Note: Descriptions are shown in the official language in which they were submitted.
CA 02799854 2012-12-21
DRAPERY SUPPORT ASSEMBLY AND METHOD OF MAKING
SAME
CROSS-REFERENCE TO RELATED APPLICATION
BACKGROUND
[0001] 1. Field.
[0002] Example embodiments in general relate to a drapery support assembly
and method
of making same for hanging draperies on wall surfaces for covering windows and
the like.
[0003] 2. Related Art.
[0004] Various temporary coverings for a window or the like have been
developed,
including an elongated paper-like sheet having equidistant parallel pleats
defined by creases
extending across the sheet. An adhesive fastening strip is located at the top
end along the
entire horizontal length of the sheet for fastening the sheet to a window,
window frame, or the
like. When mounted to a window or window frame, the temporary window covering
extends
downwardly to a selective variable length, while maintaining a pleated
appearance.
[0005] However, support assemblies such as head rails for these temporary
window
coverings, which are typically made out of a lightweight paper product have
not heretofore
been developed for heavier woven material draperies, valances and shears. A
window
treatment with fine quality material fashioned into a drape, sheer or valance
with associated
support hardware can cost in excess of several hundred to over $1,000.00 per
window,
depending on the size, scope and quality of the treatment. Accordingly, a
drapery support
assembly that can accommodate finer woven materials which can be installed
quickly and
efficiently by the end user, at a substantially reduced cost, has not
heretofore been developed.
SUMMARY
[0006] An example embodiment is directed to a drapery support assembly. The
assembly
includes a head rail, a pair of end caps removably attached at ends of the
head rail, an
adhesive strip on one lengthwise surface, and a channel slide holder on the
head rail body on a
lengthwise surface opposite the adhesive strip. The channel slide holder
includes a channel
retaining a plurality of channel slides laterally movable therein and
configured to be attached
to drapery hooks for supporting a drapery thereon.
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[0007] Another example embodiment is directed to a drapery support assembly
having a
head rail including a backing with an upper flange, lower flange and a channel
slide holder.
The backing, flanges and channel slide holder are integrally formed as the
body of the head
rail. The assembly includes a channel formed lengthwise within the channel
slide holder of
the body, and a plurality of channel slides laterally movable within the
channel, the channel
slides configured to be attached to drapery hooks for supporting a drapery
thereon.
[0008] Another example embodiment is directed to a method of fabricating a
drapery
support assembly for hanging a drapery on a wall surface. In the method, a
product design is
created in software for a mold to fabricate a head rail, the created product
design including a
head rail having a backing with an upper flange, lower flange and a channel
slide holder, the
backing, flanges and channel slide holder integrally formed as the body of the
head rail, with
a channel formed lengthwise within the channel slide holder of the body. The
method further
includes forming a mold for the head rail based on the created product design,
forcing plastic
materials through mold via a hot extrusion process to form a tubular head rail
that is cooled
and cut to size, and forming a pair of end caps and a plurality of channel
sides configured to
be attached to drapery hooks for supporting a drapery thereon by injection
molding. The
plurality of channel slides are into the channel of a cooled and cut head
rail, and the end caps
are attached to the head rail.
[0009] Another example embodiment is directed to a method of fabricating a
head rail for
hanging a drapery on a wall surface. In the method, a product design is
created in software
for a mold to fabricate a head rail, the created product design including a
head rail having a
backing with an upper flange, lower flange and a channel slide holder, the
backing, flanges
and channel slide holder integrally formed as the body of the head rail, with
a channel formed
lengthwise within the channel slide holder of the body. The method further
includes forming
a mold for the head rail based on the created product design, and forcing
plastic materials
through mold via a hot extrusion process to form a tubular head rail that is
cooled and cut to
size.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Example embodiments will become more fully understood from the
detailed
description given herein below and the accompanying drawing, wherein like
elements are
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represented by like reference numerals, which are given by way of illustration
only and thus
are not limitative of the example embodiments herein.
[0011] FIG. 1 is a plan view of a drapery support assembly according to an
example
embodiment.
[0012] FIG. 2 is a front view of the drapery support assembly of FIG. 1.
[0013] FIG. 3 is an enlarged, close up view of part of the head rail
structure to show a
splicer for connecting two support assemblies.
[0014] FIG. 4 is an enlarged, close up view showing a junction area where
two ends of
support assemblies are connected by a splicer, so as to see further detail of
the channel slides,
according to an example embodiment.
[0015] FIG. 5 is an end-on view the head rail to show structural details
thereof in more
detail.
[0016] FIG. 6 is a perspective end-on view of one side of the end cap to
head rail
connection to show structural details thereof in more detail.
[0017] FIG. 7 is an end-on view of the end cap to show a Velcro patch for
attachment to a
drapery.
[0018] FIG. 8 is an enlarged, close up rear view showing part of the
backing of the
assembly to see an adhesive strip embodiment.
[0019] FIG. 9 is a partial front view of a drapery attached onto the
assembly mounted on a
wall surface.
[0020] FIG. 10 is a close-up partial view of the drapery installed on the
mounted assembly
to illustrate hook to channel guide and Velcro connective engagements in more
detail.
[0021] FIG. 11 shows a drapery fully installed on the drapery support
assembly, as
mounted on the wall surface.
[0022] FIG. 12 is a flowchart illustrating a method of fabricating a
drapery support
assembly for supporting a drapery thereon.
[0023] FIG. 13 is a flowchart illustrating functions of creating a product
design in
software for molds in more detail.
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DETAILED DESCRIPTION
100241 FIG. 1 is a plan view of a drapery support assembly according to an
example
embodiment; FIG. 2 is a front view of the drapery support assembly of FIG. 1;
FIG. 3 is an
enlarged, close up view of part of the head rail structure to show a splicer
for connecting two
support assemblies; and FIG. 4 is an enlarged, close up view showing a
junction area where
two ends of support assemblies are connected by a splicer, so as to see
further detail of the
channel slides, according to an example embodiment.
[0025] Referring to FIGS. 1-4, there is shown a drapery support assembly
100 ("assembly
100") for a window, opening, wall, door and the like. Assembly 100 includes a
head rail 110
with a backing 111 that includes an adhesive strip 115 (not shown) attached to
a rear side
thereof for attachment to a wall surface 200. The adhesive may be a bonding
strip agent made
by 3MS, for example, which adheres to almost any painted surface.
[0026] The backing 11 includes a pair of flanges 117A and 117B. In an
example, each
flange 117A, 117B extends about 1/2" above and below a channel slide holder
113, and is
designed to lay flush against the wall surface. The flanges 117A, 117B are
integral with
backing 111, and may include one or more holes therein (not shown), for
optional fasteners, if
the wall surface is uneven, if additional holding power is desired, and/or if
the wall surface is
of a material that does not easily accept adhesive strip 115. The head rail
110 includes the
channel slide holder 113 integral therewith, the channel slide holder 113
having a lengthwise
channel 114 in which is retained a plurality of slidable channel slides 120.
The channel slides
120 are adapted to receive hooks 301 (not shown) from a drapery (not shown).
[0027] Each head rail 110 includes a pair of end caps 118, each end cap 118
including an
adhesive patch 119 on an outer surface thereof One or more splicers 130 may be
provided to
connect one or more head rails 110 together, depending on the length of the
assembly 100
desired or width of the window space to cover. In one example, assemblies 100
may be
employed in 24", 36", 48", 60" and/or 72" wide embodiments. Thus for areas
requiring
greater-width coverage, it may require utilizing two or more assemblies 100 in
adjacent
relation; hence the use of one or more splicers 130.
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[0028] FIG. 5 is an end-on view the head rail to show structural details
thereof in more
detail; FIG. 6 is a perspective end-on view of one side of the end cap to head
rail connection
to show structural details thereof in more detail; FIG. 7 is an end-on view of
the end cap to
show a Velcro patch for attachment to a drapery.
[0029] Referring primarily to FIGS. 3-7, the head rail 110 is formed as a
single-molded
piece and includes a body designed to distribute the weight of a drapery there
across, and a
channel slide holder 113 that extends along the length of the body. Formed
lengthwise
support ribs 112 connect the body and backing 111 with flanges 117A, 117B to
inward
curving retaining lips 116 of the channel slide holder 113.
[0030] The channel slide holder 113 includes a lengthwise channel 114 along
which the
channel slides 120 may laterally move or slide. The channel slide holder 113
has the pair of
opposed facing, inward curving retaining lips 116 which extend the length of
the head rail 110
that constrain the channel slides 120 within channel 114. This is best shown
in FIG. 5. FIG. 5
also shows one example of the adhesive strip 115 on the surface of backing 111
opposite that
of the channel slide holder 113. The end cap 118 provided at either end of
head rail 110 as
shown in FIG. 6 has a mirror image structure, but is dimensioned with
tolerances so as to
friction fit within the end of head rail 110. The other end of end cap 118 is
a planar surface
that is affixed with an adhesive patch 119, such as Velcro. This is provided
to mate with an
opposing patch provided on an inside upper corner surface of a drapery,
valance or sheer to
obscure the head rail 110 once the drapery is wall mounted thereon.
[0031] As also shown in FIG. 4, each channel slide 120 is retained within
the channel 114
via the retaining lips 116, but can slidably move along channel 114 within the
channel slide
holder 113 of head rail 110. The channel slide 120 includes a lower planar
base 121 and an
upstanding tab 122 perpendicular to the base 121 so that when the head rail
110 is mounted on
a wall surface 200, the tab 122 protrudes outward from the wall 200. Each tab
122 includes
an aperture 123 for receiving a corresponding hook 301 affixed along the top
seam of a
drapery, sheer, valance, etc in spaced relation.
[0032] As best shown in FIGS. 3 and 4, to extend the overall length of the
assembly 100,
two or more head rails 110 can be attached using the splicer 130. The splicer
130 is
CA 02799854 2012-12-21
dimensioned so as to friction fit between facing ends of two head rails 110,
so that there is a
seamless mating between channel slide holders 113 and the adjacent channels
114 thereof
[0033]
FIG. 8 is an enlarged, close up rear view showing part of the backing of the
assembly to see an adhesive strip embodiment; FIG. 9 is a partial front view
of a drapery
attached onto the assembly mounted on a wall surface; FIG. 10 is a close-up
partial view of
the drapery installed on the mounted assembly to illustrate hook to channel
guide and Velcro
connective engagements in more detail; and FIG. 11 shows a drapery fully
installed on the
drapery support assembly, as mounted on the wall surface.
[0034]
FIG. 8 shows another variant of adhesive strips, with strips 115A, 115B
arranged
on rear surfaces of flanges 117A, 117B of backing 11. Referring to FIGS. 9-11,
for
installation, the user first ensures that the number of channel slides 120
matches the number
of hooks 301 on the drapery, valance, sheer, etc. to be mounted. In an
example, the assembly
100 could be packaged with an accompanying stylistic, patterned or material
drapery, sheer,
valance, etc, so this step may not be necessary. In the event that greater or
fewer channel
slides 120 need to added/removed, one end cap 118 is removed from the end of
head rail 110,
the slides 120 inserted into the channel with the base 121 aligned between the
lips 116, and
then the end cap 118 is replaced.
[0035] The
assembly 100 is then mounted as desired with any necessary leveling on a
wall surface 200, as shown in FIG. 9. The drapery 300 may then be attached by
inserting the
hooks 301 through corresponding apertures 123 in tabs 122, as best shown in
FIG. 10. The
end corner flaps of the drapery may be affixed with adhesive patches 302 so as
to mate with
patches 119 on end caps 118. This will obscure the head rail 110, as shown in
FIG. 11. In an
alternative embodiment, a finial or other decorative trim could be placed over
head rail 110 to
provide a more decorative looking treatment.
[0036]
FIG. 12 is a flowchart illustrating a method 400 of fabricating a drapery
support
assembly for supporting a drapery thereon. The method 400 includes creating a
product
design (S410) in software for a mold to fabricate the head rail 110. As known,
any CAD
software design may be used to create the product design from which the mold
is to be
formed. One example is SOLIDWORKS . Creating the product design involves
developing
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a number of specific design features in software from which machining centers
create the
mold.
[0037] FIG. 13 is a flowchart illustrating functions of creating a product
design in
software for molds in more detail. Creating the product design at S410 for the
drapery
support assembly includes the following. Design of these product design
features may be
done by the designer in no particular order, in software, to include: forming
a tubular body
portion (S411), forming a backing with upper and lower flanges (S412) having a
width
extending the length of the tubular body portion, forming the tubular body
portion further
comprising forming ribs (S413) extending outward from the backing and forming
opposed
facing sides (S414) from the ribs which extend the length of the tubular
portion and which
curve inward at an upper end as retaining lips, the ribs and lips creating a
lengthwise channel
along the body portion.
[0038] Creating the product design at S410 further includes forming a
plurality of channel
slides (S415) slidable in the channel for receiving corresponding hooks of a
drapery thereon.
Forming each channel slide at S415 further includes forming a planar base
(S416) slidable in
the channel, forming a tab (S417) extending perpendicular from the base, and
forming an
aperture (S418) in the tab to receive a hook on a drapery. The channel slide
120, end caps
118 and splicer may be injection molded parts.
[0039] Referring again to FIG. 12, method 400 includes forming a mold for
the head rail
110 (S420) based on the created product design. This is done by at hot
extrusion process.
The formed extrusion mold is attached to a hot extrusion machine (S430). A
plurality of
small ABS pellets are loaded into a metal holder, heated to high temperature
to deform and
melt as the molten plastic material is forced continuously through the
extrusion mold (S440)
made for the head rail 110 with integral backing 111. The head rail 110 takes
shape is and is
slowly cooled and straightened as it continues down the production line. It is
then cut at
desired lengths (S450). At this point, the head rail 110 manufacturing process
is complete.
[0040] Accordingly, the head rail 110, splicer 118, channel slides 120, and
splicer 130
may be composed of a hard plastic such as TPE, ABS or other synthetic material
such as a
talc-filled polypropylene, for example. The parts of assembly 100 have been
described as
being formed hot extrusion and/or an injection molded process. Example
processes may
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include over-molding, insert molding, co-injection molding, etc. The forming
process herein
is not limited to extrusion or injection molding as other manufacturing
methods known to one
having ordinary skill in the art, such as a compression process may be used to
form assembly
100.
[0041] Once the head rail 110 with integral backing 111 has been formed by
hot
extrusion, and the end caps 118 and channel slides 120 by injection molding,
the process is
completed (assembly 100 is assembled) by inserting the plurality of channel
slides 120 into
the channel 114 (S460) of the formed head rail 110, and then attaching the end
caps 118 to the
head rail 110 (S470) to form the assembly 100 shown in FIGS. 1-11. Thereafter,
the
adhesive strips 115 such as shown in FIG. 8 may be applied (S480) to the rear
surface of the
backing 111 (along the top and bottom rear edges of flanges 117A/B), and the
Velcro patches
119 may be applied to the surface of end caps 118 (S490) as shown best in FIG.
7. The full
assembly 100 is complete.
[00421 The example embodiments being thus described, it will be obvious
that the same
may be varied in many ways. Such variations are not to be regarded as
departure from the
example embodiments, and all such modifications as would be obvious to one
skilled in the
art are intended to be included in the following claims.
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