Note: Descriptions are shown in the official language in which they were submitted.
1
COVERING FOR AN ARCHITECTURAL OPENING HAVING NESTED ROLLERS
FIELD
The present disclosure relates generally to coverings for architectural
openings, and more
particularly to apparatus and methods for operating a covering for an
architectural opening having nested
rollers.
BACKGROUND
Coverings for architectural openings, such as windows, doors, archways, and
the like, have taken
numerous forms for many years. Some coverings include a retractable shade that
is movable between an
extended position and a retracted position. In the extended position, the
shade of the covering may be
positioned across the opening. In the retracted position, the shade of the
covering may be positioned
adjacent one or more sides of the opening.
Some coverings, when in the fully extended position, transmit light through
the material from
which the covering is constructed. In some instances, even when the covering
has operable vanes that open
and close to control the amount of light passing through the covering, a
greater amount of darkening is
desired. Additionally, or alternatively, in some instances a user may desire a
different pattern or appearance
of the covering when in the fully extended position. Typically, these goals
are accomplished by having a
separate roller positioned behind the primary roller for separate actuation by
the user. These separate rollers
for the supplemental function or appearance increase the size of the head
rail, and may
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require the use of a second set of control cords and operating mechanisms,
thus increasing
size and weight of the covering structure.
SUMMARY
Examples of the disclosure may include a covering for an architectural opening
having nested rollers. In some examples, the covering may include a rotatable
outer roller
defining an elongated slot extending along a length of the outer roller and
opening to an
interior of the outer roller, a rotatable inner roller received within the
outer roller and defining
a central longitudinal axis, a first shade secured to the outer roller, the
first shade retractable
onto and extendable from the outer roller, and a second shade secured to the
inner roller, with
the second shade extending through the elongated slot and retractable onto and
extendable
from the inner roller. The elongated slot may be substantially horizontally
aligned with the
central longitudinal axis of the inner roller when the first shade is in a
fully extended position.
In some examples, the inner and outer rollers are concentric about the central
longitudinal axis of the inner roller. In some examples, the first and second
shades have the
same width. In some examples, the width of the first shade extends along the
entire length of
the outer roller, and the width of the second shade extends along the entire
length of the inner
roller. In some examples, the slot is oriented orthogonally to a direction of
extension of the
first shade.
In some examples, the covering includes a bottom rail secured to the second
shade
and engaging the outer roller when the second shade is in a fully retracted
position. In some
examples, the outer roller defines a longitudinal seat formed along the slot,
and the bottom
rail is received in the seat when the second shade is in the fully retracted
position. In some
examples, the covering includes a mounting system supporting the inner and
outer rollers for
rotative movement about the central longitudinal axis of the inner roller. In
some examples,
the covering includes an operating mechanism for selectively rotating the
inner roller.
In some examples, the outer roller includes a first shell and a second shell
each having
a longitudinally-extending terminal edge, and the edges of the first and
second shells are
peripherally spaced apart from one another to define the elongated slot. In
some examples,
the covering includes a first bushing locked into one end of the first and
second shells, and a
second bushing locked into an opposing end of the first and second shells;
wherein the first
and second bushings maintain a constant width of the slot.
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In some examples, the covering includes a lock mechanism movable between a
first
position restricting the rotation of the outer roller and a second position
peimitting rotation of
the outer roller. In some examples, the lock mechanism moves from the first
position to the
second position upon engagement of the bottom rail with the lock mechanism. In
some
examples, the outer roller defines an elongated groove formed in the sidewall,
the lock
mechanism includes a bearing, and in the first position of the lock mechanism,
the bearing is
received in the groove. In some examples, the lock mechanism includes a pin,
and the lock
mechanism is actuated upon engagement of the pin by the bottom rail to remove
the bearing
from the groove. In some examples, the bearing movably engages the outer
surface of the
outer roller in the second position.
In some examples, the lock mechanism includes a locking member that pivots
between the first and second positions. In some examples, the lock mechanism
includes a
locking member that axially translates between the first and second positions.
In some
examples, the lock mechanism includes a rotatable shaft positioned external to
the outer roller
and oriented substantially parallel to the central longitudinal axis of the
inner roller. In some
examples, the covering includes an end cap, the inner and outer rollers are
rotatably coupled
to the end cap, the lock mechanism includes a housing cantilevered from the
end cap, and the
rotatable shaft is journaled to the housing. In some examples, the lock
mechanism includes a
gear mechanism that couples rotation of the rotatable shaft and the outer
roller.
In some examples, the covering may include a rotatable outer roller defining
an
elongated slot, a first shade secured to and wrappable around the outer
roller, a lock
mechanism positioned external to the outer roller and at least partially
defining a bottom stop
for the first shade, a rotatable inner roller received within the outer
roller, a second shade
secured to and wrappable around the inner roller, the second shade extendable
and retractable
through the elongated slot, and a non-rotatable shaft extending within the
inner roller and at
least partially defining a bottom stop for the second shade.
In some examples, the lock mechanism includes a rotatable shaft positioned
external
to the outer roller, and a locking member that axially translates along the
rotatable shaft. In
some examples, the lock mechanism includes a pivotable locking member
positioned external
to the outer roller.
Examples of the disclosure may include a method of operating a covering for an
architectural opening. In some examples, the method includes unwrapping a
first shade from
a periphery of an outer roller, upon the first shade reaching a fully extended
position,
unwrapping a second shade from a periphery of an inner roller positioned
within the outer
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roller, wherein unwrapping the second shade comprises extending the second
shade through
an elongated slot formed in the outer roller and positioned in substantial
horizontal alignment
with a central longitudinal axis of the inner roller.
In some examples, the method includes pivoting a locking member into locking
engagement with the outer roller to lock rotation of the outer roller,
rotating the inner roller
relative to the outer roller to retract the second shade onto the inner roller
through the
elongated slot formed in the outer roller, pivoting the locking member out of
locking
engagement with the outer roller at a fully retracted position of the inner
roller to allow the
outer roller to rotate, and rotating the outer roller by driving the inner
roller to retract the first
shade onto the outer roller.
In some examples, the method includes during extension of the first shade,
axially
traversing a locking member external to the periphery of the outer roller,
restricting rotation
of the outer roller with the locking member upon the first shade reaching the
fully extended
position, during extension of the second shade, axially traversing a nut
positioned within the
inner roller, and restricting rotation of the inner roller with the nut upon
the second shade
reaching a fully extended position.
The disclosure is given to aid understanding, and one of skill in the art will
understand
that each of the various aspects and features of the disclosure may
advantageously be used
separately in some instances, or in combination with other aspects and
features of the
disclosure in other instances. Accordingly, while the disclosure is presented
in terms of
examples, it should be appreciated that individual aspects of any example can
be claimed
separately or in combination with aspects and features of that example or any
other example.
The present disclosure is set forth in various levels of detail in this
application and no
limitation as to the scope of the claimed subject matter is intended by either
the inclusion or
non-inclusion of elements, components, or the like in this summary. In certain
instances,
details that are not necessary for an understanding of the disclosure or that
render other
details difficult to perceive may have been omitted. It should be understood
that the claimed
subject matter is not necessarily limited to the particular examples or
arrangements illustrated
herein.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated into and constitute a part
of the
specification, illustrate examples of the disclosure and, together with the
general description
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given above and the detailed description given below, serve to explain the
principles of these
examples.
FIG. 1 is an isometric view of a covering with first and second shades in
fully-
retracted positions in accordance with some examples of the present
disclosure.
5 FIG. 2 is an
isometric view of the covering of FIG. 1 with a first shade in a partially-
extended position and a second shade in a fully-retracted position in
accordance with some
examples of the present disclosure.
FIG. 3 is an isometric view of the covering of FIG. 1 with a first shade in a
fully-
extended position and a second shade in a fully-retracted position in
accordance with some
examples of the present disclosure.
FIG. 4 is an isometric view of the covering of FIG. 1 with a first shade in a
fully-
extended position and a second shade in a partially-extended position in
accordance with
some examples of the present disclosure.
FIG. 5 is an isometric view of the covering of FIG. 1 with first and second
shades in
fully-extended positions in accordance with some examples of the present
disclosure.
FIG. 6 is an isometric, partially-exploded view of head rail components of a
covering
in accordance with some examples of the present disclosure. The head rail
cover and the first
and second shades are not shown for clarity.
FIG. 7 is a lengthwise cross-sectional view of a covering taken along line 7-7
of FIG.
1 with the head rail components of FIG. 6 in accordance with some examples of
the present
disclosure.
FIG. 8 is a transverse cross-sectional view of a covering taken along line 8-8
of FIG. 2
with the head rail components of FIG. 6 in accordance with sonic examples of
the present
disclosure.
FIG. 9 is a transverse cross-sectional view of a covering taken along line 9-9
of FIG. 3
with the head rail components of FIG. 6 in accordance with some examples of
the present
disclosure.
FIG. 10 is a transverse cross-sectional view of a covering taken along line 10-
10 of
FIG. 4 with the head rail components of FIG. 6 in accordance with some
examples of the
present disclosure.
FIG. 11 is a transverse cross-sectional view of a covering taken along line 11-
11 of
FIG. 5 with the head rail components of FIG. 6 in accordance with some
examples of the
present disclosure.
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FIG. 12 is an isometric view of head rail components of a covering in
accordance with
some examples of the present disclosure. The head rail cover is not shown for
clarity.
FIG. 13 is an isometric, partially-exploded view of the head rail components
of FIG.
12 in accordance with some examples of the present disclosure.
FIG. 14 is a transverse cross-sectional view of the head rail components of
FIG. 12
taken along line 14-14 of FIG. 12 in accordance with some examples of the
present
disclosure.
FIG. 15 is a side elevation view of some of the head rail components of FIG.
12
depicting three intermeshed gears rotatably supported on an end cap of a
covering in
accordance with some examples of the present disclosure.
FIG. 16 is an isometric view of a lock mechanism of the head rail components
of FIG.
12 in accordance with some examples of the present disclosure.
FIG. 17 is a side elevation view of the lock mechanism of FIG. 16 in
accordance with
some examples of the present disclosure.
FIG. 18 is another isometric view of the lock mechanism of FIG. 16 in
accordance
with some examples of the present disclosure.
FIG. 19 is a side elevation view of a dual roller unit attached to the lock
mechanism of
FIG. 16 in accordance with some examples of the present disclosure.
FIG. 20 is a detail view of a locking interface between first and second
shells of an
outer roller of the dual roller unit of FIG. 19 in accordance with some
examples of the present
disclosure.
FIG. 21 is a front elevation view of a housing of the lock mechanism of FIG.
16 in
accordance with some examples of the present disclosure.
FIG. 22 is a side elevation view of the housing of FIG. 21 in accordance with
some
examples of the present disclosure.
FIG. 23 is a shaft of the lock mechanism of FIG. 16 in accordance with some
examples of the present disclosure.
FIG. 24 is an isometric view of a nut of the lock mechanism of FIG. 16 in
accordance
with some examples of the present disclosure.
FIG. 25 is another isometric view of the nut of FIG. 24 in accordance with
some
examples of the present disclosure.
FIG. 26 is a front elevation view of the shaft of FIG. 23 rotatably supported
in the
housing of FIG. 21 and the nut of FIG. 24 threadedly mounted onto the shaft,
with the
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housing and nut shown in lengthwise cross-section, in accordance with some
examples of the
present disclosure.
FIG. 27 is a transverse cross-sectional view of the housing, the nut, and the
shaft of
FIG. 26 taken along line 27-27 of FIG. 26 in accordance with some examples of
the present
disclosure.
FIG. 28 is an isometric, partially-exploded view of head rail components of a
covering in accordance with some examples of the present disclosure. The head
rail cover
and the second shade are not shown for clarity.
FIG. 29 is another isometric, partially-exploded view of the head rail
components of
FIG. 28 in accordance with some examples of the present disclosure.
FIG. 30 is a transverse cross-sectional view of a covering taken along line 30-
30 of
FIG. 5 with the head rail components of FIG. 28 in accordance with some
examples of the
present disclosure.
FIG. 31 is a transverse cross-sectional view of a covering taken along line 31-
31 of
FIG. 3 with the head rail components of FIG. 28 in accordance with some
examples of the
present disclosure.
FIG. 32 is a transverse cross-sectional view of the covering of FIG. 31 with a
bottom
rail seated against the outer roller and a lock mechanism unseated from the
outer roller in
accordance with some examples of the present disclosure.
FIG. 33 is a transverse cross-sectional view of the covering of FIG. 32 with
the outer
roller rotated counterclockwise relative to the position of the outer roller
in FIG. 32 in
accordance with some examples of the present disclosure.
FIG. 34 is a transverse cross-sectional view of a covering taken along line 34-
34 of
FIG. 4 with the head rail components of FIG. 28 in accordance with some
examples of the
present disclosure.
FIG. 35 is a transverse cross-sectional view of the covering of FIG. 31 with
the inner
roller and second shade removed for clarity in accordance with some examples
of the present
disclosure.
FIG. 36 is a transverse cross-sectional view of the covering of FIG. 32 with
the inner
roller and second shade removed for clarity in accordance with some examples
of the present
disclosure.
FIG. 37 is a transverse cross-sectional view of the covering of FIG. 33 with
the inner
roller and second shade removed for clarity in accordance with some examples
of the present
disclosure.
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FIG. 38 is an isometric view of a lock mechanism of the head rail components
of FIG.
28 in accordance with some examples of the present disclosure.
FIG. 39 is another isometric view of the lock mechanism of FIG. 38 in
accordance
with some examples of the present disclosure.
FIG. 40 is an isometric view of a bracket of the head rail components of FIG.
28 in
accordance with some examples of the present disclosure.
FIG. 41 is an isometric view of the lock mechanism of FIG. 38 rotatably
mounted
onto the bracket of FIG. 40 in accordance with some examples of the present
disclosure.
FIG. 42 is a fragmentary isometric view of some of the head rail components of
FIG.
28 and depicts the interface of the lock mechanism of FIG. 38 with a bottom
rail of the
covering in accordance with some examples of the present disclosure.
FIG. 43 is a fragmentary isometric view of some of the head rail components of
FIG.
28 and depicts the interface of the lock mechanism of FIG. 38 with a bottom
rail of the
covering in accordance with some examples of the present disclosure.
FIG. 44 is a fragmentary view of an end of the bottom rail of FIGS. 42 and 43
in
accordance with some examples of the present disclosure.
FIG. 45 is an isometric view of an actuator rim of the bottom rail of FIG. 44
in
accordance with some examples of the present disclosure.
FIG. 46 is a lengthwise cross-sectional view of one end of a covering taken
along line
7-7 of FIG. 1 with the head rail components of FIG. 28 in accordance with some
examples of
the present disclosure.
FIG. 47 is a lengthwise cross-sectional view of another end of a covering
taken along
line 7-7 of FIG. 1 with the head rail components of FIG. 28 in accordance with
some
examples of the present disclosure.
DETAILED DESCRIPTION
The present disclosure provides a covering for an architectural opening. In
general,
the covering may include a first shade and a second shade both suspended from
the same
head rail by a pair of nested rollers ft:inning a dual roller unit. The first
shade (front shade in
this configuration) is engaged with an outer roller for retraction onto and
extension therefrom
by wrapping around and unwrapping from the outer roller as actuated by a user.
The second
shade (rear shade in this configuration) is engaged with an inner roller,
which is positioned
inside the outer roller, for retraction onto and extension therefrom by
wrapping around and
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unwrapping from the inner roller as actuated by the user. The inner roller may
be positioned
inside the outer roller and collectively the inner and outer rollers may form
a roller unit, as
further described below. The second shade may be extended and retracted as
directed by the
user when the first shade is in the fully extended position. The operating
unit that causes the
rollers to rotate as directed by the user may be operated by, for example, a
motor or a single
control cord. The operating unit may engage and control the rotation of the
inner roller,
which in turn may control the rotation of the outer tube.
Referring to FIGS. 1-5, a retractable covering 10 for an architectural opening
is
provided. The retractable covering 10 may include a head rail 14, a first
bottom rail 18, a
second bottom rail 20, a first shade 22, and a second shade 24. The first
shade 22 may extend
between the head rail 14 and the first bottom rail 18. The second shade 24 may
extend
between the head rail 14 and the second bottom rail 20. The head rail 14 may
include two
opposing end caps 26a, 26b, which may enclose the ends of the head rail 14 to
provide a
finished appearance. The first bottom rail 18 may extend horizontally along a
lower edge of
the first shade 22 and may function as a ballast to maintain the first shade
22 in a taut
condition. The second bottom rail 20 may extend horizontally along a lower
edge of the
second shade 24 and may function as a ballast to maintain the second shade 24
in a taut
condition.
The first shade 22 may include vertically suspended front 30 and rear 34
sheets of
flexible material (such as sheer fabric) and a plurality of horizontally-
extending, vertically-
spaced flexible vanes 38. Each of the vanes 38 may be secured along horizontal
lines of
attachment with a front edge attached to the front sheet 30 and a rear edge
attached to the rear
sheet 34. The sheets 30, 34 and vanes 38 may form a plurality of
elongated,vertically-
aligned, longitudinally-extending cells, which collectively may be referred to
as a cellular
panel. The sheets 30, 34 and/or the vanes 38 may be constructed of continuous
lengths of
material or may be constructed of strips of material attached or joined
together in an edge-to-
edge, overlapping, or other suitable relationship. The second shade 24 may be
a single panel
and may be constructed of strips of material attached or joined together in an
edge-to-edge,
overlapping, or other suitable relationship.
The first and second shades 22, 24 may be constructed of substantially any
type of
material. For example, the shades 22, 24 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. The shades
22, 24 may have
any suitable level of light transmissivity. For example, the first and second
shades 22, 24
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may be constructed of transparent, translucent, and/or opaque materials to
provide a desired
ambience or decor in an associated room. In some examples, the first shade 22
includes
sheets 30, 34 that are transparent and/or translucent, and vanes 38 that are
translucent and/or
opaque. In some examples, the second shade 24 is made of a single sheet of
material with
5 zero light transmissivity, often referred to as a black-out shade. The
second shade 24 may
include patterns or designs so that when the second shade 24 is extended
behind the first
shade 22, the second shade 24 creates a different aesthetic appearance than
the first shade 22
by itself.
Referring to FIGS. 1-6, the covering 10 may include a drive or operating
mechanism
10 40 configured to raise or retract the first shade 22, the second shade
24, or both. The
operating mechanism 40 may be controlled mechanically and/or electrically. The
operating
mechanism 40 may include a speed governing device to control or regulate the
extension or
lowering speed of the shades 22, 24.
In some examples, the operating mechanism 40 may include an operating element
42
(such as a ball chain, a cord, or a wand) to allow the user to extend or
retract the first and/or
second shades 22, 24. To move the shades 22, 24, an operator may manipulate
the operating
element 42. For example, to raise or retract the shades 22, 24 from an
extended position, the
operator may pull the operating element 40 in a downward direction. To extend
or lower the
shades 22, 24 from a retracted position, the operator may manipulate the
operating element
42 to release a brake, which may allow the shades 22, 24 to automatically
lower under the
influence of gravity.
Additionally, or alternatively, the operating mechanism 40 may include an
electric
motor 44 configured to extend or retract the shades 22, 24 upon receiving an
extension or
retraction command. The motor 44 may be hard-wired to a switch and/or operably
coupled to
a receiver that is operable to communicate with a transmitter, such as a
remote control unit
46, to petinit a user to control the motor 44 and thus the extension and
retraction of the
shades 22, 24. The motor 44 may include a gravity lower state to permit the
shades 22, 24 to
lower via gravity without motor intervention, thereby reducing power
consumption.
Referring to FIG. 6, the covering 10 may include a dual roller unit 46, which
may be
disposed within the head rail 14. The dual roller unit 46 may include an inner
roller 48 and
an outer roller 50. The inner roller 48 may be positioned inside the outer
roller 50, and the
rollers 48, 50 may be coaxially aligned about the same rotational axis 52. The
rollers 48, 50
may be concentric about a central axis of the inner roller 48.
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Referring to FIGS. 6 and 7, the inner roller 48 may be generally cylindrical
in shape
and may be formed as a tube. The second shade 24 may be attached at a top edge
to the inner
roller 48 by adhesive, corresponding retention features, or other suitable
attachment means.
In some examples, a longitudinally-extending recess 52 is foliated in the
circumferential wall
of the inner roller 48 and may receive an adhesive bead configured to adhere
the top edge of
the second shade 24 to the inner roller 48.
The outer roller 50 may be generally cylindrical in shape and may surround the
inner
roller 48. The outer roller 50 may be formed of two pieces that interlock with
one another.
Referring to FIG. 6, the outer roller 50 may include a first shell 54 and a
second shell 56 that
nest together. Referring to FIGS. 6 and 8-11, longitudinally-extending edge
portions 58, 60
of the first and second shells 54, 56, respectively, may overlap and interlock
with one
another. The first shade 22 may be attached at a top edge to the outer roller
50 by adhesive,
corresponding retention features, or other suitable attachment means. In some
examples, a
pair of channels 62 is formed in the circumferential wall of the outer roller
50 and configured
to receive and secure the top edges of the first shade 22. Referring to FIGS.
8-11, inserts 64
may be positioned in a hem formed on each of the top edges and may act to
retain the top
edges in the respective channels 62.
Referring to FIG. 7, the inner and outer rollers 48, 50 may extend
substantially the
entire distance between the right and left end caps 26a, 26b. The inner and
outer rollers 48, 50
may have the same or substantially the same length. The first and second
shades 22, 24 may
have the same or substantially the same width, which may be equivalent to the
length of the
rollers 48, 50. In some examples, the first and second shades 22, 24 have
equivalent widths
that match the length of the inner and outer rollers 48, 50, which may
eliminate the existence
of a light gap between the edges of the shades 22, 24 and the sides of the
architectural
opening.
Referring to FIGS. 6 and 7, the dual roller unit 50 may be rotatably supported
by the
opposing end caps 26a, 26b. The operating mechanism 40 may be anchored to the
right end
cap 26a and may be actuated, for example, by the operating element 42 or the
remote control
unit 46. The operating mechanism 40 may be operably associated with the inner
roller 48 to
cause it to rotate. The operating mechanism 40 may include an internal fitting
64, which may
be received within the inner roller 48 and may tightly engage the wall of the
inner roller 48.
The internal fitting 64 may be driven in rotation by the operating mechanism
40, such as the
motor 44, and thus may drive the inner roller 48 in rotation. The operating
mechanism 40
may include a planetary gear drive often utilized in window covering
applications.
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Continuing with FIGS. 6 and 7, a limit screw 66 may be positioned inside the
inner
roller 48 and may be fixed to the left end cap 26b such that the limit screw
66 does not rotate.
A limit nut 68 may be threadedly engaged with the limit screw 66 and may be
rotationally
keyed to the wall of the inner roller 48. The key structure may allow movement
of the limit
nut 68 along the length of the inner roller 48. As the inner roller 48
rotates, the limit nut 68
may move along the threaded limit screw 66, and may engage a limit stop formed
on the limit
screw 66 to define the lowermost extended position of the second shade 24 (see
FIG. 5).
Additionally, or alternatively, a top limit stop may be employed on the limit
screw 66 if
desired.
Referring to FIG. 6, right and left bushings 70a, 70b may be axially aligned
with the
inner roller 48 and may be disposed adjacent opposing ends of the inner roller
48. The right
bushing 70a may be rotatably mounted onto the operating mechanism 40, and the
left bushing
70b may be rotatably mounted onto the limit screw 66. The bushings 70a, 70b
may lock into
the ends of the outer roller 50 to maintain a desired spatial relationship
between the shells 54,
56. The bushings 70a, 70b each may include a pair of axial projections 72a,
72b. One of the
projections 72a may engage the first shell 54, and the other projection 72b
may engage the
second shell 56. When the bushings 70a, 70b are engaged with the opposing ends
of the
outer roller 50, the bushings 70a, 70b and the outer roller 50 may rotate in
unison about the
rotation axis 52 of the inner and outer rollers 48, 50.
Referring to FIGS. 8-11, the first and second shells 54, 56 of the outer
roller 50 each
may define a retention feature that snugly receives the axial projections 72a,
72b of the
bushings 70a, 70b. The retention feature may be formed as circumjacently-
spaced shelves 74
that extend inwardly from the outer roller 50 into an interior space defined
by the outer roller
50. When the bushings 70a, 70b are engaged with the ends of the outer roller
50, the axial
projections 72a, 72b may be snugly received between the shelves 74 and the
circumferential
wall of the outer roller 50 to prevent relative movement between the first and
second shells
54, 56.
Continuing with FIGS. 8-11, the first and second shells 54, 56 may define a
slot 76
extending along a length of the outer roller 50 and in communication with the
interior of the
outer roller 50. The slot 76 permits passage of the second shade 24 during
extension and
retraction of the second shade 24. When the first end portions 58, 60 of the
first and second
shells 54, 56, respectively, are interlocked together, second longitudinally-
extending edge
portions 78, 80 of the first and second shells 54, 56 may be peripherally
spaced apart from
one another to define the slot 76. The confronting second edge portions 78, 80
of the first
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and second shells 54, 56 may be spaced a sufficient distance from one another
to permit
passage of the second shade 24 yet prevent passage of the bottom rail 20 of
the second shade
24. The axial projections 72a, 72b of the bushings 70a, 70b may maintain the
width of the
slot 76 during operation of the covering 10. The slot 76 may be positioned on
the outer roller
50 so as to be located above and adjacent to the rearward most of the pair of
channels 62
when the first shade 22 is in its extended, vane-open configuration.
With continued reference to FIGS. 8-11, the outer roller 50 may define a
recessed seat
81 in the circumferential wall on both sides of the slot 76. The seat 81 may
be formed as a
recess extending along the length of the slot 76. The seat 81 may include a
generally
vertically-oriented base wall 84 spanning the slot 76 and formed by the
opposing edge
portions 78, 80 of the outer roller 50. The seat 81 may be configured to
receive the second
bottom rail 20 when the second shade 24 is in the fully retracted position
(see FIG. 8). The
base wall 84 may allow a relatively vertical-tangential engagement and
disengagement
between the second bottom rail 20 and the outer roller 50. The slot 76 and the
seat 81 may be
positioned on the circumference of the outer roller 50 above the attachment
point 62 of the
rear sheet 34 of the first shade 22, and the position of the slot 76 and the
seat 81 may be
referred to in FIGS. 9-11 as 3 o'clock. The location of the seat 81 and the
slot 76 near the
furthest rearward position on the circumference of the outer roller 50, along
with the shape of
the seat 81, may allow for secure receipt of the second bottom rail 20 as it
is pulled vertically
up and into the seat 81 during retraction (see FIGS. 8-10).
The shape of the seat 81 and its orientation on the outer roller 50 may
encourage
smooth and predictable disengagement of the second bottom rail 20 from the
seat 81 to begin
the extension of the second shade 24. The shape and orientation of the seat 81
may allow the
bottom rail 20 to drop vertically out of the seat 81, which takes advantage of
the force of
gravity on the relatively heavy bottom rail 20. The generally tangential
orientation of the seat
81 on the outer roller 50 may assist in this regard. The lower free edge of
the slot 76 (defined
by the edge portion 80 of the second shell 56 of the outer roller 50) may be
curved or rounded
to allow for smooth travel of the second shade 24 over the edge portion 80 as
the second
shade 24 is extended and retracted through the slot 76.
The second bottom rail 20 may be an elongated member, having relatively high
mass,
and defining a groove running along its length to receive and retain a lower
edge of the
second shade 24. The lower edge of the second shade 24 may be held in the
groove of the
bottom rail 20 by an insert 82 positioned in a hem formed in the lower edge of
the second
shade 24. A portion of the profile of the second bottom rail 20 may generally
match the
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shape of the seat 81 formed in the outer roller 50 to conform thereto when the
second shade
24 is in the retracted position.
Referring to FIGS. 7-11, the first shade 22 may be coupled to and wrappable
about
the outer roller 50. An upper edge of each of the front and rear sheets 30, 34
may be attached
to the outer roller 50 at circumferentially-spaced locations. The first shade
22 may be
wrapped about or unwrapped from a rear side of the outer roller 50, with the
rear side of the
roller 50 positioned between a front side of the roller 50 and a street side
of an associated
architectural opening (in FIGS. 8-11, the rear side of the roller 50 is to the
right). Generally,
rotation of the outer roller 50 in a first direction (counterclockwise in
FIGS. 8-11) retracts the
first shade 22 by winding it about the outer roller 50 to a position adjacent
one or more sides
(such as the top side) of an associated architectural opening, and rotation of
the outer roller
50 in a second, opposite direction extends the first shade 22 across the
opening (such as to the
bottom side).
Referring still to FIGS. 7-11, the second shade 24 may be coupled to and wrapp
able
about the inner roller 48. An upper edge of second shade 24 may be attached to
the inner
roller 48, as discussed previously. The second shade 24 may be wrapped about
or unwrapped
from a rear side of the roller unit 46, with the rear side of the roller unit
46 positioned
between a front side of the roller unit 46 and a street side of an associated
architectural
opening (in FIGS. 8-11, the rear side of the roller unit 46 is to the right).
Generally, rotation
of the inner roller 48 in a first direction (counterclockwise in FIGS. 8-11)
retracts the second
shade 24 by winding it about the inner roller 48 to a position adjacent one or
more sides (such
as the top side) of an associated architectural opening, and rotation of the
inner roller 48 in a
second, opposite direction extends the second shade 24 across the opening
(such as to the
bottom side).
The operation of the covering is described below with reference to FIGS. 1-5
and 7-
11. As shown in FIGS. 1 and 7, the first and second shades 22, 24 are in fully-
retracted
positions and concealed within the head rail 14. In this configuration (see
FIG. 7), the second
shade 24 is fully wrapped about the inner roller 48 and the first shade 22 is
fully wrapped
about the outer roller 50. In some examples, the first bottom rail 18 engages
a portion of the
head rail 14 to define a top limit stop.
To extend the first shade 22 from the head rail 14, the user may actuate the
operating
mechanism 40 to cause the inner roller 48 to rotate in an extension direction
(clockwise in
FIGS. 8-11), which in turn causes the outer roller 50 to rotate in an
extension direction
(clockwise in FIGS. 8-11) due at least in part to the weight of the first
bottom rail 18 applying
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a downward force to the first shade 22. As the first shade 22 extends off of
the rear of the
outer roller 50, the outer roller 50 generally rotates in unison with the
inner roller 48. The
dual roller unit 46 generally rotates in the direction the user controls the
inner roller 48 to
rotate.
5 Referring to
FIGS. 2 and 8, the first shade 22 extends off of the rear of the outer roller
50 in a closed or collapsed configuration in which the front and rear sheets
30, 34 are
relatively close together and the vanes 38 extend vertically in an
approximately coplanar,
contiguous relationship with the front and rear sheets 30, 34. Once the first
shade 22 is
substantially unwrapped from the outer roller 50, continued rotation of the
outer roller 50 in
10 the
extension direction moves the front and rear sheets 30, 34 generally
vertically relative to
each other to shift the vanes 38 from a closed position (FIGS. 2 and 8) to an
open position
(FIGS. 3 and 9). A rear portion of the first bottom rail 18 may be weighted
more than a front
portion of the bottom rail 18 to facilitate the full opening of the vanes 38.
Referring to FIGS. 3 and 9, the covering 10 is shown with the first shade 24
in a fully
15 extended
position with the vanes 38 in an open or expanded configuration. In this
position,
the front and rear sheets 30, 34 are horizontally spaced with the vanes 38
extending
substantially horizontally therebetween, and the attachment points 62 of the
front and rear
sheets 30, 34 with the outer roller 50 may be disposed at the same height. In
FIG. 9, for
instance, the positions of the attachment points 62 may be referred to as
being at 4 o'clock
and 8 o'clock, and are disposed at substantially the same level with each
other. Rotation of
the outer roller 50 in either direction from that shown in FIG. 9 causes the
front and rear
sheets 30, 34 to move toward one another and the vanes 38 to re-orient into
more vertical
alignment.
When the first shade 22 is fully unwrapped from the outer roller 50, the slot
76 in the
outer roller 50 is rotationally oriented within the head rail 14 such that the
bottom rail 20 of
the second shade 24 may drop vertically out of the seat 81 upon further
rotation of the inner
roller 48 in the extension direction. The generally tangential orientation and
generally
vertical positioning of the seat 81, with a relatively vertical base wall 84
(see FIGS. 10 and
11), allows the weight of the second bottom rail 20 to unseat the bottom rail
20 from the outer
roller 50 when the tension in the second shade 24 is decreased due to
continued rotation of
the inner roller 48 in the extension direction. The operating mechanism 40 may
include a
brake system operably coupled to the inner roller 48 to restrict unwanted
downward
movement of the second shade 24, and thus of the first shade 22.
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In order to extend the second shade 24, the operating mechanism 40 is further
actuated by the user to rotate the inner roller 48 in the extension direction.
During extension
of the second shade 24 (see FIGS. 4 and 10), the outer roller 50 and the first
shade 22 may
remain stationary due to the weight of the first shade 22 and the weight of
the first bottom rail
18 maintaining the rotational position of the outer roller 50, without a
positive lock. In some
examples, as discussed below, a positive lock may be used to prevent rotation
of the outer
roller 50 upon full extension of the first shade 22. As shown in FIGS. 10 and
11, during
extension of the second shade 24, the slot 76 defined in the outer roller 50
may be directed
rearwardly and may be substantially horizontally aligned with the rotational
axis 52 (see FIG.
6) of the inner and outer rollers 48, 50. In other words, the second shade 24
may deploy off
of the rear side of the inner and outer rollers 48, 50.
During extension of the second shade 24, the inner roller 48 rotates relative
to the
outer roller 50, with the fitting 64 and the limit nut 68 supporting the
respective ends of the
inner roller 48. As the inner roller 48 rotates in the extension direction,
the second shade 48
is unwound from the inner roller 48 as it is extended through the slot 76
formed in the outer
roller 50. The rotation of the inner roller 48 in the extension direction
moves the limit nut 68
along the limit screw 66 towards the bottom limit stop.
Referring to FIGS. 5 and 11, the covering 10 is shown with the first and
second
shades 22, 24 both in the fully extended positions with the vanes 38 in an
open or expanded
configuration. In this position, the front and rear sheets 30, 34 are
horizontally spaced with
the vanes 38 extending substantially horizontally therebetween. The second
shade 24 may be
a blackout shade and inhibit light from passing through the second shade 24,
and thus through
the first shade 22. When the second shade 24 is fully extended (see FIGS. 5
and 11), the
second shade 24 may be offset rearwardly from the first shade 22, but may
extend
coextensively in length and width with the first shade 22. To control the
amount of light
passing through the first shade 22, the second shade 24 may be withdrawn into
the head rail
14 and wrapped about the inner roller 48 of the dual roller unit 46.
When the second shade 24 is in the fully extended position (lowermost
extension), the
limit nut 68 may be positioned on the limit screw 66 (see FIG. 6) in
engagement with a lower
limit stop formed on the limit screw 66 to prevent further rotation of the
inner roller 48. The
limit screw 66 also may include an upper limit stop to define the upper limit
of the covering
10. Alternatively, the bottom rail 18 of the first shade 22 may engage a
portion of the head
rail 14 when the first shade 22 is fully retracted to serve as the upper limit
stop of the
covering 10.
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At any point during the extension process, the user may stop the operating
mechanism
40 or reverse the direction of the operating mechanism 40 to move the first
and second shades
22, 24 into a desired position. In examples including a motorized covering 10,
pre-
programmed commands may be used to control the motor 44 and thus control the
position of
the first and second shades 22, 24. The commands may instruct the motor 44 to
move the
first and second shades 22, 24 into predetermined shade positions, such as a
first position in
which the first and second shades 22, 24 are fully retracted, a second
position in which the
first shade 22 is fully extended and the second shade 24 is fully retracted,
and a third position
in which the first and second shades 22, 24 are fully extended. The commands
may be
transmitted to the motor 44 by the remote control unit 46.
Retraction of the first and second shades 22, 24 may be accomplished in
reverse order
as compared to the extension sequence described above, such as generally
following FIG. 11
to FIG. 8. In FIGS. 5 and 11, the first and second shades 22, 24 are disposed
in fully
extended positions. When both the first and second shades 22, 24 are in the
fully extended
position, the limit nut 68 (see FIG. 6) may be engaged with a lower limit
stop, which may be
formed on the limit screw 66. Actuation of the operating mechanism 40, such as
by the
operating element 42 and/or the motor 44, from this position moves the limit
nut 68 axially
away from the lower limit stop and begins the retraction process of the
covering 10. The
retraction process generally involves actuation of the operating mechanism 40
to first rotate
the inner roller 48 in a retraction direction (counterclockwise in FIG. 11) to
retract the second
shade 24, and when the second shade 24 is fully retracted, the outer roller 50
is then rotated in
a retraction direction (counterclockwise in FIG. 11) to retract the first
shade 22 onto the outer
roller 50. This sequence is described further below.
To retract the second shade 24 from the fully extended position of FIGS. 5 and
11. the
user actuates the operating mechanism 40 to cause the inner roller 48 to
rotate in a retraction
direction (counterclockwise in FIGS. 8-11), which in turn wraps the second
shade 24 about
the inner roller 48 and raises the second bottom rail 20 upwardly along a rear
face of the rear
sheet 34 of the first shade 22. During retraction of the second shade 24, the
inner roller 48
rotates relative to the outer roller 50, with the fitting 64 and the limit nut
68 supporting the
respective ends of the inner roller 48. As the inner roller 48 rotates in the
retraction direction,
the second shade 24 is wound onto the inner roller 48 as it is pulled through
the slot 76
formed in the outer roller 50. The rotation of the inner roller 48 in the
retraction direction
moves the limit nut 68 along the limit screw 66 towards the opposite end of
the limit screw
66. Also during the retraction of the second shade 24, the first shade 22
remains in the fully
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extended, open position due to the weight of the first bottom rail 18 and the
weight of the
portion of the first shade 22 suspended from the outer roller 50 acting upon
the outer roller 50
to inhibit rotation of the outer roller 50. This allows the user to move the
second shade 24
between fully extended and fully retracted positions without affecting the
position or
.. orientation of the first shade 22.
Referring to FIGS. 9 and 10 in reverse order, as the second shade 24 is
further
withdrawn into the outer roller 50, the second bottom rail 20 becomes securely
positioned in
the seat 81. Upon the bottom rail 20 engaging the seat 81 of the outer roller
50, the driving
force of the operating mechanism 40 may be transferred through the second
shade 24 to the
outer roller 50. That is, the operating mechanism 40 may apply a rotational
force to the inner
roller 48, which in turn may be applied to the outer roller 50 through the
engagement of the
bottom rail 20 in the seat 81 under the tension of the second shade 24.
Referring to FIGS. 8
and 9, when the second shade 24 is fully wrapped onto the inner roller 48 and
the second
bottom rail 20 is received in the seat 81 of the outer roller 50, the outer
roller 50 may be
driven in a retraction direction (counterclockwise in FIGS. 8 and 9) by the
operating
mechanism 40, through rotation of the inner roller 48 in the same retraction
direction. As
such, when the bottom rail 20 is received in the seat 81 and a retraction
force
(counterclockwise in FIGS. 8 and 9) is applied to the inner roller 48 by the
operating
mechanism 40, the outer roller 50 generally rotates in conjunction with the
inner roller 48.
Referring to FIG. 8, as the outer roller 50 continues to rotate in the
retraction
direction, the first shade 22 wraps around the outer roller 50. The first
shade 22 is under
tension as it is wrapped around the outer roller 50 due to the suspended
portion of the first
shade 22 and the weight of the bottom rail 18.
When the first shade 22 is fully retracted, the first bottom rail 18 may
engage a
portion of the head rail 14, such as an abutment, to serve as a top limit stop
for the dual roller
unit 46. It is contemplated that other mechanisms may be utilized to define
the top retraction
position, including a top limit stop positioned on the limit screw 66 opposite
the bottom limit
stop. For example, a top limit stop may be formed on the limit screw 66 and
positioned along
the screw 66 such that the nut 68 engages the top limit stop upon full
retraction of the first
shade 22.
As explained above, the retraction of the second shade 24 and then the first
shade 22
from the fully extended position occurs with the user actuating a single
operating element 42
or a motor 44 for the retraction of both shades 22, 24. The limit screw 66
includes a
sufficient length to allow the limit nut 68 to move along the screw 66 from
the bottom limit
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stop until the top retracted position is attained. It is contemplated that the
first shade 22 may
be wrapped about or unwrapped from the front side of the outer roller 42.
Accompanying
modifications to the structure described herein would be necessary to
facilitate the
implementation of the dual roller shade technology as applied to a front-
descending shade
structure.
The covering may include a lock mechanism that restricts rotation of the outer
roller
50 when the first shade 22 is in the fully extended position, thereby ensuring
the first shade
22 remains in the fully extended position and is substantially unaffected by
rotation of the
inner roller 48 during extension of the second shade 24. The lock mechanism
may be
movable (such as pivotable, translatable, or other suitable movements) between
a first
position that restricts rotation of the outer roller 50 and a second position
that permits rotation
of the outer roller 50. In one example, the lock mechanism includes a locking
member
positioned external to the outer roller 50 that translates longitudinally
along an outer
periphery of the outer roller 50 and engages a stop to restrict rotation of
the outer roller 50.
In another example, the lock mechanism includes a locking member positioned
external to
the outer roller 50 that pivots into engagement with the outer roller 50 to
restrict rotation of
the outer roller 50.
Referring to FIGS. 12-27, a covering for an architectural opening is provided
that uses
a lock mechanism to positively lock rotation of the outer roller upon full
extension of the first
shade 22. With the exception of a lock mechanism and retaining clips, the
covering depicted
in FIGS. 12-27 generally has the same features and operation as the covering
depicted in
FIGS. 1-11. Accordingly, the preceding discussion of the features and
operation of the
covering depicted in FIGS. 1-11 should be considered generally applicable to
the covering
depicted in FIGS. 12-27, except as noted in the following discussion. The
reference numerals
used in FIGS. 12-27 generally correspond to the reference numerals used in
FIGS. 1-11 to
reflect the similar parts and components, except the reference numerals are
incremented by
one hundred.
Referring to FIG. 12, the covering 110 includes an axially movable lock
mechanism
186 that, similar to the pivotally movable lock mechanism discussed below in
connection
with FIGS. 28-47, restricts rotation of the outer roller 50 when the first
shade 22 is in the
fully extended position. The axially movable lock mechanism 186 may include a
housing
187, a rotatable shaft 188 joumaled to the housing 187, and a nut 189
threadedly engaged
with and travelable axially along the shaft 188. Although the axially movable
lock
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mechanism 186 is depicted in conjunction with the left end cap 126b, the lock
mechanism
186 may be used in conjunction with the right end cap 126a.
Referring to FIGS. 12, 16, and 18, the housing 187 may be cantilevered from
the left
end cap 126b and extend axially away from the left end cap 126b along an outer
periphery of
5 the outer roller 150 towards the right end cap 126a. One end 187a of the
housing 187 may be
removably connected to the left end cap 126b with a fastener 190, and an
opposing, free end
187b of the housing 187 may be positioned laterally outward of the outer
roller 150. The
housing 187 may be laterally separated from the periphery of the outer roller
150 by a
sufficient distance so as to not interfere with the wrapping or unwrapping of
the first shade
10 (not shown) about or from the outer roller 150. The housing 187 may be
laterally separated
from the periphery of the outer roller 150 by a uniform distance.
With reference to FIGS. 16, 18, 21, and 26, the opposing end portions 187a,
187b of
the housing 187 may include axially-extending collars 191 and abutment flanges
192
extending outward from the collars 191. The collars 191 may include an
internal wall 193
15 (see FIGS. 22 and 26) that defines a shaft aperture 194 that receives a
journal portion 195 of
the rotatable shaft 188, which rotatably bears against the internal wall 193.
The internal wall
193 of the collar 191 also may define a key hole 196 that permits passage of
the rotatable
shaft 188 (particularly the stops 197 foliated on the rotatable shaft 188)
during axial insertion
or removal of the shaft 188 into or out of the housing 187. The abutment
flanges 192 each
20 may define a fastener aperture configured to receive a fastener 190 that
connects the housing
187 to a respective end cap 126a, 126b (see FIGS. 12, 14, 16, 18, and 22). The
end portions
187a, 187b of the housing 187 may be mirror images of one another to
facilitate
interconnection of the housing 187 to either the left or right end caps 126a,
126b.
With continued reference to FIGS. 12, 16, 18, 21, and 26, the housing 187 may
include an intermediate portion 187c that interconnects the end portions 187a,
187b. The
intermediate portion 187c may extend longitudinally along an outer periphery
of the outer
roller 150 in a laterally spaced relationship. The intermediate portion 187c
of the housing
187 may include a base 198 and a guide rail 199 each spanning the distance
between the
opposing end portions 187a, 187b of the housing 187. The base 198 of the
housing 187 may
define stop receiving apertures 200 proximate to the end portions 187a, 187b
to petinit
passage of the shaft 188 stops during rotation of the shaft 188 relative to
the housing 187,
thereby reducing the transverse profile of the housing 187. The base 198 of
the housing 187
also may include a stiffening rib 201 extending longitudinally between the end
portions 187a,
187b that stiffens the housing 187 and reduces lateral displacement or
buckling of the
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intermediate portion 187c of the housing 187. As shown in FIG. 27, the
stiffening rib 201
may include at least one transversely-extending buttress 202 that further
increases the
stiffness of the longitudinally-extending rib 201.
Referring to FIGS. 12, 16-19, 23, and 26, the shaft 188 of the axially movable
lock
mechanism 186 may be offset from, but parallel or substantially parallel to, a
rotation axis
152 of the inner roller 148. The shaft 188 may be positioned external to the
outer roller 150
and extend longitudinally along an outer periphery of the outer roller 150 in
a spaced
relationship. The shaft 188 may include journal portions 195 rotatably
received within the
collars 191 of the housing 187. The journal portions 195 of the shaft 188 may
include
recessed circumferential areas that reduce the contact areas (and thus the
friction) between the
bearing surface 193 of the collars 191 and the journal portions 195 of the
shaft 188. The
shaft 188 may include a threaded portion 203 extending between the journal
portions 195 of
the shaft 188 and between the collars 191 of the housing 187. Stops 197 may be
formed on
the shaft 188 near the terminal ends of the threaded portion 203 of the shaft
188. The stops
197 may extend radially outward from the shaft 188 and may be axially aligned
with the
apertures 200 formed in the base 198 of the housing 187 (see FIG. 21) so that
during rotation
of the shaft 188 relative to the housing 187 the stops 197 rotationally pass
in and out of the
apertures 200. A gear 204 may be non-rotatably attached to one end of the
shaft 188 and may
define a central cavity for laterally locating the gear (and thus the shaft
188) relative to the
end cap 126b.
Referring to FIGS. 12, 16, 18, and 24-27, the nut 189 of the axially movable
lock
mechanism 186 is positioned at least partially within the housing 187 and
travels axially
along the shaft 188 within the intermediate portion 187c of the housing 187.
The nut 189 is
keyed to the housing 187 so that as the shaft 188 rotates the nut 189
translates along, rather
than rotates about, the shaft 188. The nut 189 includes a body 205 that
extends only partially
around the shaft 188 and may be referred to as a half-nut 189. In an
alternative design, the
nut 189 may extend around the entire circumference of the shaft 188.
Referring to FIGS. 24 and 25, the nut 189 includes an internal thread 206 that
projects
inward from the body 205 and threadedly engages the external thread of the
threaded portion
203 of the shaft 188. To maintain engagement of the threads and restrict
rotation of the nut
189 about the shaft 188, the nut 189 may include two longitudinally-extending
wings 207 that
project radially outward from the body of the nut 189. The wings 207 may
include axially-
extending fins 208 that slidably contact confronting faces of the base 198 of
the housing 187
(see FIG. 27) and guide the nut 189 axially along the intermediate portion
187c of the
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housing 187 while reducing the contact area (and thus the friction) between
the nut 189 and
the housing 187.
One of the wings 207 may define a longitudinally-extending slot 208 that at
least
partially receives the guide rail 199. As shown in FIG. 27, portions of the
wing 207 defining
the slot 208 may slidably abut different sides of the guide rail 199. As such,
the wings 207 of
the nut 189 may substantially prevent the nut 189 from rotating about the
shaft 188, thereby
facilitating translation of the nut 189 along the shaft 188 during rotation of
the shaft 188
relative to the housing 187. To laterally stiffen the wings 207, the nut 189
may include a
transversely-extending rib 209 positioned outwardly of the internal thread 206
and extending
between the wings 207. In an alternative design, the nut 189 and the housing
187 may
include various other corresponding keying structures so that the nut 189
travels axially along
the shaft 188 upon rotation of the shaft 188 relative to the housing 187.
As described, rotation of the shaft 188 relative to the housing 187 generally
moves or
translates the nut 189 axially along the shaft 188. To limit the axial range
of the nut 189, the
shaft 188 may include stops 197 extending outward from a periphery of the
shaft 188. Upon
contact with the nut 189, the stops 197 generally restrict or limit
translation of the nut 189
relative to the shaft 188, thereby restricting or limiting further rotation of
the shaft 188
relative to the housing 187. To ensure a solid engagement between the nut 189
and a
respective stop 197, the nut 189 may include a longitudinally-extending
abutment wall 211
that interacts with the shaft 188 stop upon the nut 189 reaching a desired
stopping position
corresponding to a full extension of the first shade 22. As shown in FIG. 24,
the abutment
wall 211 may be formed at a terminal end of the internal thread 206 of the nut
189.
Additionally or alternatively, the body 205 of the nut 189 (which may resemble
an
axially-extending sleeve) may abut the abutment flange 192 of the housing 187
to stop
translation of the nut 189 along the shaft 188. The body 205 of the nut 189
may be radially
spaced from an outer periphery of the shaft 188 by a sufficient distance to
permit passage of
the shaft stop 197 in an annular space defined between the shaft 188 and the
body 205. The
shaft 188 and the nut 189 may include two stops 197 and abutment walls 211,
respectively, to
facilitate interoperability of the lock mechanism 186 with the right or left
end caps 126a,
126b, thereby providing a robust design capable of accommodating left and
right hand
assemblies.
Referring to FIGS. 15-17, the axially movable lock mechanism 186 may include a
gear mechanism or train 213 positioned external to the inner and outer rollers
148, 150. The
gear mechanism or train 213 may include a first gear 215 non-rotatably coupled
to the outer
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roller 150, a second gear 204 non-rotatably coupled to the shaft 188, and an
idler gear 217
intermeshed with the first and second gears 215, 204. The idler gear 217 may
be rotatably
supported on a mounting plate 219 that includes locator pins 221 projecting
axially from the
mounting plate 219 (see FIG. 17) toward the associated end cap 126. The
locator pins 221
may be receivable within the end cap 126 to restrict rotation of the mounting
plate 219
relative to the end cap 126.
The gear mechanism 213 may be altered depending on the size, weight, or other
characteristics of the shade members. In one example, the gear mechanism 213
provides a
three-to-one gear ratio between the first and second gears 215, 204. That is,
for every
revolution of the outer roller 150, the shaft 188 completes three revolutions.
In one example,
the external thread of the shaft 188 has sixteen threads per inch (or a pitch
of 1/16 of an inch).
Generally, the length of the threaded portion 203 of the shaft 188 may be
oversized relative to
the operative range of the nut 189 so that the shaft 188 may accommodate many
different
shade lengths. Thus, in some examples, the nut 189 only interacts with one of
the stops 197
on the rotatable shaft 188 during operation and the other stop is provided so
that the lock
mechanism 186 may be used with either of the right or left end caps 126a,
126b.
Referring to FIG. 15, the gear mechanism 213 is depicted in association with
the left
end cap 126b. The external gears 204, 215, 217 are rotatably supported by stub
shafts
projecting axially from the left end cap 126b. The idler gear 217 is
positioned forwardly of
the first gear 215, and the second gear 204 is positioned forwardly of the
idler gear 217, with
all three gears 215, 204, 217 disposed in the same plane adjacent to the end
cap. The idler
gear 217 is positioned upwardly of the first gear 215, and the second gear 204
is positioned
upwardly of the idler gear 217. The first gear 215 and the idler gear 217 may
be received
within a rim 223 projecting axially from the end cap 126b.
Referring to FIG. 13, a partially exploded view of the head rail components
(with the
exception of the right side components which are generally the same as those
shown and
discussed in relation to FIGS. 6-11) is provided. The components include a
left end cap
126b, a non-rotatable limit screw 166 that attaches to the left end cap 126h,
a left hushing
170b that mounts onto and rotates relative to a bearing surface of the limit
screw 166, an
inner roller 148 that internally receives a portion of the limit screw 166
(including the limit
nut 168) and mounts onto a boss 167 of the left and right bushings 170a, 170b,
an outer roller
150 that internally receives the inner roller 148, and the axially movable
lock mechanism 186
that attaches to the left end cap 126b.
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Referring to FIGS. 13, 14, 19, and 20, the outer roller 150 may include a
split shell
design. In particular, the outer roller 150 may include first and second
shells 154, 156. To
secure the first and second shells 154, 156 together and maintain a desired
spatial relationship
relative to one another, the first and second shells 154, 156 of the outer
roller 150 each may
snugly receive an axial projection 172a, 172b of the left and right bushings
170a, 170b (see
FIGS. 14, 18, and 19). The axial projections 172a, 172b may couple the outer
roller 150 to
the bushings 170a, 170b so that the outer roller 150 and bushings 170a, 170b
rotate in unison
about a rotation axis 152 of the outer roller 150. The first gear 215 may be
non-rotatably
secured to an opposing face of the left bushing 170b relative to the axial
projections 172a,
.. 172b, thereby ensuring the first gear 215 rotates in unison with the outer
roller 150. To
further secure the first and second shells 154, 156 together, the shells 154,
156 may be
clamped together by at least one retaining clip 225 (FIGS. 12-13 depict two
retaining clips,
although more or less clips may be used as desired to securely fasten the
shells together). As
shown in FIG. 20, the retaining clip 225 may be resiliently snapped around an
interlocked
region 227 of the first and second shells 154, 156.
Referring to FIG. 20, the end portions 158, 160 of the first and second shells
154, 156
may overlap one another and extend into corresponding longitudinally-extending
receiving
channels 229, 231 defined at least partially by longitudinally-extending lips
233, 235. The lip
233 of the first shell 158 may be positioned internal to a terminal,
longitudinally-extending
edge 237 of the second shell 160, while the lip 235 of the second shell 160
may be positioned
external to a terminal, longitudinally-extending edge 239 of the first shell
158 (although this
arrangement may be flipped). The retaining clip 225 may resiliently snap
around external
detents 241, 243 formed in the interlocked region of the first and second
shells 154, 156,
respectively, to clamp the first and second shells 154, 156 together.
Referring to FIGS. 14 and 19, the split-shell design of the outer roller 150
defines a
longitudinally-extending slot 176 that permits passage of the second shade 24
during
extension and retraction of the second shade 24. When the edge portions 158,
160 of the first
and second shells 154, 156 are interlocked together, opposing or second
longitudinally-
extending teiminal edge portions 178, 180 of the first and second shells 154,
156 are
peripherally spaced apart from one another and define the longitudinally-
extending slot 176.
The confronting second teiminal edge portions 158, 160 of the first and second
shells 154,
156 may be spaced a sufficient distance from one another to permit passage of
the second
shade 24 yet prevent passage of the bottom rail 20 of the second shade 24. The
function of
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the outer roller 150 is generally the same as that discussed in relation to
FIGS. 6-11 and thus
will not be repeated here for the sake of brevity.
During operation of the covering, as the outer roller 150 extends the first
shade 22
across the architectural opening, the first gear 215 drives the idler gear
217, which in turn
5 drives the second gear 204, which traverses the nut 189 axially along the
shaft 188 toward a
bottom end position. Once the nut 189 reaches the bottom end position (which
may be
defined by a stop 197 on the shaft 188), the nut 189 restricts further
rotation of the shaft 188
in the extension direction of the first shade 22, which in turn inhibits
further rotation of the
outer roller 150 in the extension direction. With the outer roller 150
restricted from further
10 .. rotation in the extension direction and the first shade 22 unwrapped
from the periphery of the
outer roller 150, the second shade 24 may be unwrapped from the inner roller
148, passed
through the slot 176 in the outer roller 150, and extended across the
architectural opening. As
the inner roller 148 rotates during extension of the second shade 24, the
internal limit nut 168
rotates in unison with the inner roller 148 and travels axially along the
limit screw 166 toward
15 a bottom end stop fomied on the non-rotatable limit screw 166. The
internal limit nut 166
generally contacts the bottom end stop upon the second shade 24 being fully
extended across
the architectural opening to define a bottom stop of the dual roller unit 146.
During retraction of the covering from a fully extended position, the inner
roller 148
pulls the second shade 24 through the slot 176 defined between the opposing
longitudinally-
20 extending edge portions 178, 180 of the shells 154, 156 of the outer
roller 150 and wraps the
second shade 24 about a periphery of the inner roller 148 until the bottom
rail 20 of the
second shade 24 seats against an outer periphery of the outer roller 150.
During retraction of
the second shade 24, the weight of bottom rail 18 of the first shade 22
maintains the bushings
170a, 170b in a stationary condition and thus the inner roller 148 rotates
relative to the
25 bushings 170a, 170b and the outer roller 150.
Once seated, the bottom rail 20 of the second shade 24 transfers the
rotational torque
from the inner roller 148 to the outer roller 150, thereby rotating the outer
roller 150 in a
retraction direction and wrapping the first shade 22 about a periphery of the
outer roller 150.
The inner and outer rollers 148, 150 continue to rotate in a retraction
direction until the
bottom rail 18 of the first shade 22 contacts a top limit stop, which may be
associated with
one or both of the end caps 126, at which point the covering is retracted into
a fully retracted
position. During rotation of the inner roller 148 in the retraction direction,
the internal limit
nut 168 traverses along the non-rotatable limit screw 166 within the inner
roller 148 away
from the bottom stop of the second shade 24. During rotation of the outer
roller 150 in the
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retraction direction, the external nut 189 traverses along the rotatable shaft
188 away from the
bottom stop of the first shade 22.
Referring to FIGS. 28-47, a covering for an architectural opening is provided
that
includes a pivotable lock mechanism. With the exception of the pivotable lock
mechanism
and the multiple-piece outer roller, the covering depicted in FIGS. 28-47
generally has the
same features and operation as the covering depicted in FIGS. 6-27.
Accordingly, the
preceding discussion of the features and operation of the covering depicted in
FIGS. 6-27
should be considered generally applicable to the covering depicted in FIGS. 28-
47, except as
noted in the following discussion. The reference numerals used in FIGS. 28-47
generally
correspond to the reference numerals used in FIGS. 12-27 to reflect the
similar parts and
components, except the reference numerals are incremented by one hundred.
Referring to FIGS. 28-34, the inner roller 248 is generally cylindrical in
shape, and
forms a retaining member for securing the top edge of the second shade 24
thereto. As noted
above, the inner roller 248 is positioned inside the outer roller 250 to
define the dual roller
unit, and in this example both rollers 248, 250 are coextensive about the same
rotational axis
252. An upper edge of the second shade 24 is attached to the inner roller 248,
and a lower
edge of the second shade 24 is received in a slot formed in the second bottom
rail 220, and
held in the slot by an insert 282 positioned in a hem formed on the bottom
edge of the second
shade 24. Other attachment structures may be used to attach the bottom rail
220 to the
.. second shade 24.
Continuing with FIGS. 28-34, the second bottom rail 220 is an elongated
member,
having relatively high mass, and defining a slot running along its length to
receive and retain,
as noted above, the bottom edge of the second shade 24. The second bottom rail
220 has a
generally triangular cross section, a portion of which generally matches the
shape of the seat
281 formed on the outer roller 250 to conform thereto when the second shade 24
is in the
retracted position. An actuator rim 247 is defined at one end of the second
rail 220, and
engages the lock mechanism 286 to disengage the lock mechanism 286 from the
outer roller
250, as is described in more detail below.
The outer roller 250 in this example is generally cylindrical, and defines
several
features in its circumferential wall. The outer roller 250 defines a
longitudinal central axis
252 about which it rotates, and about which the inner roller 248 is
coextensively positioned
also. A pair of channels 262 is formed to receive and secure the top edges of
the first shade
22, with the inserts 264 each being positioned in a hem formed on each of the
top edges, the
inserts 264 acting to retain the top edge in the respective channel 262. An
anchor groove 245
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is formed along the length of the outer roller 250 for receipt of a roller
lock bearing, as is
described below. A slot 276 is formed along the length of the outer roller 250
and is in
communication with the interior of the outer roller 250, which may be formed
as a tube. A
recessed seat 281 is foimed on either side of the slot 276. The second shade
24 is extended
and retracted through the slot 276, and when in the fully retracted position,
the second bottom
rail 220 is received in the seat 281 and nests therein for at least one of
many purposes, as is
described below. The slot 276 is positioned on the outer roller 250 so as to
be located above
and adjacent to the rearward most of the two channels 262 when the first shade
22 is in its
extended position and vane-open configuration.
Referring to FIGS. 28, 29, 46, and 47, the dual roller unit is rotatably
supported
between the right end cap 226a and the left end cap 226b, and the operating
mechanism 240
is operably associated with the inner roller tube 248 to cause it to rotate.
The operating
mechanism 240 is anchored to the right end cap 226a and is actuated by, in one
example, the
operating element 242 as noted above. The operating mechanism 240 may, in one
example,
include a planetary gear drive often utilized in window covering applications.
The operating
mechanism 240 may include an internal fitting 264 which is rotated by the
operating
mechanism 240. The fitting 264 is sized to be received within the inner roller
248, and
tightly engages the inner wall of the inner roller 248. The inner roller 248
is driven in
rotation by the internal fitting 264 as the fitting is driven by the operating
mechanism 240.
The open right end of the outer roller 250 receives a right end roller cap
270a, which includes
a central aperture having an axially extending collar rotatably receiving an
axial bearing
surface formed on the housing of the operating mechanism 240. The bearing
surface
supports the right end roller cap 270a as it rotates when the outer roller 250
rotates. The
inner roller 248 is rotatably received on the collar. The collar rotatably
supports the right end
of the inner tube 248 as it is driven by the operating mechanism 240 to
rotate.
As shown in FIG. 46, right ends 248a, 250a of the inner and outer rollers 248,
250,
respectively, may be aligned with one another, and a right side edge 24a of
the second shade
24 may he aligned with the right ends 248a, 250a of the rollers 248, 250. As
shown in FIG.
47, left ends 248b, 250b of the inner and outer rollers 248, 250,
respectively, may be aligned
with one another, and a left side edge 24b of the second shade 24 may be
aligned with the left
ends 248b, 250b of the rollers 248, 250. The first shade 22 may be wrapped
about the outer
roller 250, and the edges of the first shade 22 may be aligned with the ends
of the rollers 248,
250 and the edges of the second shade 24. The alignment of the ends of the
rollers 248, 250
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and the edges of the shades 22, 24 may reduce or eliminate light gaps between
the edges of
the shades and corresponding sides of the architectural opening.
The outer roller 250 is driven in rotation by the inner roller 248 when the
second
shade 24 is fully retracted onto the inner roller 248 and the second end rail
220 is received in
the seat 281 of the outer tube 250. In this condition, as the inner roller 248
rotates, the second
shade 24 tensions the second end rail 220, which in turn applies a force to
the outer roller 250
at the interface between the second end rail 220 and the seat 281. Thus the
outer roller 250 is
caused to rotate in conjunction with the inner roller 248. The outer roller
250 does not rotate
along with the inner roller 248 unless the second shade 24 is fully retracted
about the inner
roller 248. As noted above, the operating mechanism 240 may be actuated by an
operating
element 242 to extend or retract the first and second shades 22, 24 as desired
by the user.
Many types of mechanisms for causing the rotation of the inner roller tube 248
upon
actuation of the operating element 242 are acceptable.
Continuing with FIGS. 28 and 29, a limit screw 266 is positioned inside the
inner
roller 248, and is operably fixed to the left end cap 226b by a screw. The
limit screw 266
does not rotate. A limit nut 268 is threadedly engaged with the limit screw
266, and is
rotationally keyed to the inside of the inner roller 248, the key structure
allowing movement
of the limit nut 268 along the length of the inner roller 248. As the inner
roller 248 rotates,
the limit nut 268 moves along the threaded limit shaft 266, and engages a
limit stop defining
the bottom most extended position of the second shade 24 (see FIG. 5). The
retracted
position of the first shade 22 is defined by the first shade 22, in this
example, being wrapped
entirely around the outer roller 250. In some examples, the first bottom rail
18 engages a
portion of the head rail 14 to define this position. Alternatively or
additionally, while a top
limit stop on the limit screw 266 is not used in this example, one may be
employed on the
limit screw 266 if desired. The left end cap 226b, as best seen in FIGS. 28,
29, and 47.
rotatably supports the inner roller 248 and the outer roller 250.
Referring to FIGS. 28, 29, and 40, a pivot bracket 249 is attached to the
inside surface
of the left end cap 226b and defines a centrally positioned annular boss 251
and a post 253
extending toward the right end cap 226a that serves as an axle on which the
roller lock 255 is
pivotally mounted. The annular boss 251 on the pivot bracket 249 is rotatably
received in the
central aperture of the left outer roller cap 270b, which is itself received
in the open left end
of the outer roller 250. A collar extends axially from around the central
aperture of the cap
270b, and serves as a bearing surface for the relative rotation between the
outer roller 250 and
the left end bracket. The open left end of the inner roller 248 is rotatably
received upon the
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outer surface of the collar, which acts as a bearing surface for the rotation
of the roller 248
relative to the collar, which rotation is under the selective control through
the operating
mechanism 240.
The roller lock 255, as shown in FIGS. 28, 29, 38, and 39, is pivotally
attached to the
post 253 on the pivot bracket 249 (see FIGS. 40 and 41), and secured thereto
by a fastener
257 (see FIG. 41). The roller lock 255 is pivotable relative to the pivot
bracket 249 about the
axis defined by the post 253. A spring member 259 (see FIG. 43) is positioned
around the
post 253 of the pivot bracket 249, the spring 259 having two legs, one of
which engages the
roller lock 255 to bias the roller lock 255 into engagement with the outer
surface of the outer
roller 250, and the other leg operably engages a portion of the left end cap
226b.
Referring to FIGS. 38 and 39, the roller lock 255 includes a frame plate 261
having a
central body 263 from which extend an upper leg 265 and a lower leg 267, each
leg 265, 267
lying in the same plane as the central body 263. The upper and lower legs 265,
267 extend at
near right angles to one another, and it is contemplated that this relative
positioning may be
adjusted as needed given the geometry of the particular usage. The end of the
lower leg 267
includes a pin 269 extending orthogonally from the plate 261 toward the
opposite end cap,
the pin 269 having a cylindrical shape and being relatively short. For
instance, the pin 269
does not extend far enough to interfere with the rotation of the roller 250.
The length and
shape of the pin 269 facilitate the moving engagement between the pin 269 and
the actuator
rim 247 on the second end rail 220 as described below.
Continuing to refer to FIGS. 38 and 39, the end of the upper leg 265 rotatably
supports a relatively long cylindrical bearing 271 which extends orthogonally
from the upper
leg 265 towards the opposite end cap 226a. The bearing 271 is rotatably
supported at its
opposite end by an atm 273 extending at an angle from the central plate 261.
The arm 273
supports the distal end of the bearing 271 from a top side only, and does not
extend much
beyond the center of the bearing 271. This configuration leaves the lower
portion of the
bearing 271, along its length, unencumbered and able to be received in the
anchor groove 245
formed in the outer roller 250, as well as to engage the outer surface of the
outer roller 250
and ride along its surface, as described further below.
The operation of one example of the covering is described below with primary
reference to FIGS. 30-34. As shown in FIG. 30, both the first and second
shades 22, 24 are in
the extended position, and the vanes 38 are in an open configuration. With
brief reference to
FIG. 30, the first shade 22 may be coupled to and wrappable about the outer
roller 42. An
upper edge of each of the front and rear sheets 30, 34 may be coupled to an
inwardly-
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directed, longitudinally extending gland or rib 275. The gland 275 may define
an internal
cavity 262 that opens through a periphery of the outer roller 250. The shade
22 may be
wrapped about or unwrapped from a rear side of the roller 250, with the rear
side of the roller
250 positioned between a front side of the roller 250 and a street side of an
associated
5
architectural opening (in FIG. 30, the rear side of the roller is to the
right). Generally,
rotation of the roller 250 in a first direction (counterclockwise in FIG. 30)
retracts the shade
22 by winding it about the outer roller 250 to a position adjacent one or more
sides (such as
the top side) of an associated architectural opening and rotation of the
roller 250 in a second,
opposite direction may extend the shade 22 across the opening (such as to the
bottom side).
10 The first
shade 22 is maintained in this open position by positioning the engagement
points 262 of the rear and front sheets 30, 34 of the first shade 22 with the
outer roller 250 at
the same height. In FIG. 30, for instance, the positions of these attachment
points 262 may
be referred to as being at 4 o'clock and 8 o'clock, which puts them at close
to the same level
with each other. If the outer roller 250 is rotated either direction from that
shown in FIG. 30,
15 the front
and rear sheets 30, 34 would move toward one another and the vanes 38 would re-
orient into more vertical alignment.
At this position with both the first and second shades 22, 24 at the fully
extended
position, the limit nut 268 (see generally FIGS. 28 and 29) is engaged with
the lower limit.
Actuation of the operating mechanism 240, such as by the operating element
242, from this
20 position
begins the retraction of the second shade 24 into the head rail 14. The
operating
mechanism 240 first rotates the inner roller 248 in a counterclockwise
direction in FIG. 30 to
retract the second shade 24, and when the second shade 24 is fully retracted,
the outer roller
250 is then actuated to retract the first shade 22 onto the outer roller 250.
This sequence is
described further herein and below.
25 As noted
above, and referring still to FIG. 30, the inner roller 248 is positioned
within
the outer roller 250 to define the dual roller unit 246. The outer roller 250
defines an axis of
rotation 252 defined by the portion of the outer roller 250 having a circular
shape (such as
from 9 o'clock to 2 o'clock). The inner roller 248 is positioned so as to be
coextensive with
or concentric about the same axis 252 as the outer roller 250.
30 During
retraction of the second shade 24, the inner roller 248 rotates relative to
the
outer roller 250, with the opposing collars in the left and right roller end
caps 270a, 270b
supporting the respective ends of the inner roller 248. The outer roller 250
is held in fixed
rotational position relative to the inner roller 248 by the roller lock 255.
The roller lock 255
is oriented such that the bearing 271 is biased by the spring 259 to be
received in the anchor
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groove 245 (See FIGS. 28-30). This position of the bearing 271 inhibits the
rotation of the
outer roller 250. As the inner roller 248 rotates in the retraction direction,
the second shade
24 is wound onto the inner roller 248 as it is pulled through the slot 276
formed in the outer
roller 250. This retraction rotation moves the limit nut 268 along the limit
screw 266 towards
the opposite end of the limit screw 266.
The slot 276 through which the second shade 24 extends, and the seat 281 for
receiving the second end rail 220 is positioned on the circumference of the
outer roller 250
above the attachment point 262 of the rear sheet 34 of the first shade 22.
This may be
referred to in FIG. 30 as 3 o'clock. The slot 276 is defined by opposing free
edges fonned in
the seat 281. The seat 281 is a recess formed along the length of the slot
276, and includes
two outer edges that define the boundaries of the seat 281 on the
circumference of the outer
roller 250. The shape of the recess, as oriented in FIG. 30, is somewhat
angular overall, with
a generally vertically oriented base wall 284 allowing a relatively vertical-
tangential
engagement and disengagement between the second bottom rail 220 and the outer
roller 250.
The location of the seat 281 and slot 276 near the furthest rearward position
on the
circumference of the outer roller 250, along with the shape of the seat 281,
allows for secure
receipt of the second bottom rail 220 as it is pulled vertically up and into
the seat 281 during
retraction (see FIGS. 31 and 32).
The shape of the seat 281 and its orientation on the outer roller 250
encourages
smooth and predictable disengagement of the second bottom rail 220 from the
seat 281 to
begin the extension of the second shade 24 (from the position shown in FIG.
32). The shape
and orientation of the seat 281 allows the bottom rail 220 to drop vertically
out of the seat
281, which takes advantage of the force of gravity on the relatively heavy
bottom rail 220.
The generally tangential orientation of the seat 281 on the outer roller 250
assists in this
regard. Referring to FIG. 35, the upper wall 277a extends from the top edge of
the recess
downwardly and radially inwardly to a lip 277b, which extends directly
downwardly to an
upper free edge 277c. This portion of the seat 281 is the deepest (as measured
from the
circumference toward the center of the outer roller). The lower wall 279a
extends from the
bottom edge of the recess upwardly and inwardly at a shallow angle, and
transitions to a lip
279b which defines the lower free edge 279c of the slot 276. The lower wall
279a is
relatively vertical, and remains so even in combination with the upper lip
277b. The lower
free edge 279c of the slot 276 is curved or rounded to allow for the smooth
travel of the
second shade 24 over this feature as it is retracted onto the inner roller
248.
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The secure engagement of the second bottom rail 220 in the seat 281 aids in
consistent actuation of the roller lock 255 to disengage the bearing 271 from
the anchor
groove 245. Referring to FIG. 31, when the second shade 24 is near fully wound
around the
inner roller 248, the bottom rail 220 of the second shade 24 engages the
roller lock 255 to
disengage the roller lock 255 from the outside of the outer roller 250. The
second bottom rail
220 is shown in dash in FIGS. 31 and 35. At this position, the actuator rim
247, which
extends axially from the end of the second bottom rail 220, contacts the pin
269 formed on
the lower leg 267 of the roller lock 255. As the second bottom rail 220 is
pulled into the seat
281 by the second shade 24 being retracted, the actuator rim 247 moves the pin
269 relative
to the pivot axis of the post 253. The pin 269 is moved radially inwardly
relative to the inner
roller 248, and is moved circumferentially relative to the pivot axis of the
roller lock 255.
The movement of the roller lock 255 about the post 253 moves the upper alm
265, which
begins the movement of the bearing 271 upwardly and out of engagement with the
anchor
groove 245, which frees the outer roller 250 to rotate (see FIGS. 32, 36, and
43).
As shown in FIGS. 42 and 43, the actuator rim 247 extends off of the end of
the
second bottom rail 220 adjacent the roller lock 255. With reference to FIGS.
44 and 45, the
rim 247 is a thin, curved element that in this example conforms to the curved
shape of the
bottom side of the second bottom rail 220. The rim 247 is curved along a
dimension
consistent with the bottom side of the second bottom rail 220, and extends
axially away from
the second bottom rail 220. As best seen in FIG. 43, the rim 247 extends a
distance sufficient
to engage the pin 269 on the roller lock 255 but not contact the central plate
261 of the roller
lock 255. The inside, concave surface of the fin 247 engages the round outer
surface of the
pin 269. As the second bottom rail 220 is further retracted, the pin 269 and
fin 247 maintain
a sliding engagement. This further movement of the second end rail 220 causes
the roller
lock 255 to pivot further about the pivot axis of the post 253 and thus moves
the roller lock
bearing 271 out of the anchor groove 245.
Referring to FIGS. 32 and 36, as the second shade 24 is further withdrawn into
the
outer roller 250, the bottom rail 220 becomes securely positioned in the seat
281 and the fin
247 moves the pin 269 a sufficient amount inwardly to fully remove the bearing
271 from the
anchor groove 245, which frees the outer roller 250 to rotate. Further
actuation of the
operating mechanism 240 applies the rotational motion of the inner roller 248
to the outer
roller 250, through the engagement of the bottom rail 220 in the seat 281
under the tension of
the second shade 24. This engagement causes the outer roller 250 to rotate in
conjunction
with the rotation of the inner roller 248. As the outer roller 250 begins to
rotate in the
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retraction direction, the actuator rim 247 on the second bottom rail 220
disengages from the
pin 269 on the roller lock 255. Referring to FIGS. 33 and 37, upon release the
roller lock 255
is biased by the spring 259 to cause the bearing 271 to contact the outer
surface of the outer
roller 250 at a circumferential location spaced away from the anchor groove
245.
Referring to FIG. 34, as the outer roller 250 continues to rotate in the
retraction
direction, the first shade 22 wraps around the outer roller 250, covering the
anchor groove
245. When the roller lock bearing 271 nears the anchor groove 245 as the outer
roller 250
continues to rotate, the roller lock bearing 271 passes over the groove 245 by
riding on the
first shade 22 which spans the groove 245. The first shade 22 is under tension
as it is
wrapped around the outer roller 250, thus making the span of the shade 22
extending over the
groove 245 relatively taut. The bearing 271 may depress somewhat into the
anchor groove
245 when only a single wrap of the first shade 22 is positioned over the
anchor groove 245,
but after another full rotation the bearing 271 rides over the surface of the
first shade 22
wrapped around the outer roller 250 without interference from the anchor
groove 245.
As the first shade 22 continues to retract, it wraps around the outer roller
250 many
times, and the roller lock bearing 271 continues to ride on the outer surface
of the shade 22.
The dual roller unit 246 reaches the top retraction position when the first
bottom rail 18
contacts an abutment on the head rail housing, for example. It is contemplated
that other
mechanisms may be utilized to define the top retraction position, including a
top limit stop
positioned on the limit screw 266 opposite the bottom limit stop. As explained
above, the
retraction of the second shade 24 and first shade 22 from the fully extended
position may
occur with the user actuating one operating element (manually or
automatically) for the
retraction of both shades 22, 24. The limit screw 266 is of sufficient length
to allow the limit
nut268 to move from the bottom limit stop until the top retracted position is
attained.
Extension of the first shade 22 and the second shade 24, if desired, is
accomplished in
reverse order as described above, such as generally following FIGS. 34 to 30.
This allows
the user to select whether to have just the first shade 22 extended or to also
have the second
shade 24 extended (between fully retracted and fully extended). During
extension of the first
shade 22, the user actuates the operating mechanism 240 to cause the inner
roller 248 to
rotate in an extension direction (clockwise in FIGS. 34-30), which in turn
causes the outer
roller 250 to rotate in an extension direction. The dual roller unit 246
rotates, in this example,
in the direction the user controls the inner roller 248 to rotate. As the
first shade 22 extends
off of the rear of the outer roller 250, the roller lock bearing 271 rides on
the outer surface of
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34
the outer roller 250 until the first shade 22 is nearly fully extended. At
this point, the outer
surface of the outer roller 250 is exposed.
As the outer roller 250 continues to rotate, the roller lock bearing 271 rides
on the
outer surface of the outer roller 250 until it meets the anchor groove 245.
The bearing 271 is
biased downwardly by the spring 259 to be positioned in the groove 245 and
inhibit the
rotation of the outer roller 250 and allow the continued rotation of the inner
roller 248 (if
desired by the user). Since the roller lock 255 is biased in a direction
against the outer
surface of the outer roller 250, the bearing 271 moves into the anchor groove
245 without
further urging. At this point the first shade 22 is at its most extended
position across the
opening. It is contemplated that the roller lock 255 may be biased by means
other than a
spring 259 in these examples. For instance, the top arm 273of the roller lock
255 may be
weighted such that the roller lock 255 pivots as desired automatically under
the weight of the
top arm 273. Where a spring 259 is used, it may be a wire spring, coil spring,
resilient
material spring (such as rubber, elastic, and/or plastic) or the like.
When the bearing 271 of the roller lock 255 is seated in the anchor groove
245, the
slot 276 in the outer roller 250 is rotationally oriented within the head rail
14 such that the
bottom rail 220 of the second shade 24 may drop vertically out of the seat 281
when the
tension in the second shade 24 is lessened by the operating system 240. The
generally
tangential orientation and generally vertical positioning of the seat 281,
with a relatively
vertical base wall 284, allows the weight of the second bottom rail 220 to be
effective to
extract the bottom rail 220 from the seat 281 when the tension in the second
shade 24 is
released in the retraction position. However, if the user does not intend to
extend the second
shade 24, then the second shade 24 may remain retracted. The operating
mechanism 240
may include a brake system to restrict unwanted downward movement of the
second or first
shades 24, 22.
In order to extend the second shade 24, the operating system 240 is further
actuated to
the level as desired by the user. When the user extends the second shade 24 to
the lowest
position (most extension), the limit nut 268 is positioned on the limit screw
266 in
engagement with the lower limit stop. Thus a single limit screw 266 may be
utilized to
define the upper limit of the retracted first shade 22 attached to the outer
roller 250, and to
define the lower limit of the extended second shade 24 attached to the inner
roller 248.
It is contemplated that the first shade 22 of FIGS. 30-34 (which may be the
same as or
different than that shown in FIGS. 1-5) may be wrapped about or unwrapped from
the front
side of the outer roller 250. Accompanying modifications to the structure
described herein
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would be necessary to facilitate the implementation of the dual roller shade
technology as
applied to a front-descending shade structure. It is also contemplated that
the roller lock
mechanism and accompanying elements necessary for it to operate may be
employed on the
right end of the head rail, in affiliation with the right end cap 226a, either
in conjunction with
5 a roller
lock mechanism on the left end of the head rail, or by itself. Also, the
second bottom
rail 220 may have an actuating rim 247 on either end thereof.
The foregoing description has broad application. While the provided examples
describe a silhouette-type shade and a black-out type shade, it should be
appreciated that the
concepts disclosed herein may equally apply to many types of shades.
Accordingly, the
10 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
examples. 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
15 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 foim 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
20 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.
25 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.
The term "a" or "an" entity, as used herein, refers to one or more of that
entity. As
such, the terms "a" (or "an"), "one or more" and "at least one" can be used
interchangeably
herein.
30 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.
Connection references
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36
(e.g., attached, coupled, connected, and joined) are to be construed broadly
and may include
intermediate members between a collection of elements and relative 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 sizes reflected in the drawings attached hereto may vary.
