
trailing end of the fabric, as will be explained further below.
Finally, the apparatus ofthe invention is most preferably equipped with
control
means to automate at least some of the operational steps c~f the apparatus, as
will be
3o indicated further below.
I9
CA 02426760 2003-04-16
The preferred processing steps using the preferred form of apparatus of the
invention
are described below: The sequence of steps indicated in. this description is
the
preferred sequence, but variations in this sequence are not exclxaded.
Firstly, a roller blind tube (I 1) having a length appropriate to the desired
width of the
blind to be produced is selected, and this roller blind tube (11) is mounted
on the
driven end and idle end mounting means (9b, 9a). The roller blind tube (11)
may be
mounted in a desired rotational orientation with regaxd to the position of the
cutting
guide or other suitable feature of the tube, but as the tolerances allowed for
the length
of the manufactured blind are usually generous, especially accurate rotational
orientation of the roller blind tube ( ~ 1 ) is not necessary. The position of
the idle end
mounting means (9a) is adjusted as necessary to accommodate the particular
length
of the roller blind tube (I 1). The idle end mounting means (9a) is then
locked in
position which thereby sets the adjustable cutting means (13a) in its correct
location.
i5 The body of fabric (3a) is placed in the fabric cradle (1) and fed through
the back
tensioning means (twitch bar) (4I) and on to the support surface (5). The edge
of the
web of fabric (3) is aligned with the alignment means (17a) of the support
surface (5)
and with the alignment means (I7b) the twitch bar (41) and the twitch bar
(41)is then
rotated to introduce back tension into the fabric web (3).
The control means is then used to commence operation of the drive means (pinch
rollers (7a, 7b)) and if the facility is provided to move the cutting means
(13a, l~b)
from a disengaged to an engaged position (i.e. where the crush cutters bear
against
the pinch roller (7a)). While checking and maintaining the alignment of the
fabric
(3) with the ali~nmez~t means (1 ,7a, 17b)5 the leadi_n_a edge; of tJhe web of
fab_rjc (3) is
then fed through the pinch rollers (7a, 76) and around the upper pinch roller
(7a),
where it meets the cutting means (I3a, 13b) sa that cutting of the fabric to
the desired
width begins. From the pinch rollers (7a, 7b), the leading edge of the fabric
is guided
manually to the mounted roller blind tube (I I). When a sufficient length of
fabric
3o has been obtained, the control means is used to stop the drive means (7a;
7b) and the
leading end of the fabric (3) is mounted on the roller blind tube (1 I) using
suitable
attachment means (27) - such as double-sided sticky tape - as discussed above.
CA 02426760 2003-04-16
While mounting the fabric web (3) on the roller blind tube, a suitable tension
in the
portion of the fabric between the leading edge and the pinch rollers (7a, 7b)
is
maintained manually_ When the leading end of the fabric web has been mounted
on
the roller blind tube (l l), the leading edge is cut straight and tnae using
the cutting
guide (29) in the roller blind tube (11} and a suitable knife.
After ensuring that the scrap fabric portions produced by the cutting means
are fed
correctly through the scrap fabric guides {39), the control means can be
programmed
with the type and required length (or "drop"} of the blind. 'The control means
then
starts the fabric drive means (7a, 7b) and the drive means (19) for the roller
blind
tube mounting means, so that the fabric web (3) continues to be cut and the
cut fabric
web (3) is taken up onto the roller blind tube (11) in the correct alignment
and with
the required tension. After an interval of time calculated by the control
means in
accordance with the required drop of the blind, for example on the basis of a
r5 ca.Iculated number of rotations of the pinch roller (or alternatively, of
the roller blind
tube), the control means stops the respective drive means {7a, 7b, 19). The
point at
which the drive means (7a, 7b, 19) are stopped is calculated by the control
means so
that the cutting guide (IS) in the support surface (5} corresponds to the line
along
which the fabric web (3) should be cut to form the trailing edge.
?5
Either at the instigation of the operator or of the control means, the
clamging means
(49) is moved to its clamping position and the fabric web (3) is cut by the
operator
along the cutting groove (IS) in the support surface {5}. The clamping means
(49) is
then moved from its clamping position.
The control means (if necessary as a result of an instruction input by the
operator)
then re-starts the drive means (7a, 7b, l9) so that most of the remainder of
the fabric
web (3) is taken up onto the roller blind tube. Towards the end of the
process, the
control means causes application of the brake for a short duration (which may
be as
little as one revolutions of the roller blind tube (1 I). From this point
onwards, it is
preferred that the operator applies a light pressure to the fabric wound on
the roller
blind tube (11), in order to maintain the tension of the fabric. ~'y applying
the brake,
z1
CA 02426760 2003-04-16
the tension in the fabric (3) at the point at which the cutting means are
cutting the
fabric is released or lessened. The point of application c~f the brake is
selected to
correspond with the time at which the trailing end of the fabric is passing
the cutting
means (13a, 13b). In this way, the fabric (3) towards the trailing end is cut
straight
and true {i.e. parallel to the first direction) and the problem of splaying of
the end of
the fabric is avoided. When all of the fabric has been rolled onto the roller
blind
tube, the trailing end can be secured with a piece of sticl~:y tape in order
to maintain
the tension of the fabric. The roller blind can now be ~usbed on the table if
desired
or the roller blind tube carrying the fabric can then be dismounted and sent
for
1o packing or such final finishing stages as might be required.
Where the apparatus of the invention is modified to manufacture more than one
blind
simultaneously, the first roller blind tube (11') is mounted as described
above. When
the first modified idle end mounting means (9a') has been set in position the
second
roller blind tube {11 ") is mounted on the second side of the first modified
idle end
mounting means (9a'). A second modified idle end mounting means (9a") is then
adjusted to a position for mounting the second end of the; second roller blind
tube
(11 "). alternatively, if the apparatus is constr~zcted to accommodate more
than two
roller blind tubes, further modified idle end mounting means (9a") and roller
blind
2o tubes (I 1 ") are added to mount the respective ends of the roller blind
tubes, ending
with the second modified idle end mounting means (9a") at the second end of
the
final roller blind tube.
~2
