U.S. patent application number 09/892279 was filed with the patent office on 2001-12-13 for fabric venetian blind and method of fabrication.
Invention is credited to Corey, John A., Marusak, Thomas J..
Application Number | 20010050131 09/892279 |
Document ID | / |
Family ID | 23374480 |
Filed Date | 2001-12-13 |
United States Patent
Application |
20010050131 |
Kind Code |
A1 |
Corey, John A. ; et
al. |
December 13, 2001 |
Fabric venetian blind and method of fabrication
Abstract
A method of making a fabric Venetian blind comprises helical
winding of a narrow, elongated strip, which, when properly
overlapped and bonded along longitudinal glue lines, will form the
vanes and front and rear facings of the blind. The strips may be
formed of a single, uniform material, or of adjacent,
longitudinally extending portions of relatively opaque and
relatively translucent fabric. An alternative embodiment uses the
same winding technique to similarly form a structure of only
translucent fabric, but with pockets for subsequent insertion of
opaque vanes. Several alternative strip configurations and assembly
arrangements are disclosed. The disclosed method and structure may
also be used to form products for other applications.
Inventors: |
Corey, John A.; (Melrose,
NY) ; Marusak, Thomas J.; (Loudonville, NY) |
Correspondence
Address: |
RADER, FISHMAN & GRAUER PLLC
39533 WOODWARD AVENUE
SUITE 140
BLOOMFIELD HILLS
MI
48304-0610
US
|
Family ID: |
23374480 |
Appl. No.: |
09/892279 |
Filed: |
June 26, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09892279 |
Jun 26, 2001 |
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09349907 |
Jul 8, 1999 |
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09349907 |
Jul 8, 1999 |
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09288389 |
Apr 8, 1999 |
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09288389 |
Apr 8, 1999 |
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08947608 |
Oct 9, 1997 |
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6024819 |
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Current U.S.
Class: |
156/73.4 |
Current CPC
Class: |
B29C 66/8242 20130101;
B29C 65/4825 20130101; B29C 65/08 20130101; B29C 65/4815 20130101;
E06B 9/34 20130101; B29C 65/02 20130101; B29C 66/131 20130101; B29C
66/8221 20130101; B29C 66/83413 20130101; E06B 2009/2435 20130101;
B31D 3/0215 20130101; B29C 65/50 20130101; B29C 66/1122 20130101;
B29C 66/71 20130101; E06B 9/262 20130101; B29C 66/437 20130101;
E06B 9/266 20130101; B29C 66/71 20130101; B29K 2067/00
20130101 |
Class at
Publication: |
156/73.4 |
International
Class: |
B32B 031/16 |
Claims
I now claim:
1. A method of forming a light-control panel comprising: providing
first and second elongated light-transmitting strip portions and an
elongated, relatively opaque strip portion; orienting said strip
portions in a generally parallel array, each strip portion having
right and left longitudinally extending edges and upper and lower
opposed faces; positioning said strip portions so that said first
strip portion overlaps at least a substantial portion of the
transverse width of said relatively opaque strip portion, and said
right edges of said first strip portion and said relatively opaque
strip are substantially superimposed, and so that said left edge of
said relatively opaque strip portion overlaps only the right edge
of said second strip portion, leaving the remainder of said second
strip portion free of overlap by said relatively opaque strip
portion; and joining said right edge of said first strip portion to
said right edge of said relatively opaque strip, and welding said
left edge of said relatively opaque strip portion to said right
edge of said second strip portion to thereby form a three-element
strip member.
2. The method of claim 1 which further comprises the steps of:
positioning longitudinally extending segments of said three-element
strip member in partially transversely overlapping and parallel
relationship; securing a first segment to an adjacent second
segment by joining said left edge of said first segment first strip
portion to said right edge of said second segment first strip
portion, and by joining said left edge of said first segment second
strip portion to said right edge of said second segment second
strip portion, the secured segments forming an elongated cell
having front and rear walls defined by said first and second
light-transmitting strip portions of said second segment, said cell
further having two additional walls defined by said relatively
opaque strip portions of said first and second segments; and
repeating said segment-securing step with additional adjacent
segments to form an extended array of parallel cells.
3. The method of claim 2 wherein said segment-positioning step is
accomplished by helically winding a continuous length of said
three-element strip member, with each successive winding segment
partially overlapping the immediately preceding winding
segment.
4. The method of claim 2 wherein said segment-positioning step is
accomplished by cutting said three-element strip member into pieces
of predetermined lengths and then laterally offsetting adjacent
pieces by a predetermined amount.
5. A method of forming a light-control panel comprising: providing
first and second elongated light-transmitting strip portions and an
elongated, relatively opaque strip portion; orienting said strip
portions in a generally parallel array, each strip portion having
right and left longitudinally extending edges and upper and lower
opposed faces; positioning said strip portions so that said first
strip portion overlaps a substantial but less than the entire
portion of the transverse width of said relatively opaque strip
portion, and said left edges of said first strip portion and said
relatively opaque strip portion are substantially superimposed, and
so that said left edge of said second strip portion overlaps only
the right edge of said relatively opaque strip portion; and bonding
said left edge of said first strip portion to said left edge of
said relatively opaque strip portion, and bonding said left edge of
said second strip portion to said right edge of said relatively
opaque strip portion to thereby form a three-element strip
member.
6. The method of claim 5 which further comprises the steps of:
positioning longitudinally extending segments of said three-element
strip member in partially transversely overlapping and parallel
relationship; securing a first segment to an adjacent second
segment by bonding said left edge of said first segment first strip
portion to said right edge of said second segment first strip
portion, and by bonding said left edge of said first segment second
strip portion to said right edge of said second segment second
strip portion, the secured segments forming an elongated cell
having front and rear walls defined by said first and second
light-transmitting strip portions of said second segment, said cell
further having two additional walls defined by said relatively
opaque strip portions of said first and second segments; and
repeating said segment-securing step with additional adjacent
segments to form an extended array of parallel cells.
7. A light-control panel comprising: a first three-element strip
including a first elongated light-transmitting strip portion having
a left edge bonded to a left longitudinally extending edge of an
elongated, relatively opaque strip portion at a first bond line and
a second elongated light-transmitting strip portion having a left
edge bonded to a right longitudinally extending edge of said opaque
strip portion at a second bond line; a second three-element strip
having a first elongated light-transmitting strip portion having a
left edge bonded to a left longitudinally extending edge of an
elongated, relatively opaque strip portion at a first bond line and
a second elongated light-transmitting strip portion having a left
edge bonded to a right longitudinally extending edge of said opaque
strip portion at a second bond line; a right edge of said first
elongated strip portion of said first three-element strip being
bonded to a left edge of said first elongated strip portion of said
second three-element strip at a third bond line that is
substantially directly over the first bond line of the second
three-element strip; and a right edge of said second elongated
strip portion of said first three-element strip being bonded
adjacent to a left edge of said second elongated strip portion of
said second three-element strip at a fourth bond line that is
offset from the second bond line of the second three-element strip
to form an elongated cell.
8. A light-control panel comprising: a first elongated
light-transmitting strip portion; a second elongated
light-transmitting strip portion; an elongated, relatively opaque
strip portion; each strip portion having right and left
longitudinally extending edges and upper and lower opposed faces;
said first elongated strip portion having a left edge bonded to the
left longitudinally extending edge of said opaque strip portion;
said second elongated strip portion having a left edge bonded on a
right longitudinally extending edge of said opaque strip portion;
and wherein said first and second elongated strip portions are each
bonded to a same face of the opaque strip portion.
Description
[0001] This is a continuation-in-part of U.S. patent application
Ser. No. 09/288,389, filed Apr. 8, 1999, which is a
continuation-in-part of U.S. patent application Ser. No.
08/947,608, filed Oct. 9, 1997.
FIELD OF INVENTION
[0002] This invention relates to window coverings, and more
particularly to the field of Venetian blinds having front and rear
panels of sheer or translucent fabric between which are arrayed a
series of relatively opaque fabric slats or vanes which can be
tilted for light control by means of limited rotation of a wind-up
roll to which the front and rear panels are connected. The
invention includes an improved product, fabricating technique and
apparatus for fabricating such blinds, which technique can also be
applied to forming multi-layered composite sheets used in other
types of products and for other purposes.
BACKGROUND OF THE INVENTION
[0003] The most familiar type of Venetian blind window covering
comprises a series of rigid slats or vanes suspended and controlled
by a ladder cord system. The slats are typically wood, plastic or
metal, and rest on the ladder cord rungs. The rungs are secured to
front and rear vertical cords whose upper ends are secured to
circumferentially spaced locations on a wheel. Limited rotation of
the wheel, by means of a control wand or cords, causes relative
motion between the front and rear cords, which in turn tilts the
rungs and vanes. The entire array can be raised and lowered by
additional cords which act to lift a bottom rail.
[0004] A modified type of Venetian blind is disclosed in U.S. Pat.
No. 3,384,519 to Froget. There, the ladder cord system is replaced
by front and rear cloth panels to which the vanes are heat welded.
Preferably, the cloth panels and vanes are all made of
thermoplastic yarns, to facilitate bonding by heat welding. Partial
rotation of an upper drum, to which the panels are connected,
shifts the panels relative to each other, thereby causing the vanes
to tilt for light control. Another similar product is disclosed in
French Patent No. 1,521,488 to Demerson. Demerson prefers films to
woven fabrics, and discloses adhesive bonding of the vanes to the
facing panels.
[0005] Several more recent patents are directed to modifications of
Froget's basic idea, wherein the vanes are made of flexible fabric,
adhesively bonded to the front and back panels. Additionally, the
entire array can be retracted from the window opening by winding it
onto an upper wind-up roller by means of cords which lift a bottom
rail. Representative of these patents are U.S. Pat. Nos. 5,287,908,
5,313,999, 5,320,154, 5,394,922 and 5,456,304, all assigned to
Hunter Douglas, Inc., and a patent to Ren Judkins patent, U.S. Pat.
No. 5,339,882.
[0006] U.S. Pat. No. 5,664,613 (and subsequently assigned to a
company owned by the assignee of the present application) describes
another form of construction for a fabric Venetian blind. A
continuous panel of relatively translucent material forms one
facing of the blind. To that panel is bonded a series of parallel
fabric strips at uniform intervals. Each strip comprises two
adjacent portions of dissimilar material, one being relatively
translucent and the other relatively opaque. The free edge of the
opaque portion is bonded to the facing panel, while the free edge
of the translucent portion is bonded to the adjacent strip at the
junction line of that strip's two portions. The assembled
translucent portions of the constituent strips become the second
facing panel of the completed blind. That is, the second facing
panel, rather than being a single continuous panel of fabric, is a
composite of several parallel strips, each having a height
dimension approximately equal to the width (or depth) of the
vanes.
[0007] U.S. Pat. No. 5,888,639, assigned to Newell Operating Co.,
discloses in FIGS. 15-19 a fabric Venetian blind having a structure
very similar to that disclosed in FIGS. 3-6 of my parent
application, Ser. No. 08/947,608, filed Oct. 9, 1997 (which Figures
are also found in the present application). As in my parent
application, the product is a laminated assembly of previously
formed three-element strips. However, the relationship of the
individual components of each three-element strip, and the method
of preparing each such strip for subsequent assembly to adjacent
strips, is substantially different. Furthermore, the method of
assembly of the three-element strips to each other is substantially
different, in that the strips are cut to a predetermined length,
prior to their lamination to each other, which length corresponds
to the desired width of the fabric Venetian blind. The method of
assembly disclosed in my parent application and herein, wherein the
three-element strip is helically wound upon itself in partially
overlapping successive layers, represents a substantial improvement
in the speed and economy of manufacture.
[0008] U.S. Pat. Nos. 5,490,553 and 5,603,369, assigned to Hunter
Douglas, disclose in FIGS. 16-19 a vertical blind wherein each
vertical blind vane is formed of the same strip of material as an
adjoining portion of a facing panel on one side of the vanes. The
single facing is a composite of narrow vertical strips. The vane
portion of this strip is doubled back on itself. Another patent
assigned to Hunter Douglas, U.S. Pat. No. 5,638,880, discloses in
FIG. 26 a vertical blind wherein the facing on one side of the
vanes comprises a series of vertical strips of material, each
joined along one vertical edge to an adjacent strip, and at the
other vertical edge to both the adjacent facing strip on that side
and a discrete piece of substantially rigid, planar material
forming the vane. The patent further discloses that both a front
and a rear facing may be fabricated of such strips, and the strips
and vanes can be oriented in either the vertical or horizontal
directions.
[0009] U.S. Pat. No. 4,631,217, also assigned to Hunter Douglas,
discloses in FIG. 2 a honeycomb or cellular type of window covering
wherein a series of pleated, generally Z-shaped strips, each formed
of a single piece of fabric, are bonded together in a manner
whereby each strip forms the front portion of one cell, the rear
portion of an adjacent cell, and a dividing wall between the two
cells. The dividing walls, however, are incapable of functioning as
the vanes of a Venetian blind type of product, because they remain
substantially perpendicular to the front and rear faces of the
window covering throughout the full range of expansion and collapse
of the cells.
[0010] Known processes for manufacturing these prior art fabric
Venetian blinds are complex, slow and costly, and have contributed
to a high price for these otherwise attractive products.
[0011] Accordingly, it is a principal object of the present
invention to create additional alternative three-element or
multi-element strip configurations and bonding procedures which
also lend themselves to the use of the more economical helical
winding technique disclosed in my above-mentioned parent
application.
SUMMARY OF THE INVENTION
[0012] The presently contemplated application for the disclosed
invention is the formation of fabric Venetian blinds, using a
technique of helically winding an elongated strip of fabric. In one
embodiment of the Venetian blind, a three-portion strip is
initially formed from three side-by-side, longitudinal, bands or
portions of approximately equal width and length. Each edge of the
central portion is joined by ultrasonic welding to an edge of the
adjacent outer portion. The outer portions are formed of sheer or
relatively transparent material, and the central portion is
relatively opaque.
[0013] As a result of the helical winding process, the central
portion becomes the blind vane, while the two outer portions
ultimately become segments of the front and rear composite facings
of the blind. Successive windings are staggered and partially
overlapped so that two of the three portions of the underlying
winding are covered by the overlying winding. Two longitudinally
extending glue lines are applied along the underside of the
infeeding overlapping strip, these being positioned to bond
together adjacent windings. A tube-like wound structure is formed
which, when cut open along a line perpendicular to the helix angle,
will result in a fabric Venetian blind. The disclosed method of
fabrication thus differs significantly from the prior art. Indeed,
this product and its benefits could not so economically be achieved
by known manufacturing processes.
[0014] The strips, once assembled by the winding operation, produce
both the flexible vanes and the front and rear face panels in a
single continuous process. The resulting composite face panels
comprise narrow, horizontal strips which have been joined
successively to one another in the winding operation. The resulting
flexible vanes swing between light-admitting and light-blocking
positions upon relative movement between the two composite face
panels.
[0015] Alternative constructions may include an additional layer of
fabric in the vane portion, to create a pocket into which an opaque
insert can subsequently be inserted, and the formation of products
having multiple rows of vanes or central ligaments.
[0016] Another alternative construction relates to a modified
three-element strip configuration wherein the entirety of one sheer
strip more fully overlaps the relatively opaque vane strip, with
one edge substantially aligned with a first edge of the vane and
ultrasonically welded thereto, while the other sheer strip is
slightly lapped under and ultrasonically welded to the second edge
of the vane. The vane is slightly wider than each of the sheer
strips, permitting the vane to be simultaneously welded to each of
the sheers without interference by overlapping the other sheer at
the desired weld zone.
[0017] The novel winding technique disclosed herein may also be
used to fabricate products from other types of materials or
intended for other fields of use. For example, multi-layered
materials made from thermally non-conductive or reflective material
may be made for insulation applications; polarized or tinted films
may be used to create desired optical effects; and materials of
selected porosity may be used to form air filtration products.
[0018] Also disclosed is the use of a resiliently deformable
circumferential surface on a nip roll which functions to steer the
sheet-like material which is driven by the roll set when
differential pressure is applied to the two ends of the deformable
roll.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1A is a simplified perspective view of the fabric
Venetian blind of the present invention, shown with the vanes
positioned in their maximum light-admitting setting.
[0020] FIG. 1B is a view similar to FIG. 1A, showing the vanes
positioned in a partially closed setting.
[0021] FIG. 2 is a side view, in simplified form, of a
representative prior art fabric Venetian blind, wherein the vanes
are joined to single, continuous-sheet type front and rear sheer
panels. The blind is shown in the fully-open position of the vanes,
while a partially closed position is shown in phantom lines.
[0022] FIG. 3 is an enlarged fragmentary side view of the blind of
FIG. 1A.
[0023] FIG. 4 is an exploded schematic view of the blind of FIG. 3,
showing the relationship of adjacent three-portion strips.
[0024] FIG. 5 is an enlarged, simplified view of the blind of FIG.
3, with the vertical scale exaggerated to reveal the relationship
of adjacent three-portion strips.
[0025] FIG. 6 is a perspective view of a fragment of a
three-portion strip such as used in the embodiments of FIGS. 4 and
5.
[0026] FIG. 7 is an exploded end view of a second form of the
three-portion strip.
[0027] FIG. 8 is a view similar to FIG. 7, showing a third form of
three-portion strip.
[0028] FIG. 9 is a simplified perspective view of equipment
suitable for forming a blind according to FIGS. 3-5 using the
process of the present invention.
[0029] FIG. 10 is a schematic side elevational diagram of the
equipment shown in FIG. 9.
[0030] FIG. 11 is a simplified plan view of the equipment of FIG.
9, showing the supporting framework.
[0031] FIG. 12 is a simplified side elevational view of the
equipment of FIG. 11.
[0032] FIG. 13 is a perspective view of a helically wound tube of
blind material, prior to being cut open, viewed from the opposite
end of the spars from the end shown in FIG. 9.
[0033] FIG. 14 is a schematic end view, in the direction of the
cutting plane C-C, of the helically wound tube showing how it is
cut open to form a full-width fabric Venetian blind.
[0034] FIG. 15 is a schematic elevational view of nip roll set
66.
[0035] FIG. 16 is an end view of the nip roll set of FIG. 15.
[0036] FIG. 17 is a plan view of the nip roll set of FIG. 15.
[0037] FIG. 18 is a view similar to FIG. 5, showing an alternative
embodiment having pockets to receive opaque vane inserts.
[0038] FIG. 19 is a view similar to FIG. 5, showing still another
alternative embodiment wherein multiple rows of vanes or central
ligaments are provided.
[0039] FIG. 20 is a view similar to FIG. 9, showing a modified
system for feeding the fabric strip to the winding equipment.
[0040] FIG. 21 is a view similar to FIG. 9, showing another
modified system for feeding the fabric strip to the winding
equipment.
[0041] FIG. 22 is an enlarged, simplified view, similar to FIG. 3,
but showing the configuration which results from a modified
location of the glue line which joins successive three-element
strips.
[0042] FIG. 23 is an end view, with the vertical scale exaggerated,
of a prior art three-element strip configuration.
[0043] FIG. 24 is an end view, similar to FIG. 23, showing one of
the modified three-element strip configurations of the present
invention.
[0044] FIG. 25 is a fragmentary perspective view, with the vertical
scale exaggerated, of a portion of the helical winding sequence
used in conjunction with the three-element strip configuration of
FIG. 24.
[0045] FIG. 26 is an enlarged fragmentary side view of the blind
which results from use of the three-element strips of FIG. 24.
[0046] FIG. 27 is a view similar to FIG. 26, but showing the
configuration which results from a modified location of the glue
lines which join successive three-element strips.
[0047] FIG. 28 is a view similar to FIG. 25, but showing the glue
lines initially applied to the opposite element of the opposed
elements to be joined.
[0048] FIG. 29 is a view similar to FIG. 25, but showing a modified
orientation of the three-element strip of FIG. 24 as the strip is
fed into the helical winding apparatus.
[0049] FIG. 30 is a fragmentary perspective view of a portion of
the winding apparatus adapted for use with the three-element strip
of FIGS. 24-26.
[0050] FIG. 31 is a fragmentary plan view of a portion of the
winding apparatus illustrated in FIG. 30.
[0051] FIGS. 32a-32b through FIGS. 38a-38b are end views, similar
to FIG. 23, showing additional alternative embodiments of
three-element strips according to the present invention, and
wherein the "a" and "b" figures of each pair show the strip in its
flattened configuration after welding and in its partially opened,
light-admitting configuration (as achieved after assembly with
other such strips in a light-controlling product, respectively.
[0052] FIGS. 39a-39b through FIGS. 42a-42b are end views, similar
to FIGS. 32-38, showing still further alternative embodiments,
wherein two-element fabric strips are welded to form a pocket for
subsequent reception of an opaque material.
[0053] FIG. 43 is an end view, with the vertical scale exaggerated,
of a modified three-element strip configuration of the present
invention.
[0054] FIG. 44 is an enlarged fragmentary side view of the blind
which results from use of the three-element strips of FIG. 43.
DETAILED DESCRIPTION
[0055] FIG. 2 of the drawings shows a fabric Venetian blind 20
which, in its general construction, is typical of the prior art.
The solid lines indicate the fully-open position of the vanes. The
blind comprises a front facing 22, rear facing 24 and vanes or
slats 26. The front and rear facings are each typically formed of a
continuous panel of sheer material, chosen for its combination of
soft, aesthetic appeal, its ability to permit a substantial amount
of light to be transmitted when the vanes are in their open
position, and, depending upon the selected weave, its ability to
permit viewing of scenes through the material. The vanes are bonded
along their respective longitudinal edges to the front and rear
facings. Bonding can be by adhesive or thermal welding. When the
wind-up roller from which the blind is suspended is rotated
slightly, the front and rear facings shift in a vertical direction
relative to each other, causing the angle of the vanes to change. A
position near the fully-closed setting of the vanes is shown in
phantom in FIG. 2, with the elements labeled with primed
numerals.
[0056] FIGS. 1A and 1B show, in simplified form, the basic elements
of a complete fabric Venetian blind assembly 28 in full-open and
near-closed conditions, respectively. The blind comprises front and
rear sheer or relatively translucent facings 30,32, respectively, a
plurality of relatively opaque vanes 34, a wind-up roller 36 and a
bottom rail 38. Not shown are the cords or other means for rotating
roller 36 to adjust the vane angle and to roll the shade around the
roller to fully expose all or a portion of the window opening.
[0057] Comparing FIGS. 1A and 1B it can be seen how the points of
attachment of the front and rear facings to opposite sides of the
circumference of the roller result in relative vertical movement of
the facings, and therefore adjustment of the vane angle, when the
roller is rotated slightly.
[0058] FIG. 3 and the following figures illustrate various novel
aspects of the present invention. A first embodiment is best shown
in FIGS. 4-6. Fabrication begins with the creation of an elongated
strip 40 (see FIG. 6) comprising at least two dissimilar fabric
materials. The outer portions 30',32' are formed of relatively
translucent or sheer material, while central portion 34 is formed
of a relatively opaque material. Outer portions 30',32' may be
formed of the same or different fabrics. The central portion can be
opacified by use of a more densely woven fabric, or by coating or
laminating (see discussion of FIGS. 7 and 8 below) or by the use of
opaque inserts (see discussion of FIG. 18 below). The adjoining
edges of these portions may be connected by gluing, ultrasonic
welding, thermal bonding or stitching. Ultrasonic welding is the
preferred method, because it is speedy and permits precision
location of adjoining edges.
[0059] To accomplish such welds, the strip portions are made to
overlap one another in the region to be welded, which overlap is
then melted together by a commercially available ultrasonic seam
welding device such as a Seam Master LM 720 or LM 920 manufactured
by Sonobond Corporation. By way of example, the overlap may be
about 0.10-0.20 inches, with the welding performed by a
stitch-wheel having about one and one-half times the pitch of the
main knit, in order to assure fiber capture. A continuous (rather
than stitch knit) will also work if the vane is non-woven or film
material. This process also beneficially compresses the welded zone
and destroys the fabric interstices, so that the joint will not be
porous to subsequently applied glue lines. Thus, unsightly
bleed-through of the glue lines is avoided. The width of strip 40
is approximately three times the desired vane width (i.e., blind
thickness in the fully open setting of the vanes). It should be
noted that the illustrations of FIGS. 4-6, for simplicity, show the
three-element strips as if they are each an entirely coplanar
composite structure, without_overlapping junctions at the adjoining
edges of their individual component strips,. In practice, it is
preferred that the vane overlaps one sheer and underlaps the other
sheer, with the strips being overlapped with adjacent three-element
strips so that the sheer of one strip overlaps and is directly
glued to the sheer of the preceding and succeeding strips.
[0060] Unlike known processes of the prior art, the fabric Venetian
blind of the present invention is generated by helically winding
the strip upon itself, in partially overlapping fashion, with each
winding being bonded to the preceding winding along uniformly
located longitudinal bonding lines. The result is that each winding
of strip material 40 constitutes one vane and an adjacent fragment
of each of the front and rear facings of the completed fabric
Venetian blind.
[0061] The relationship of adjacent windings of strips 40 of this
first embodiment is best seen in FIGS. 4 and 5. Each strip winding
40 overlaps approximately two-thirds of the preceding strip
winding. Specifically, the leading edge (i.e., the right edge as
viewed in FIG. 6) of a winding is placed at or near the
sheer/opaque junction of the preceding winding. A previously
applied front glue line 42 is located on the underside of the upper
strip at that contact line, while a previously applied rear glue
line 44 is located at the underside of the upper strip at or near
the junction between the rear sheer portion 32' and the opacified
vane portion 34. That rear glue line 44 will then join such strip
to the trailing edge of the previously wound or lower strip 40.
[0062] The choice of location of glue lines 42 and 44 relative to
the junctions between the sheer and relatively opaque portions of
each winding is not critical. FIG. 22 shows the identical
three-element strip illustrated in FIG. 5, but with the front and
rear glue lines 42", 44", respectively, shifted laterally away from
the junction between the respective sheer and relatively opaque
portions of each three-element strip. That relocation of the glue
lines creates short tab-like extensions 43", 45" of the respective
sheer portions, which tabs project into the interior of the cells
defined by the sheers and vanes.
[0063] Initial indications are that these tab-like extensions 43",
45" appear to be beneficial. Fabric Venetian blinds which have the
vane material connected essentially directly to the planes of the
front and rear facings have a tendency not to fully close in the
overlapping, light-blocking position. This phenomenon appears to
result from the "memory" which the vanes retain of their shape in
the open position. However, the optional use of sheer tabs 43",
45", resulting from relocation of the glue lines, places much less
resilient sheer material in these flexing or hinging zones. The
reduced memory and/or resilience of the sheer material allows the
relatively opaque vanes to lay flatly against the faces, even if
there is some residual splay in the weld joints. This benefit is
even greater where the tab extends in the reverse direction from
the vane, as in the case of the upper tabs shown in FIG. 27 as
compared with the lower tabs of that Figure.
[0064] Furthermore, if the extreme edge of the center opaque vane
(outboard of its weld to the sheer tab) overlays the sheer tab to a
substantial degree, as is typical, then the reverse-style tab
beneficially acts as a buttress against the facing when the vanes
are pulled into the open, view-through position. The Vane must then
adopt greater transverse flex and curvature, which is an
established aesthetic benefit, rather than locally hinging as a
stiff and flat element from the facing at the much softer sheer
tab.
[0065] As exemplified by the configuration of FIG. 22, the
relatively opaque portions need not fully span the distance between
the front and rear facings, as long as the opaque portions overlap
when the blind is in the fully closed position. Glue lines 42 and
44 may be spaced from the exposed, exterior edges of the strips, if
desired, as when a series of unsupported, fringe-like bands are
desired on one or both of the facing panels.
[0066] Alternative forms of the three-portion strip 40 are shown in
FIGS. 7 and 8. In FIG. 7, the strip is formed of a full-width
relatively translucent portion 46, with a relatively opaque central
portion 48 laminated to it by any of the previously described
joining techniques. This embodiment is not preferred, because it
tends to be too stiff to hang uniformly. In the FIG. 8 embodiment,
the three-portion strip is formed of a single piece of fabric, but
with less dense weaving patterns being used for the outer portions
50, and a more dense or opaque weaving pattern being used for the
central portion 52 which will become the vane of the finished
blind. The embodiments of FIGS. 6 and 8 are preferred, because they
tend to hang in a more uniform, wrinkle-free manner.
[0067] The method and equipment employed for fabricating the
embodiment of FIGS. 3-5 is illustrated in FIGS. 9-17 of the
drawings. The manufacturing equipment includes a pair of parallel,
non-rotating spars 56,58 skewed at an angle to two parallel nip
roll sets. The first nip roll set 60 serves to drive the fabric by
tensioning the upper reach of fabric tube 88. Nip roll set 60
comprises a lower, motor-driven roll 60 and an upper, pressure roll
62. The second nip roll set 66 serves to provide tensioning drag
and to steer fabric tube 88. It comprises a lower, motor-driven
roll 68 (which is driven in a manner to tension or brake the span
of fabric between it and drive nip roll set 60) and an upper,
steering pressure roll 70. The steering action is described below.
Rolls 62 and 68 may be driven by belt-driven sprockets (not shown).
The fabric between nip sets is thus held flat and substantially
planar for attachment of the infeeding strip, assuring that the
final product will also lie flat.
[0068] The three-portion fabric strip 40 is fed from strip supply
roll 72, which has its own drive motor M which drives roll 72 at a
speed controlled by the position of dancer 73. If the strip loop
around dancer 73 gets smaller, the motor driving roll 72 speeds up
to maintain a uniform amount of strip in that portion of the strip
feed system. Strip 40 continues from dancer 73 through a nip roll
set comprising upper roll 74 and lower motor-driven roll 75 to
tension-sensing roll 76, which is provided with a load cell on its
axle. This load cell senses tension in the strip between rolls 76
and 64, and adjusts the speed of motor M associated with nip roll
75 to maintain the desired tension in that portion of the
in-feeding strip.
[0069] Two adjacent glue applicators 78 apply continuous beads of
glue 42,44 to strip 40.
[0070] The support structure for the two pairs of nip rolls 60,66
comprises main mounting plate 80 (see FIGS. 11-12) and end plate 82
connected thereto by cantilevered beams. End plate 82 supports the
end of upper rolls 64,70 remote from main plate 80, while lower
rolls 62, 68 are supported by similar cantilevered beams and end
plate 82'. These end plates must be supported in this fashion so
that no support structure crosses from inside to outside the fabric
loop or tube 88 defined by spars 56, 58. Spars 56,58 are
cantilevered from a separate frame structure 84, which can be
pivoted about vertical axle 86 to permit the spars to be set at a
predetermined angle relative to the two nip roll sets. This angle
is a function of the desired lead angle for the helical winding of
strip 40, as will be explained below. Appropriate clearance holes
are placed in frame 84 to permit passage of spars 56,58. The end of
cantilevered spars remote from mounting frame 84 is free of
connection to supporting structure to permit removal of the
continuously formed fabric tube therefrom and to allow adjustment
of the spar angle relative to the lower rolls. Alternatively, if
spar angle adjustment were deemed unnecessary, the ends of the
spars could be attached to the lower roll support or to any other
structure lying entirely within fabric loop 88. Alternatively, the
spars can extend far beyond the longest desired window shade and be
supported to ground at both ends. In that case, the fabric tube
must be cut open as described below to remove the fabric product
from the spars.
[0071] As best shown in FIG. 9, the process begins with the
three-portion fabric strip 40 being pulled from supply roll 72 by
drive nip roll set 74-75. Controlled feed rate of the strip between
supply roll 72 and nip roll set 60 is provided by motor-controlling
signals from dancer 73. Constant tension in the strip between nip
roll set 74-75 and drive nip set 60 is provided by
motor-controlling signals from tension-sensing roll 76, as
explained above. The strip is directed past glue applicators 78,
and the upper, glue line-bearing side of the strip is inverted by
roller 76 so that such glue lines come face-to-face with the
preceding winding between the rolls of nip roll set 60. There, the
glue joint is closed and the overlapping windings are bonded to
each other.
[0072] As will be appreciated by reference to FIG. 5, the infeeding
strip 40, with glue lines 42, 44 already applied by applicators 78,
must precisely register with the preceding winding traveling on the
upper reach of the fabric loop extending from spar 58, through drag
nip roll set 66 to drive nip roll set 60, where infeeding strip 40
first comes into contact with the preceding winding for bonding.
FIG. 9 shows how the skewing of spar 56 causes the lower reach of
the endmost fabric strip winding to shift laterally as it travels
to spar 58 and back to the point between the rolls of drive nip
roll set 60 where the incoming strip, with freshly applied glue
strips 42,44 on its underside, is pressed against it. The lateral
shift, a result of the helix lead angle, is selected to cause a
shift of approximately one-third of the width of strip 40, so that
glue lines 42,44 will register with the previous winding as shown
in FIG. 5. Thus, the required relative positioning of the
relatively opaque vane portion 34 with the relatively translucent
facing portions 30',32' will be achieved when the vanes of the
finished blind are placed in their light-blocking or fully closed
angular setting.
[0073] Precise control of the amount of overlap between successive
windings is provided by two independent controllers. First, the
lateral position of infeeding strip 40 from supply roll 72 is
provided by a controller (not shown), or other known web guiding
device, which laterally shifts the placement of roll 72 along its
rotational axis.
[0074] Secondly, additional control of registration of the
overlapping windings of strip 40 is provided by drag nip roll set
66, which has a "steering" capability. Both pressure rolls 64 and
70 are rubber-coated, to provide a compressible surface. Unlike
pressure roll 64 of drive nip roll set 60, which has a constant
force pressing it downward toward drive roll 62, steering pressure
roll 70 has independently controllable downward pressure (described
below) applied at its opposite ends. When the applied pressures are
equal at both ends of roll 70, the roll has a strip-contact zone of
uniform width along its entire length, where the rubber roll is
deformed about the unyielding surface of roll 68. The passing
fabric strip does not deviate from its straight-line path, and
continues to take the shortest route from spar 58 to nip roll set
60. An increase in the nip pressure at one end of roll 70 increases
the concavity of its rubber-coated surface as it is deformed by the
cylindrical contour of the non-yielding surface of lower roll 68.
The path of the fabric strip at that end of the roll lengthens as
it is forced to assume the longer curved shape of the further
deformed surface of roll 70. That is, the strip-contact zone (at
that end) between the opposed rolls of nip roll set 66 increases to
a greater segment of an arc about the rigid roll's surface
resulting from the extra deformation of the surface of roll 70
straddling a lengthened portion of the perimeter of lower roll 68.
The resulting longer strip path on the edge with increased steering
pressure creates increased strip tension on that edge, pulling or
steering the fabric toward that edge. Reducing pressure at one end
similarly reduces the path there relative to the nominal condition,
drawing the web toward its other edge.
[0075] FIGS. 15-17 schematically illustrate a steering control
system for varying the pneumatic pressure applied to cylinder P1 on
one end of pressure roll 70. That end of pressure roll 70 is
mounted in vertically slideable bearings. The control signal is
provided by a proportional voltage output device in the form of an
edge-position sensor 92, which may be in the form of a linear array
of light-emitting outputs and photocells on opposite sides of the
plane of the passing fabrics. Any deviation from the desired edge
position of the strip generates a corresponding deviation from a
nominal pressure-demand voltage signal sent by sensor 92 to control
computer/proportional regulating valve 94. Valve 94 bleeds or
supplies air pressure from source 96 as required to maintain a
desired cylinder pressure defined by the voltage signal. The
resulting tilting and deformation of roll 70 is shown in
exaggerated form in FIGS. 15-16, and the corrected path of the
upper reach of fabric tube 88 is shown in the plan view of FIG.
17.
[0076] While the use of crowned rolls to "steer" a web or flat belt
to a central position, and the use of flared-end rollers to spread
and de-wrinkle a web, are well known, it is believed that the use
of a selectively deformable roller at a nip to steer a web by local
control of path length is novel. Those skilled in the art will
recognize that steering can be achieved either by varying the
pressure on both ends, or maintaining nip pressure constant on one
end while increasing or decreasing the pressure on the other end,
as required.
[0077] Because fabric strip 40 has a helix lead angle as it winds
onto spar 56 (which is skewed by such angle relative to drive nip
roll set 60), the fabric "tube" 88 continuously advances toward the
opposite end of the non-rotating spars. The spars, which do not
rotate, are highly polished to facilitate this sliding movement
without damage to the fabric.
[0078] The spars are preferably sufficiently long to permit them to
hold an entire tube formed from a feed roll. For example, a machine
has been built with twelve-foot long spars, for use with a three
hundred-yard long feed roll. The spars may be perforated to permit
pressurized air to provide an air bearing to reduce the drag of the
fabric tube as it advances along the spars. When the machine is
shut down to install a fresh feed roll, the tube may be cut off,
using a scissors, by first cutting around the circumference of the
tube, generally along a given strip. Alternatively, a razor knife
may be plunged through the still-forming tube, just beyond the ends
of nip sets 60, 66, and held in position for one full rotation of
the tube. Then the knife is drawn quickly across the severed
winding to separate the formed length of tube downstream from the
still-forming tube upstream. The separated tube is then slid away
along the spars and cut open along line C-C while the machine
continues to form more tube. Then, the severed tube, while still
hanging on the spars, is cut along a line C-C (see FIGS. 15-16),
which is perpendicular to the edge of the windings, so that the
tube may be laid open to form a parallel-edged flat form or slab 90
with the wound strips perpendicular to the parallel edges. If an
automatic splicer is fitted to the supply roller 72, the operation
of the machine can be thus made continuous.
[0079] In the presently constructed machine, the cut open product
slab 90 is about ten feet wide and about ten or more feet long. The
fabric slab is then cut to size for particular windows, and the
fabric Venetian blind is fully formed except for its connection to
a wind-up roll and associated hardware.
[0080] Many different products and visual effects can be achieved
by use of the present invention. A basic Venetian blind may
preferably be formed of polyester (for strength and UV resistance)
knitted mesh front and rear, of different mesh patterns, and a
knitted polyester relatively opaque fabric for the vanes. Where
minimization of the moir effect is not a primary concern, the same
fabric may be used for the front and rear facing panels. A
preferred fabric is a stabilized tricot of 28 gage 20/1 semi dull
polyester, manufactured by Gehring Tricot Corporation, and
identified as P201. Stabilized tricots provide a preferred
combination of visual sheerness with a high degree of structural
stability for ease in handling during manufacture. Where moir
effect minimization is a concern, then such fabric may preferably
be paired with a rear facing fabric in the form of a diamond tulle,
such as 36 gage, 20/12 bright polyester, manufactured by Gehring,
and identified as P1732. The relatively opaque vane may be a jersey
fabric, 70/33, 20/1 semi-dull textured polyester, like that
manufactured by Native Textiles, and identified as P7020.
[0081] A significant advantage of the use of the helical
strip-winding technique of the present invention is that the
resulting front and rear sheer panels, being composites of
multiple, narrow, horizontally disposed sheer strips, tend to
suppress objectionable moir effects which would arise if the same
choice of fabrics were used in the form of single-sheet, continuous
panels for the entire front and rear facings. Tricot type fabric, a
preferred form of weave, has heavily barred patterns extending in
the longitudinal or "machine direction" of the fabric as it is
manufactured. When such barring is oriented in the vertical
direction (of a normally hanging window shade) for continuous
manufacture of single panel facing, a cross-grid pattern is
established with the horizontally oriented vanes and vane shadows,
leading to a relatively dramatic and objectionable moir effect.
With the strip-winding technique disclosed herein, the sheer strips
and associated machine-direction bars of the tricot fabric can be
oriented horizontally. In this orientation, the barring pattern
does not form a cross grid with the vanes, but tends to blend in
with the parallel vanes and vane shadows. Also, the multiplicity of
narrow sheer strips acts to break up otherwise large-scale moir
patterns into smaller, more localized, banding patterns which are
less objectionable. Still further, the individual sheer strips tend
to be slightly tilted or bowed relative to each other, rather than
more truly parallel, as in the case facing panels formed of single,
continuous sheets. This fact, along with small, local differences
in tension and alignment of individual threads in adjacent wraps,
further diminishes large scale coherence in the moir interference
patterns.
[0082] Alternatively, other knits, wovens or nonwovens may be used
for either the facings or vanes, and hot-melts, pressure
sensitives, tapes or other adhesives may also be used, provided
they possess UV resistance, non-yellowing and strength with no flow
at up to 200 degrees Fahrenheit for durability in sunlit
windows.
[0083] While many of the known glues can be used, hot-melt
adhesives are preferred, such as the high-temperature polyester
manufactured by Bostik and identified as 7199 or W4360B. This type
of adhesive is advantageous because of the ability to be precisely
metered through application nozzles, high initial tack, rapid cure
to a flexible final state, ultraviolet resistance for use in sunlit
windows and minimum of bleed-through adhesion as a result of the
rapid cooling of its surface once applied. Alternatively,
moisture-cure polyurethane hot-applied glue, such as HL-9608
manufactured by H. B. Fuller, has many of the same features, plus
added strength and flexibility once cured, but these benefits must
be considered in light of slower curing and associated
bleed-through tendencies.
[0084] Another alternative Venetian blind product which may be
formed by this helical winding technique would use fabric of
uniform light-transmitting ability throughout. That is, instead of
a three-segment strip of varying opacity, the winding strip could
be made of a single, ultralight, non-woven fabric. In the "open"
position, light would be filtered through two layers (the front and
rear composite facings), while in the partially and fully closed
positions, it would be further filtered through the vane layer of
fabric, causing an additional fifty percent diminution in the light
transmission through the blind. If angle-dependent polarizing
material were used, further control of the light transmission could
be obtained.
[0085] Because this helical winding process permits use of narrow
strips of material to form the composite facing panels, the face
panels can be formed of lace material. Heretofore, continuous sheet
facing panels were too wide to permit lace to be used at an
acceptable price. Also, it would be difficult to match the pitch of
the finished shade to the repeats of the wide-goods lace. As
further alternatives, the vane portion may be a thin wood veneer
laminate, or printed cloth with different colors on its opposite
sides.
[0086] The modified embodiment of FIG. 18 is similar to the
embodiment of FIG. 5, but employs a different means of opacifying
the center or vane portion of each strip. These pocketed strips 102
each comprise overlapping rear and front sheer facings 104, 106,
respectively, pre-joined (i.e., prior to winding) by glue lines or
ultrasonic junctions 108. The central overlapping thirds and glue
lines define an insert-receiving pocket 110. Strips 102 are wound
and bonded together at glue lines 112, as in the previously
described embodiment of FIGS. 5, 9 and 10. Later, after cutting
open the helically wound tube, opaque inserts 114 may be inserted
in pockets 110 to provide the desired opaque vanes. As a further
alternative, the pocketed strips can have the sense of the overlap
reversed. That is, front sheer facing 106 can overlap rear sheer
facing 104. Alternatively, the individual facing strips 104, 106
and a continuous strip of opaque insert 114 can be helically wound
together by use of multiple feed rolls 72 appropriately positioned
to feed with the desired overlaps onto the winder.
[0087] FIG. 19 illustrates an example of a double-deep structure
having multiple rows of vanes or central ligaments. Each strip 116
comprises five segments, namely, rear, front and central sheer
portions 118, 120, 122, respectively, and first and second
opacified portions 124, 126, respectively. Successive strips are
helically wound and bonded together at glue lines 128, as
previously described. Opacified portions 124, 126 could have
different degrees of opacity, so that, depending upon which column
of vanes was closed, a light-blocking or a semi-translucent mode
could be selected. Alternatively, these two portions could be
cross-polarized to provide a choice of opacities. With both vanes
fully open, a transparent light path would be provided through the
aligned sheer portions 118, 120, 122.
[0088] By shortening the length of central ligament or sheer
portion 122, it will "go straight" or taut before the front and
rear facings, providing uniform pitch for the hanging blind, and
allowing the front and rear facing segments 118 and 120 to assume a
softer, slightly looped or curving, appearance.
[0089] In an alternative winding process, a multi-lead winding
arrangement can be employed. A first such arrangement, illustrated
in FIG. 20, introduces a second distinct pre-formed three-portion
strip 40b from a separate supply roll 72. For the simplicity of
illustration, dancer 73 has been omitted from this Figure, as well
as from the further alternative illustrated in FIG. 21. A similar
pair of glue nozzles 78b is provided to apply glue stripes to strip
40b in the same manner and location as in the case of the primary
strip 40a. Because the fabric loop or tube 88 is lengthened by two
non-overlapping strip portions per revolution, rather than one, the
helix lead angle must be doubled. That is, the angle between spars
56, 58 and nip sets 60 and 66 must be doubled.
[0090] A second multi-feed arrangement is illustrated in FIG. 21.
Instead of feeding a pre-formed three-portion strip from supply
roll 72, the individual portions of the strip can be fed from
separate supply rolls and joined to each other (with minimal
overlap) as they are laid upon and joined to the previously applied
winding of fabric tube 88. These junctions are preferably achieved
by ultrasonic welding, but glue lines may alternatively be used. In
FIG. 21, three supply rolls simultaneously feed separate strip
portions 40a, 40b and 40c. Only a single glue line (from nozzle
78a) is required to secure portion 40a to the prior winding or
wrap. Similarly, only a single glue line (from nozzle 78c) is
required to secure central portion 40c to adjacent portion 40b of
the same wrap. However, two widely spaced glue lines (from nozzles
78b) are required to join central portion 40b to portion 40a of the
same wrap and to separately join portion 40b to portion 40c of the
prior wrap. Note that two or more strip portions (here, portions
40a and 40b) can be fed into the fabric loop at the same place,
i.e., at nip set 66, with an offset equal to the desired offset per
lap or wrap. A strip portion (here, portion 40c) can also be fed in
at a separate location on the fabric loop, i.e., at nip set 60. As
long as the feed-in locations are within the flat portion of the
fabric loop 88, the offset remains equal to the desired offset per
lap in the finished goods.
[0091] FIG. 23 shows, with the vertical scale exaggerated for
clarity, a prior art three-element strip construction used to form
the fabric Venetian blind disclosed in U.S. Pat. No. 5,888,639.
Strip 130 comprises an opacified vane portion 132 whose opposite
longitudinal edges are ultrasonically welded to front and rear
sheer strips 134, 136, respectively (each shown as a small "x"), at
weld lines 138, 140 respectively. The relatively opaque strip is
wider than the sheer strips, and the sheers are aligned with the
opposite edges of the opaque strip. Thus, there is only one sheer
present at each edge, allowing a through-welding of one sheer to
each edge of the relatively opaque strip. This prior art process
then subjects the welded three-element strip to a series of
operations, including edge trimming, opening of the welded joints
(as shown by dotted lines in FIG. 23), and flattening to ultimately
obtain a flattened, three-element strip. The resulting strip is
then cut to a length corresponding with the width of the window
into which the blind is to be inserted. The cut-to-length strips
are then, according to this prior art disclosure, stacked and
bonded together, using a technique substantially different from the
helical winding technique disclosed herein.
[0092] FIG. 24 is a view similar to FIG. 23, but showing a modified
three-element strip construction according to one embodiment of the
present invention. Unlike the three-element strip constructions of
each of FIGS. 6, 7 and 8 of the present invention, and also unlike
the prior art configuration of FIG. 23, the construction of
three-element strip 142 of FIG. 24 comprises a relatively opaque
strip 144 to which one sheer strip 146 (which may be the front
sheer strip) is lapped slightly thereunder and preferably
ultrasonically welded at weld line 148, just as in the embodiment
of FIG. 6, while the other sheer strip 150 (which may be the rear
sheer strip) is aligned with the opposite edge of relatively opaque
strip 144, and in fully overlapping relationship thereto, and
welded at weld line 152.
[0093] The resulting "half-lapped" three-element strip 142 is then
helically wound, as shown in FIG. 25, with the double-thick edge of
incoming strip 142a closer to the previously formed winding 142b of
the helix. FIG. 25 is a view generally in the direction of left to
right in FIG. 9, but showing a modified assembly sequence adapted
for winding the half-lapped strip 142. For clarity of illustration
only, drive nip roll set 60, tension sensing roll 76 and idler roll
162 have been omitted from FIG. 25. This fragmentary perspective
view shows the incoming strip 142a as it turns over the omitted
tension sensing roll 76 and idler roll 162 just prior to
interfitting with the immediately preceding wrap 142b. As is
evident in FIG. 25, the trailing edge of the helix, namely, the
free edge of rear sheer strip 150b, is temporarily lifted up or
partially curled back from underlying opaque strip 144b by picker
or finger 164 just upstream from the zone where the incoming
three-element strip 142a is brought into alignment to join the
previously wound helix. This lifting action permits the
double-thick edge of incoming strip 142a to enter that gap beneath
rear sheer strip 150b and slightly overlap relatively opaque strip
144b.
[0094] The lifting action is accomplished by a finger 164
illustrated in FIGS. 30-31. Only a slight modification to the
winding apparatus of FIGS. 9-10 is required to adapt it to the use
of half-lapped three-element strip 142. The fragmentary perspective
view of FIG. 30 is taken generally in the direction of left to
right in the unmodified apparatus of FIG. 9, but with drive nip
roll set 60, tension sensing roll 76 and idler roll 162 (which is
added for use with strip 142) omitted for visual clarity only. FIG.
31 is a fragmentary plan view of the zone of FIG. 30 where the
incoming strip 142a is engaged by finger 164 and interfits with the
preceding winding 142b.
[0095] As compared with the apparatus illustrated in FIGS. 9-10,
two structural changes appear in FIGS. 30-31. First, idler roll 162
has been added, to re-direct the infeeding strip so that it has a
horizontal run immediately upstream of nip rolls 62,64. This
horizontal run is necessary so that the incoming and preceding
windings can be properly interfit with each other for bonding.
Second, finger 164 has been added as an aid in opening up the
trailing free edge of rear sheer strip 150b of the preceding
winding so that it can receive the double-thick edge of incoming
strip 142a.
[0096] Referring to FIGS. 25, 30 and 31, it will be seen that the
trailing free edge of rear sheer strip 150b is pushed laterally and
lifted slightly by finger 164, which is mounted on the end of
support rod 170. To accomplish that shifting, finger 164 has a
lower horizontal ledge portion 166, shown in dotted lines in the
plan view of FIG. 31, which the free edge of sheer strip 150b rides
upon as it moves toward idler roll 162. As a portion of such strip
edge is lifted onto ledge 166, it is then engaged by a generally
vertical leg 168 of finger 164. Vertical leg 168 cooperates with
horizontal ledge portion 166 to laterally shift as well as lift the
edge of strip 150b for a sufficient longitudinal running length to
permit the double-thick edge of incoming three-element strip 142a,
which is offset from the previously wound wrap 142b by the helix
lead, to overlap the relatively opaque and lower or front sheer
portions 144b and 146b, respectively, of previously wound wrap
142b, and tuck in underneath the lifted edge of upper or rear sheer
150b.
[0097] Application of front glue line 150 is accomplished by an
applicator (not shown) located immediately above the double-thick,
interfitting edge of rear sheer strip 150a and downstream from
idler roll 162, that is, at a point where the free edge of the rear
sheer strip 150b of the preceding wrap is still curled back to
expose the glue-receiving edge of strip 150a (see FIGS. 25 and 31).
After that overlapping relationship is established between the
double-thick edge of incoming strip 142a and the underlying
relatively opaque vane 144b of previously wound strip 142b (see
FIGS. 25 and 31), the overlapping portion of strip 142a moves
beyond vertical leg 168 of finger 164 (i.e., below the finger as
viewed in FIG. 31) and returned to a flat-lying condition. The
underside of the now lowered free edge of rear sheer strip 150b
will then contact glue strip 156 on the upwardly facing edge of
incoming rear sheer strip 150a to permit the required bond to be
created.
[0098] The horizontal ledge portion 166 of finger 164 may serve an
additional purpose. Where the glue line is shifted away from the
underlying welded joint, as shown in the embodiment of FIG. 27,
there is a tendency for the glue to bleed through the underlying
sheer and temporarily form a fragile, weak attachment to the
underlying relatively opaque vane. This unintended attachment would
typically break the first time that the cells are fully opened,
allowing the assembled panel to function normally, with the vanes
fully free except at their welded joints. However, assuring such
spontaneous separations occur uniformly and totally throughout the
entire product may require a closer and more costly control of glue
application than otherwise necessary. This problem can be
completely avoided by dimensioning ledge portion 166 so that its
left edge (as viewed in FIG. 31) is positioned to separate any
temporary glue attachment resulting from bleed through of glue
between sheers 150b and 150c.
[0099] Referring again to FIG. 25, front glue line 154 has already
been applied to front sheer 146a of incoming strip 142a before it
makes the turn around roll 76, as shown in the upper right of
portion FIG. 25. Thus, glue line 154 will be properly positioned on
the lower side of the strip for engagement with and bonding to
preceding front sheer 146b. Rear glue line 156, however, must be on
the upwardly facing side of rear sheer strip 150a in order to
engage and bond to the underside of the uplifted trailing edge of
rear sheer strip 150b. Therefore, the applicator (not shown) for
glue line 156 must be located to apply the glue after the strip has
passed roll 76 and before it passes under drive pressure roll
64.
[0100] The resulting helix is cut open, as previously described,
and cut to size for particular windows. FIG. 26 shows the end view
of the resulting cellular structure in its partially open
condition. It is evident that, in contrast to the structures of
FIGS. 3-8, the two sheer strips of a given three-element strip form
the front and rear portion of the same, rather than adjacent,
cells. Significantly, another difference is that the direction of
lapping of adjacent facing segments is the same on both the front
and rear of the resulting panel. That is, e.g., rear sheer segment
150b overlaps adjacent rear sheer segment 150a, just as front shear
segment 146b overlaps adjacent front sheer segment 146a. This
configuration is advantageous in that, if the fabric Venetian blind
is mounted so that the overlap is oriented shingle style, both
front and rear facing panels will be so oriented, and the exposed
sheer edges will less likely to collect dust or fray from contact
with downwardly directed cleaning strokes or falling objects.
[0101] Furthermore, overlaying one of the sheer strips onto the
stiffer relatively opaque vane reduces the instability of the
three-element strip, thereby improving wrap-to-wrap alignment and
the smoothness of the assembled composite facing panels. This
advantage is particularly beneficial when using extremely fine
knits such as diamond tulle, which is preferred in conjunction with
a tricot knit for the opposite face when reduction of the moir
effect is desired.
[0102] FIG. 27 shows a modified version of FIG. 26. As in the
difference between the embodiments of FIG. 22 and FIG. 5, the
modification results from a shifting of the location of glue lines
154' and 156'. The relocation of the glue lines away from the weld
lines 148, 152, respectively, creates inwardly projecting front and
rear sheer tabs 158' and 160', respectively.
[0103] FIG. 28 shows the same three-element strip structure and
orientation as shown in FIG. 25, except that glue lines 154 and 156
have been initially applied to the opposite elements of the
to-be-bonded surfaces. That is, front glue line has been shifted
from the lower side of the left edge of incoming front sheer strip
146a (as shown in FIG. 25) to the upper side of the right edge of
the front sheer strip 146b" of the preceding wrap of the helix (as
shown in FIG. 28). Similarly, rear glue line 156 in the FIG. 28
illustration is applied to the curled back, upwardly facing,
underside of the rear sheer strip trailing edge of the previously
wound three-element strip 142b". An appropriate picker or finger
(not shown) would be provided to temporarily curl back and invert
that trailing edge of rear sheer strip 150b".
[0104] FIG. 29 shows a further modification of the manner of
winding the three-element strip of FIG. 24. In this embodiment, the
orientation of the strip is reversed, with the double-thick edge of
the previously wound strip trailing rather than leading. Therefore,
the free edge of the incoming rear sheer strip 150a'" must be
opened and curled back to receive rear glue line 156'" and to
permit entry of the double-thick trailing edge of preceding wound
strip 142b'", and then uncurled to enclose such trailing edge. This
arrangement presents greater alignment and guidance difficulties,
and is therefore not preferred.
[0105] FIGS. 32a-32b through FIGS. 38a-38b show additional
embodiments of three-element strips. As in the case of FIGS. 23 and
24, the proportions of the strips in these drawings are exaggerated
for clarity, and the location of the weld lines is shown with an
"x". The relatively opaque vanes are shown with cross-hatching.
Within each numbered pair of drawings, the "a" Figure shows the
three strip portions in their flattened condition as welded, while
the "b" Figure shows the three-element strip partially opened as it
would be in the light-admitting position within a fabric Venetian
blind.
[0106] In the light of the foregoing explanation of the winding and
assembly technique employed with the embodiment of FIG. 24, those
skilled in the art will understand how to wind and assemble these
alternative three-element strip configurations. The embodiments of
FIGS. 36-42 would require, during the winding operation, a
temporary lifting of the previously wound upper sheer free end to
allow tucking under the edge of the incoming three-element strip,
as described above with reference to FIGS. 25 and 30-31. It will
also be recognized that a choice exists as to which element will
overlap the other at the required glue joints between adjacent
three-element strips. That is, by way of example, each of the glue
joints required for adjacent three-element strips according to the
embodiments of FIGS. 32-35 can only be made with the incoming
winding as the overlapping element at each joint. Conversely, in
the embodiments which are generally Z-shaped, such as FIGS. 38,
both free edges of the incoming three-element strip can be either
overlaid or tucked under the corresponding portion of the
previously wound three-element strip. In the configurations of
FIGS. 36 and 37, the upper sheer (as shown in the Figures) can only
overlap, whereas the lower sheer can overlap or tuck under, as
desired.
[0107] The embodiments of FIGS. 39-42 show two-element strips which
are formed with a pocket for subsequent insertion of a preferably
semi-rigid opaque vane, which vanes are shown in the "b" Figures of
each numbered pair. Otherwise, the same winding and assembly
considerations as discussed above apply.
[0108] As discussed with respect to the embodiment of FIG. 27, each
of these embodiments of FIGS. 32-42 can be constructed as shown,
with the glue line between adjacent windings essentially overlying
previously formed weld joints in the overlapped winding, or they
may have the glue line shifted laterally away from such weld line
(as shown in FIG. 27), creating a short, inwardly projecting sheer
tab or ligament.
[0109] While the helical winding technique disclosed herein is
normally the preferred technique for assembling the three-element
strips into an array of cells, some circumstances may make it
preferable to initially cut the three-element strips to length and
then overlap them in staggered, parallel alignment for joining them
together. One such circumstance is where the material chosen for
the relatively opaque vanes is not suitable for the repeated
longitudinal bending experienced as the strip traverses the various
rolls in the disclosed helical winding operation. In that event, a
cutting and assembling technique such as disclosed in the
previously mentioned U.S. Pat. No. 5,888,639 may be preferred.
[0110] Another advantage of the constructions disclosed herein is
that they all lend themselves to simple lap joints, parallel to the
plane of the facing panels, at the points of attachment of
successive strips to each other. When so joined, the smooth,
generally planar character of the facing panels is more likely to
be maintained at the joints. Lap joints so constructed and
positioned are to be contrasted with the inwardly turned tabs,
perpendicular to the facing panels, such as disclosed in FIGS. 11
and 11a of U.S. Pat. No. 5,888,639, which is more typical of
honeycomb type cellular constructions as shown in FIG. 1 of that
patent. The latter construction requires an additional folding step
for assembly, and, unless there are post-assembly creases set at
the face joints, it will not lie flat. Furthermore, if it is
creased to make the faces lie flat, the vanes will not lie closed
naturally or fully (as desired) and will not make the desired
curving shapes when open.
[0111] Another advantage of the half-lap three-element strip, as
exemplified by FIG. 24 and 26 hereof, is that when the strip is
spooled into roll 40 after welding, the double-thick portion is
wide and stable enough to make a smooth, uniform roll with no
distortion of the material. Subsequently, during the winding and
gluing steps, this type of strip has improved directional stability
and flatness, resulting in a smoother and more uniform product.
[0112] FIG. 43 illustrates a still further three-element strip
configuration 172 wherein both front and rear sheer strips are
bonded to the same face of the opacified strip. The term bonded
includes any suitable technique for joining the strip elements
together including, but not limited to, gluing, welding and/or
sewing. Front sheer strip 176 is bonded at 178 to opacified strip
174, while rear sheer strip 180 is bonded at 182 to the opposite
end of opacified strip 174.
[0113] In positioning and gluing successive three-element strips in
partially overlapping position, according to the method described
with respect to other embodiments hereof (see FIG. 44), front glue
line 184 is preferably placed directly over front bond line 178, to
minimize any possible glue bleed-through problems. Rear glue line
186 is preferably offset from rear bond line 182, thereby creating
a short internal sheer tab between rear bond line 182 and rear glue
line 186. By way of example, front sheer strip 176 may be
approximately one and three-quarters inches in width, rear sheer
strip 180 approximately one and seven-eighths inches in width, and
pacified strip 174 approximately two and one-eighth inches in
width. With those dimensions, the width of the internal sheer tab
between rear bond line 182 and rear glue line 186 may be about one
thirty-second to one sixteenth of an inch. The resulting sheer tabs
are contiguous parts of the sheer composite sheet (180a+180b+180c,
etc . . . ) that results from the bonding together at rear glue
line 186 of adjacent rear sheer strips 180. Any minor glue
bleed-through at this rear location creates no problems because the
sheer fabric layer in this region are backed only by a steel roll
during the fabrication process.
[0114] Still further alternatives (not illustrated) for use of a
three-element strip similar to the FIG. 43 embodiment could utilize
glue line placement to create sheer tabs on the front side of the
blind and/or to eliminate the sheer tabs on the rear side.
[0115] This invention may be further developed within the scope of
the following claims. Accordingly, the above specification is to be
interpreted as illustrative of only a few operative embodiments of
the invention, and not in a strictly limiting sense. In the
following claims, the words "right", "left", "upper" and "lower"
have been used as relative orthogonal directions for ease of
description only, and are not intended to be defined in relation to
any external datum, such as the surface of the Earth. Also, "edge"
or "edges", as used in the claims, means the extreme lateral edges
of the strips or strip portion faces, along with a relatively
narrow immediately adjacent portion of such faces.
* * * * *