U.S. patent application number 11/890186 was filed with the patent office on 2008-02-14 for hembar for a shade fabric and assembly method.
Invention is credited to David A. Kirby.
Application Number | 20080035281 11/890186 |
Document ID | / |
Family ID | 38982546 |
Filed Date | 2008-02-14 |
United States Patent
Application |
20080035281 |
Kind Code |
A1 |
Kirby; David A. |
February 14, 2008 |
Hembar for a shade fabric and assembly method
Abstract
A hembar includes front and rear walls and top and bottom spline
channels adjacent a top and a bottom of the hembar. Each spline
channel receives a spline in an oblique orientation to a vertical
line and is arranged to conceal the channel from any viewing
location in front of the hembar. A shade fabric is received in the
channels through longitudinal slots and the splines are received
through an open end. A notch opposite the slot receives part of the
shade fabric to facilitate spline insertion. A pocket for a
weighting element is off-centered such that it is closer to the
rear wall. The hembar is assembled using a support member having
obliquely angled walls to support the hembar with one channel
horizontally oriented. The front and rear walls of the hembar may
be covered by the shade fabric in a full wrap option.
Inventors: |
Kirby; David A.; (Emmaus,
PA) |
Correspondence
Address: |
Drinker Biddle & Reath LLP;Patent Docketing
One Logan Square, 18th and Cherry Streets
Philadelphia
PA
19103-6996
US
|
Family ID: |
38982546 |
Appl. No.: |
11/890186 |
Filed: |
August 3, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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60836517 |
Aug 9, 2006 |
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Current U.S.
Class: |
160/265 ;
160/368.1 |
Current CPC
Class: |
E06B 9/42 20130101 |
Class at
Publication: |
160/265 ;
160/368.1 |
International
Class: |
A47H 1/04 20060101
A47H001/04 |
Claims
1. A hembar adapted for attachment to a shade fabric comprising: a
front wall defining a substantially vertical front surface; a rear
wall defining a substantially vertical rear surface, the front wall
and the rear wall spaced from each other by a horizontal distance;
and at least one spline channel defined between the front and rear
walls, the spline channel oriented at an oblique angle with respect
to a vertical line such that a width of the spline channel is
greater than the horizontal distance between the front and rear
walls.
2. The hembar of claim 1, wherein the at least one spline channel
includes a top spline channel adjacent a top of the hembar and a
bottom spline channel adjacent a bottom of the hembar.
3. The hembar of claim 2, wherein the oblique angle of each spline
channel is approximately 45 degrees.
4. The hembar of claim 2, wherein each of the spline channels is
oriented with respect to the front wall such that the spline
channel is concealed from view from any location in front of the
hembar.
5. The hembar of claim 1, wherein the spline channel defines a
longitudinally-extending slot opening for receiving a shade fabric
within the interior of the spline channel and at least one open end
for receiving a spline within the interior of the spline
channel.
6. The hembar of claim 5, wherein the spline channel defines a
notch in a wall of the channel, the notch located opposite the slot
opening for receiving part of a looped portion of a shade fabric
placed into the interior of the spline channel to facilitate
insertion of a spline into the looped portion of the shade
fabric.
7. The hembar of claim 1, further comprising a
longitudinally-extending retainer pocket between the front and rear
walls adapted for receiving a weighting element.
8. The hembar of claim 7, wherein the retainer pocket is adapted to
receive the weighting element in an off-centered manner with
respect to the front wall and the rear wall.
9. The hembar of claim 8, wherein the retainer pocket is adapted to
receive the weighting element such that the weighting element is
located closer to the rear wall than to the front wall.
10. The hembar of claim 1, wherein the distance between the front
wall and the rear wall is approximately 0.4 inch or less.
11. A hembar assembly for a shade fabric comprising: an elongated
body having a front wall and an opposite rear wall respectively
defining substantially vertical front and rear surfaces and spaced
from each other by a horizontal distance, the elongated body
defining top and bottom fabric-attachment channels respectively
located between the front and rear walls adjacent a top and a
bottom of the hembar, each fabric-attachment channel defining a
width and adapted for receiving a looped portion of a shade fabric;
and a pair of elongated splines each adapted for receipt by one of
the fabric-attachment channels within the looped portion of the
shade fabric such that the shade fabric is wedged within the
channel by the spline to secure the shade fabric to the hembar,
each fabric-attachment channel oriented obliquely with respect to a
vertical line such that the width of the channel is greater that
the horizontal distance between the front and rear walls.
12. The hembar assembly of claim 11, wherein each fabric-attachment
channel is arranged with respect to the front wall of the hembar
body such that the fabric-attachment channel is concealed from view
when the hembar body is viewed from any location in front of the
hembar.
13. The hembar assembly of claim 12, further comprising an
elongated weighting element received within a weight-retainer
pocket between the front and rear walls of the hembar body, the
weighting element located closer to the rear wall of the body than
to the front wall.
14. The hembar assembly of claim 11, wherein the distance between
the front wall and the rear wall of the elongated body is
approximately 0.4 inch or less.
15. A method of attaching a shade fabric to a hembar comprising the
steps of: providing an elongated hembar body having a substantially
vertical front wall, a substantially vertical rear wall opposite
the front wall, and top and bottom spline channels respectively
located between the front wall and the rear wall adjacent a top and
a bottom of the hembar body, each of the spline channels adapted to
receive an elongated spline such that the spline is oriented
obliquely to the front and rear walls, the hembar body defining a
longitudinally-extending slot opening for each channel
communicating with the interior of the channel; providing a pair of
elongated splines each adapted for receipt within one of the spline
channels; providing a hembar support member including at least one
obliquely oriented support surface for receiving either one of the
front and rear walls of the hembar body and supporting the hembar
body such that one of the spline channels is substantially
horizontal; placing the hembar body on the hembar support member
such that the bottom spline channel is substantially horizontal;
directing a shade fabric into the interior of the bottom spline
channel through the associated slot opening of the hembar body to
define a looped portion of the shade fabric; inserting a spline
into the bottom spline channel through an open end of the bottom
spline channel within the looped portion of the shade fabric such
that the spline wedgingly secures the shade fabric to the hembar
body in the bottom spline channel; wrapping the shade fabric about
the hembar body between the bottom spline channel and the top
spline channel such that the front wall of the hembar body is
covered by the shade fabric; placing the hembar body on the hembar
support member such that the top spline channel is substantially
horizontal; directing the shade fabric into the interior of the top
spline channel through the associated slot opening of the hembar
body to define a looped portion of the shade fabric; and inserting
a spline into the top spline channel through an open end of the top
spline channel within the looped portion of the shade fabric such
that the spline wedgingly secures the shade fabric to the hembar
body in the top spline channel.
16. The method of claim 15, wherein the steps of directing a shade
fabric into the interior of the bottom channel and directing the
shade fabric into the interior of the top channel include the step
of using a creasing tool.
17. The method of claim 15, wherein the steps of inserting a spline
into the bottom spline channel and inserting a spline into the top
spline channel include the step of using a spline tool having a
fabric-engaging portion including a tapered flange and a post
adapted for receipt in an opening defined by each spline for
applying a pulling force to the spline.
18. The method of claim 15, wherein the steps of directing a shade
fabric into the interior of the bottom spline channel and directing
the shade fabric into the interior of the top spline channel are
respectively performed as part of two-step procedure with the steps
of inserting a spline into the bottom spline channel and inserting
a spline into the top spline channel, the steps of directing and
inserting performed over a length of the hembar body during the
two-step procedure and repeated to advance the spline from a first
end of the hembar body to an opposite second end of the hembar
body.
19. The method of claim 15, comprising the further step of wrapping
the shade fabric about the hembar body between the top spline
channel and the bottom spline channel such that the rear wall of
the hembar body is covered by the shade fabric.
20. The method of claim 19, wherein the step of wrapping the shade
fabric to cover the rear wall occurs before the step of wrapping
the shade fabric to cover the front wall, and wherein the method
further comprising the steps of: removing the spline from the top
spline channel through the open end of the spline channel;
directing the shade fabric into the top spline channel through the
associated slot opening of the hembar body such that two looped
portions of the shade fabric are defined, the two looped portions
arranged in a stacked fashion within the top spline channel; and
re-inserting the spline into the top spline channel through the
open end of the top spline channel within the two looped portions
of the shade fabric such that the spline wedgingly secures the
shade fabric to the hembar body in the top spline channel.
21. An elongated hembar adapted for attachment to a shade fabric
for weighting a lower end of the shade fabric, the hembar
comprising: a front wall; a rear wall opposite the front wall; a
top spline channel defined between the front wall and the rear wall
adjacent a top of the hembar; and a bottom spline channel defined
between the front wall and the rear wall adjacent a bottom of the
hembar, each of the spline channels defining an interior adapted to
receive a spline such that the spline is oriented obliquely with
respect to a vertical line.
22. The hembar of claim 21, wherein each of the spline channels is
arranged with respect to the front wall such that the spline
channel is concealed from view when the hembar is viewed from any
location in front of the hembar.
23. The hembar of claim 21, wherein each of the spline channels
defines a longitudinally-extending slot opening for receiving a
shade fabric within the interior of the spline channel and at least
one open end for receiving a spline within the interior of the
spline channel, each of the spline channels further defining a
notch in a wall of the channel, the notch located opposite the slot
opening for receiving part of a looped portion of a shade fabric
placed into the interior of the spline channel to facilitate
insertion of a spline into the looped portion of the shade
fabric.
24. The hembar of claim 21, further comprising a
longitudinally-extending retainer pocket between the front wall and
the rear wall adapted for receiving a weighting element in an
off-centered manner with respect to the front wall and the rear
wall.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from commonly-assigned U.S.
provisional application No. 60/836,517, filed Aug. 9, 2006, the
entire disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to roller shades
having flexible shade fabrics, and more particularly to a hembar
adapted for attachment to a lower end of a shade fabric.
BACKGROUND OF THE INVENTION
[0003] Roller shades include a flexible shade fabric supported by
an elongated roller tube for winding and unwinding of the shade
fabric. A hembar is attached to a lower end of the shade fabric to
weight the lower end of the shade fabric. The weighting of the
shade fabric by the hembar limits wrinkling of the shade fabric to
facilitate smooth operation of the roller shade as the shade fabric
is wound and unwound.
[0004] A variety of attachment means are used to secure shade
fabrics to hembars including the use of adhesives and staples. It
is also known to secure shade fabrics to hembars using elongated
splines received in channels defined by the hembar. Referring to
FIG. 1, there is shown a prior art hembar 2 including elongated
splines 6 received in spline channels 4 of the hembar 2 to secure a
flexible shade fabric 8 to the hembar 2. The spline 6 is received
in the spline channel 4 within a looped portion of the shade fabric
8, which is also received in the spline channel 4. The spline 6 and
the spline channel 4 are dimensioned such that the receipt of the
spline 6 within the looped portion of the shade fabric 8 secures
the shade fabric 8 to the hembar 2. The shade fabric 8 covers an
interior-facing side of the hembar 2. As shown, an exterior-facing
side of the hembar remains uncovered by the shade fabric 8. The
hembar 2 shown in FIG. 1 is made from an extruded plastic material
and includes end caps 9 received in opposite ends of the hembar
2.
[0005] Roller shades are often used with blackout side rails to
eliminate light gaps along opposite sides of the shade fabric. The
blackout side rails define vertical channels that receive side edge
portions of the shade fabric. To minimize light leakage, the
channels of the blackout side must be narrow in width, i.e., narrow
in dimension perpendicular to the shade fabric, for example,
approximately 0.5 inch in width. However, prior art hembars
utilizing spline-attachment means, such as hembar 2, are not usable
with blackout side rails because the hembars will not fit within
the narrow channels of the blackout side rails. For example, the
typical prior art hembar 2 has a width of approximately 0.6 inch in
width.
[0006] What is needed is a hembar defining spline channels adapted
for receipt of elongated splines that defines a narrow
cross-section adapted for receipt of the hembar within blackout
side rails.
SUMMARY OF THE INVENTION
[0007] According to the present invention, a hembar includes a
front wall defining a substantially vertical front surface, a rear
wall defining a substantially vertical rear surface opposite the
front wall, and at least one spline channel between the front and
rear walls. The front and rear walls are spaced from each other by
a horizontal distance and the spline channel is oriented at an
oblique angle with respect to a vertical line such that a width of
the spline channel is greater than the horizontal distance between
the front and rear walls. The oblique orientation of the spline
channel, instead of perpendicular to the vertical line, provides
for reduction in the hembar dimensions without reduction of the
spline dimensions to facilitate receipt of the hembar in blackout
side rails having correspondingly narrow vertical channels.
Preferably the hembar includes top and bottom spline channels. Each
of the top and bottom spline channels is preferably oriented with
respect to the front wall such that the channel is concealed from
view when the hembar is viewed from any location in front of the
hembar.
[0008] According to one embodiment, each of the spline channels
defines a longitudinally-extending slot opening for receiving a
looped portion of a shade fabric within the interior of the channel
and an open end for receiving a spline. Each spline channel may
also define a notch in a wall opposite the slot opening of the
channel for receiving part of the looped portion of the shade
fabric to facilitate insertion of the spline.
[0009] According to one embodiment, the hembar includes a
longitudinally-extending retainer pocket between the front wall and
the rear wall adapted to receive a weighting element. The retainer
pocket is adapted to receive the weighting element in an
off-centered manner such that the weighting element is located
closer to the rear wall than to the front wall.
[0010] According to a method of attaching a shade fabric to a
hembar body having obliquely oriented spline channels, a hembar
support member is provided. The hembar support member includes at
least one obliquely oriented support surface for receiving either a
front wall or a rear wall of the hembar and supporting the hembar
such that one of the spline channels is oriented horizontally. The
method includes the steps of placing the hembar on the hembar
support member such that the bottom spline channel is substantially
horizontal, directing a shade fabric into the bottom spline channel
to define a looped portion and inserting a spline into the bottom
spline channel to secure the shade fabric to the hembar body in the
bottom channel. The method includes the steps of wrapping the shade
fabric between the channels to cover the front wall, placing the
hembar body on the hembar support member such that the top spline
channel is horizontal, directing shade fabric into the top spline
channel to define a looped portion, and inserting a spline into the
top spline channel to secure the shade fabric to the hembar body in
the top spline channel.
[0011] According to one embodiment, the shade fabric is directed
into the channels using a creasing tool and the splines are
inserted into the channels using a spline tool having a
fabric-engaging portion including a tapered flange and a post
adapted for receipt in an opening defined by each spline for
applying a pulling force to the spline.
[0012] The method may also include the step of wrapping the shade
fabric between the spline channels to cover the rear wall of the
hembar body so as to provide a full wrap of the hembar body. The
wrapping the rear wall by the shade fabric may occur prior to the
wrapping of the front wall. The method further comprises the
removing the spline from the top spline channel, directing the
shade fabric into the top spline channel such that two looped
portions of the shade fabric are defined and arranged in a stacked
fashion within the top spline channel, and re-inserting the spline
into the top spline channel within the two looped portions of the
shade fabric such that the shade fabric is secured to the hembar
body in the top spline channel.
[0013] The steps of directing a shade fabric into one of the spline
channels and inserting a spline into the spline channel may be
performed in a two-step procedure that is performed over a length
of the hembar body and repeated to advance the spline from a first
end of the hembar body to an opposite second end of the hembar
body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] For the purpose of illustrating the invention, the drawings
show a form of the invention that is presently preferred. However,
it should be understood that this invention is not limited to the
precise arrangements and instrumentalities shown in the
drawings.
[0015] FIG. 1 is a perspective view of a prior art hembar attached
to a shade fabric.
[0016] FIG. 2 is a cross-sectional view of a hembar according to an
exemplary embodiment of the invention.
[0017] FIG. 3A is a perspective view comparing a hembar according
to the present invention with a prior art hembar, the hembars
secured to shade fabrics and shown from a front side of the
hembars.
[0018] FIG. 3B is a perspective view of the hembars and shade
fabrics of FIG. 3A shown from a rear side of the hembars.
[0019] FIG. 4 is a perspective view of a hembar according to the
present invention secured to a shade fabric using a full wrap
option.
[0020] FIG. 5 is a perspective view of the hembar and shade fabric
of FIG. 4 during assembly, the hembar supported on a hembar support
having obliquely-oriented support surfaces, shown with a creasing
tool being used to direct a looped portion of the shade fabric into
a bottom spline-receipt channels.
[0021] FIG. 6 is a perspective view of the hembar and shade fabric
of FIG. 5 shown with a spline tool being directed into the looped
portion of the shade fabric from an open end of the hembar
body.
[0022] FIG. 7 is a perspective view of the hembar and shade fabric
of FIG. 6 shown with a spline attached to the spline tool being
pulled into the bottom spline-receipt channel within the looped
portion of the shade fabric.
[0023] FIG. 8 is a perspective view of the hembar and shade fabric
of FIG. 7 showing the creasing tool being used to direct a looped
portion of the shade fabric into the top spline-receipt channel
over a previously placed looped portion, the hembar supported on an
opposite side of the hembar support from that of FIG. 7.
[0024] FIG. 9 is a perspective view of the spline tool of FIGS. 6
and 7.
[0025] FIG. 10 is a perspective view of an alternative spline
tool.
[0026] FIG. 11 is a perspective view of the creasing tool of FIGS.
5 and 8.
DESCRIPTION OF THE INVENTION
[0027] Referring to the drawings, where like numerals identify like
elements, there is illustrated in the cross-sectional view of FIG.
2 a hembar 10 according to an exemplary embodiment of the present
invention. As shown in FIG. 2 and described in greater detail
below, the hembar 10 is configured to define a narrowed cross
section allowing receipt of the hembar 10 within blackout side
rails having correspondingly narrow vertical channels to facilitate
limited light leakage.
[0028] The hembar 10 includes an elongated body 12 including a
front wall 14, an opposite rear wall 16, a top 18 and a bottom 20.
The front and rear walls 14, 16 respectively define front and rear
surfaces that are substantially vertical when the hembar is
oriented as shown in FIG. 2. As should be understood, the
orientation of FIG. 2 represents the substantially vertical
orientation for the hembar when it is attached to a lower end of a
suspended shade fabric. The hembar body 12 is preferably made from
an extruded material such as aluminum or plastic. The invention,
however, is not limited to any particular material. The hembar 10
includes top and bottom channels 22, 24 extending along the length
of the hembar body 12 and located between the front wall 14 and the
rear wall 16 adjacent the top 18 and the bottom 20, respectively,
of body 12. As described below, the channels 22, 24 are used to
attach a shade fabric 28 (see FIG. 4) to the hembar and, therefore,
may hereinafter be referred to as "fabric attachment channels". As
also described below, the desired attachment between the hembar and
a shade fabric is provided by elongated splines 26 (FIG. 4)
received in the channels 22, 24. As such, the channels 22, 24 may
also hereinafter be referred to as "spline-receipt channels" or
"spline channels".
[0029] As shown in FIG. 2, the front and rear walls 14, 16 of
hembar body 12 are spaced from each other by a horizontal distance,
H. The spline channels 22, 24, defined between the front and rear
walls 14, 16 and having a width, W (e.g., approximately 0.35 inch),
are not horizontal like the spline channels 4 of prior art hembar
2. Instead, as shown in FIG. 2, the spline channels 22, 24 are
oriented obliquely to a vertical line, V. As a result of the
oblique orientation, the width W for the spline channels 22, 24 is
greater than the horizontal distance, H, between the front and rear
walls 14, 16. As described below, obliquely orienting the spline
channels 22, 24 in this manner allows for a reduction in the
overall width of the hembar body 12 (i.e., horizontal distance
between the front and rear surfaces defined by walls 14, 16)
without a corresponding reduction in dimensions for splines
received in the spline channels 22, 24. This feature, therefore,
desirably facilitates use of the hembar 10 in blackout side rails
having correspondingly narrow vertical channels.
[0030] As shown in FIG. 4, the splines 26 are received in the
channels 22, 24 within looped portions of the shade fabric 28. The
respective widths of the spline 26 and the spline-receipt channels
22, 24 permit the splines 26 to be pulled into the spline-receipt
channels 22, 24 within the looped portion of the shade fabric 28
through one of opposite open ends defined by hembar body 12. The
relative widths, however, are preferably selected such that the
receipt of the spline 26 wedgingly compresses the shade fabric 28
along opposite sides of the spline 26. Such wedging receipt of the
spline 26 firmly secures the shade fabric 28 to the hembar 10
within the spline-receipt channels 22, 24.
[0031] Referring to FIG. 2, the spline-receipt channels 22, 24 are
respectively located adjacent the top and bottom 18, 20 of the
hembar body 12. This construction provides for alternative wrapping
options including a half-wrap option and a full-wrap option. In the
half-wrap option, shown in FIGS. 3A and 3B, looped portions of the
shade fabric 28 are secured within each of the spline-receipt
channels 22, 24 and an intermediately located portion of the shade
fabric 28 extends between the spline-receipt channels 22, 24 along
the front wall 14 of the hembar body 12. The rear wall 16 of the
hembar body 12, however, remains uncovered by the shade fabric 28
in the half-wrap option. The full wrap option is shown in FIG. 4.
As shown, both the front wall 14 and the rear wall 16 of the hembar
body 12 are covered by the shade fabric 28 in the full-wrap option.
The full wrap option is described in greater detail below. As
should be understood, the front and rear walls 14, 16 of the hembar
body 12 will respectively define interior-facing and
exterior-facing sides of the hembar 10 when an associated shade is
installed within a building, for example, to shade a window.
[0032] Referring to FIGS. 3A and 3B, the hembar 10 of the present
invention can be compared to the prior art hembar 2 of FIG. 1. As
shown, the spline-receipt channels 22, 24 of hembar 10 are
dimensioned to receive splines 26 substantially similar (i.e.,
having approximately similar dimensions) as the splines 6 received
in the spline-receipt channels 4 of hembar 2. In this manner, the
splines 6 and 26 should function in similar fashion to provide
similar attachment characteristics (i.e., similar wedging action)
assuming other factors such as material properties are equivalent.
However, the orientation of the similarly-sized splines 6 and 26 to
their respective hembars 2, 10 is not similar. As shown, the change
in the orientation of the spline 26 allows the front and rear walls
14, 16 of hembar 10 to be spaced more closely to each other than
the front and rear walls of the prior art hembar 2 while still
accommodating an appropriately sized channel between the walls 14,
16 receiving the similarly sized spline 26. This reduction in the
distance between the front and rear walls 14, 16 reduces the
overall thickness or profile of the hembar 10 as compared to that
of hembar 2. For example, the width of the hembar 10 (i.e., the
distance between the front and rear walls 14, 16 of hembar body 12)
according to the present invention is approximately 0.4 inch or
less. As should be understood, the reduction in the overall
thickness of the hembar 10 provides for the desired receipt of the
hembar 10 within blackout side rails having correspondingly narrow
vertical channels (i.e., approximately 0.5 inch wide) that are too
narrow to accommodate prior art hembar 2 (i.e., approximately 0.6
inch wide).
[0033] Referring to FIG. 2, the hembar 10 of the present invention
is shown in cross section without splines 26 and an attached shade
fabric 28 to facilitate illustration of the hembar. However, it
should be understood that were hembar 10 to be suspended from a
shade fabric 28 in the manner shown in FIG. 1 for prior art hembar
2 and shade fabric 8, the shade fabric 28 would exit from the top
spline-receipt channel 22 along the vertical line represented in
FIG. 2 as line V. For the prior art hembar 2 of FIG. 1, the
comparable vertical line (i.e., exit line) is defined by the
portion of shade fabric 8 shown above the hembar 2. As shown in
FIG. 1, the spline channel 4 of prior art hembar 2 is oriented to
receive spline 6 such that spline 6 is substantially horizontal.
Thus, spline 6 in prior art hembar 2 is perpendicular to the
vertical line of the hembar. In contrast, the spline-receipt
channels 22, 24 of hembar 10 have been rotated from the horizontal
orientation associated with the prior art hembar 2 into an oblique
relationship to the vertical line V. As should be understood,
therefore, splines 26 received in the channels 22, 24 to attach a
shade fabric would also be oriented obliquely with respect to the
vertical line V.
[0034] As discussed above, the oblique angling of the
spline-receipt channels 22, 24 allows the splines 26 to be
dimensioned substantially similar to the splines 6 of prior art
hembar 2 (i.e., requiring no reduction in the width of the spline
as would be the case if the spline remained perpendicular to the
vertical line V). In this manner, the splines 26 used with hembar
10 will function to secure a shade fabric to the hembar 10 in a
similar fashion as the splines 6 used with the prior art hembar 2
(i.e., there will be no reduction in the clamping action provided
by the splines). Such a result would not be achieved if the
dimensions of the hembar 2 simply reduced in an overall manner to
fit within narrower channels of blackout side rails. In such a
case, the dimensions of the spline-receipt channels would be
reduced in proportion requiring a correspondingly reduction in the
dimensions of the splines (e.g., the width of the splines).
[0035] In addition to providing for reduction in the overall
thickness or profile of the hembar body 12 as described above, the
hembar 10 of the present invention is also adapted to desirably
conceal both of the spline-receipt channels 22, 24 from view when
the hembar 10 is viewed from a location in front of the hembar.
Referring again to FIG. 2, the top spline-receipt channel 22 is
rotated approximately 45 degrees in a clockwise direction (from the
point of view shown in FIG. 2) with respect to the substantially
horizontal orientation of the upper spline channel 4 of prior art
hembar 2. As a result, the front wall 14 extends upwardly beyond an
upper end of the rear wall 16 in order to define the opposite side
edges of the top channel 22. Arranged in this manner, the top
channel 22 is concealed behind the upper extending portion of the
front wall 14 when the hembar 10 is viewed from anywhere in front
of the hembar. The bottom spline-receipt channel 24 is rotated
approximately 45 degrees in a counter-clockwise direction with
respect to the substantially horizontal spline channel 4 of hembar
2. In a similar fashion to the top of the hembar 10, the front wall
14 extends downwardly beyond a lower end of the rear wall 16 in
order to define the opposite side edges of the bottom channel 24.
Arranged in this manner, the bottom channel 24 is concealed behind
the lower extending portion of the front wall 14 when the wall is
viewed from anywhere in front of the hembar 10.
[0036] Still referring to FIG. 2, the hembar body 12 defines a
retainer pocket 34 within an interior of the hembar body 12. As
shown, the retainer pocket 34 is adapted to receive an elongated
weighting element 36 for adding weight to the hembar 10. This
desirably permits the body 12 of hembar 10 to be formed from a
lighter material such as plastic while still providing the intended
weighting function for the hembar 10 to limit wrinkles in the shade
fabric 28. As shown, the retainer pocket 34 is adapted to receive
the weighting element 36 in an off-centered manner between the
front and rear walls 14, 16 of the hembar body 12 such that the
weighting element 36 is located adjacent the rear wall 16 of the
body 12. Arranged in this manner, the weighting element 36 will be
substantially aligned with the vertical line V (i.e., the exit line
of for a shade fabric 28). As a result of the alignment between the
weighting element 36 and the vertical exit line of the shade fabric
28, the hembar 10 will tend to hang plumb even though the line of
the shade fabric 28 (i.e., the vertical line, V) is not aligned
with a centerline of the hembar 10.
[0037] The hembar 10 of the present invention also facilitates
assembly between the hembar 10 and shade fabric 28 as follows.
Still referring to FIG. 2, the hembar body 12 includes a reservoir
notch 38 defined within each of the spline-receipt channels 22, 24.
The reservoir notch 38 is located along an inner wall of each of
the channels 22, 24 and substantially opposite to a longitudinal
slot 40 that extends along the hembar body 12. The longitudinal
slot 40 facilitates insertion of the shade fabric 28 into the
associated channel 22, 24 in the form of a looped portion of the
shade fabric 28. As described in greater detail below, the
reservoir notch 38 receives an additional portion of the shade
fabric 28 when the shade fabric 28 is driven into the channels 22,
24. The receipt of extra shade fabric (i.e., a slack portion)
facilitates the subsequent pulling insertion of the spline 26 into
the channel 22, 24 within the looped portion of the shade fabric
28.
[0038] Referring now to FIGS. 4-10, there is illustrated a method
of assembling the hembar 10 so as to attach a shade fabric 28 to
the hembar 10 in a full-wrap option. As shown in FIG. 4, the shade
fabric 28 extends about the entire hembar body 12 in the full wrap
option such that both the front wall 14 and the rear wall 16 of the
hembar 10 are covered by the shade fabric 28.
[0039] Referring to FIG. 5, the hembar 10 is illustrated in a
partially completed condition in which a spline 26 has been pulled
into the top spline-receipt channel 22 within a looped portion of
the shade fabric 28 to secure the shade fabric 28 to the top
channel 22. The shade fabric 28 has also been placed over the rear
wall 16 of the hembar body 12 in FIG. 5.
[0040] As shown in FIG. 5, the hembar body 12 is supported on a
hembar support member 42 having a first pair of support surfaces
44, 45 extending along one side of the support member 42 and a
second pair of support surfaces 46, 47 extending along an opposite
side of the support member 42. The support surfaces 44, 46 are
oriented at an oblique angle from a vertical line. The angle for
each of the support surfaces 44, 46 provides for support of the
hembar body 12 such that one of the spline-receipt channels 22, 24
is oriented substantially horizontal. In FIG. 5, the hembar body 12
is shown supported on support surface 44 such that bottom channel
24 is substantially horizontal. Support surface 45 defines a ledge
contacting the top 18 of the hembar body 12 to keep the hembar body
12 in position on the hembar support member 42. As should be
understood, if the hembar body 12 were moved to the opposite side
of the hembar support member 42, then the bottom 20 of body 12
would contact the ledge defined by support surface 47 and the
hembar body 12 would be supported at an oblique angle on support
surface 46 such that top channel 22 is substantially
horizontal.
[0041] The above-described horizontal orientation for the channels
22, 24 provided by the hembar support 42 facilitates the following
assembly procedure for securing the shade fabric 28 to the hembar
10. It should be understood that the spline 26 shown in FIG. 5 in
the top spline-receipt channel 22 would have been installed with
the hembar body 12 positioned on the hembar support member 42 with
the top channel 22 in a horizontal orientation (i.e., by supporting
the hembar body 12 on support surfaces 46, 47). See FIG. 8, for
example, in which the hembar body 12 is shown placed on the second
pair of support surfaces 46, 47 for horizontal orientation of the
top spline-receipt channel 22.
[0042] Referring again to FIG. 5, a creasing tool 48 is brought
into contact with the shade fabric 28 and driven into the interior
of the bottom spline-receipt channel 24 such a looped portion of
the shade fabric 28 is directed into the bottom channel 24. The
creasing tool 48 is shown separately in FIG. 11. As shown in FIG.
5, the location of the reservoir notch 38 directly opposite the
slot opening 40 allows the creasing tool 48, and the looped portion
of the shade fabric 28, to be driven all the way to the bottom of
the reservoir notch 38.
[0043] Referring now to FIG. 6, a spline tool 50 (see also FIG. 9)
is inserted into the looped portion of the shade fabric 28 within
the bottom spline-receipt channel 24 through one of the open ends
of the hembar body 12. The spline tool 50 includes a handle 52,
preferably wooden, and a fabric-engaging portion 54 that is
preferably metal. The fabric-engaging portion 54 includes a flange
56 extending along an edge of the tool 50. As shown in FIG. 9, the
flange 56 is tapered along its length to facilitate insertion of
the flange 56 into the channel 24 within the looped portion of the
shade fabric 28 previously formed by the creasing tool 48. The
spline tool 50 includes a post 58 extending from an upper surface
of the flange 56 adjacent an end of the flange 56. The post 58 is
adapted for receipt within a hole formed in the spline 26 such that
a pulling force can be applied to the spline 26 by the spline tool
50.
[0044] Referring to FIG. 7, the spline tool 50 pulls the spline 26
into the bottom spline-receipt channel 24 through the open end of
the hembar body 12 into the looped portion of the shade fabric 28.
As described above, the spline 26 is coupled to the spline tool 50
by placing the post 58 of the tool 50 into a hole formed in the
spline 26 (see FIG. 10 for example showing a spline 26 engaged to
an alternative spline tool 60). Thus, as the fabric-engaging
portion 54 of tool 50 is pulled into the bottom channel 24 through
the open end of body 12, the coupled spline 26 is pulled into the
channel 24 behind the tool 50.
[0045] According to one preferred assembly method, a two-step
process can be repeated to advance the spline 26 along the hembar
body 12 within the spline-receipt channel 24 as follows. Starting
first at the end of the hembar 10 shown in FIG. 7, a length of the
shade fabric 28 adjacent the end of hembar 10 is driven into the
bottom spline-receipt channel 24 using the creasing tool 48 in the
manner illustrated in FIG. 5. Next, the spline tool 50 is used in
the manner shown in FIG. 7 to pull the spline 26 into the bottom
channel 24 within the looped portion of shade fabric 28 formed in
the first step of the two-step process. This two-step process
(i.e., first driving shade fabric material into a portion of the
channel using the creasing tool 48 and then pulling the spline 26
using the spline tool 50 to advance the spline 26 into the shade
fabric loop) is then repeated to advance the spline 26 along the
length of the hembar body 12. The use of the two-step advancement
process facilitates adjustment of the shade fabric 28 as needed as
the spline 26 is pulled into the bottom channel 24.
[0046] Upon completion of the two-step process to pull the spline
26 across the bottom channel 24, the shade fabric 28 is wrapped
around half of the hembar body 12 covering the rear wall 16 of the
hembar body as shown in FIG. 7 (i.e., the half-wrap option). To
fully wrap the shade fabric 28 around the hembar body 12 (i.e., the
full-wrap option), the hembar body is moved onto the second pair of
support surfaces 46, 47, such that the top spline-receipt channel
22 is substantially horizontal as shown in FIG. 8. The hembar 10
and shade fabric 28 are shown in a final stage of the assembly
method for the full wrap option in FIG. 8. The shade fabric 28 has
been placed over the front wall 14 such that both the front wall 14
and the rear wall 16 of body 12 are covered by the shade fabric 28.
The creasing tool 48 is shown being used to drive the shade fabric
28 into the top spline-receipt channel 22 to create a looped
portion of the shade fabric 28. As should be understood, the spline
26 that was previously placed into the top spline-receipt channel
22 in an earlier stage of the assembly method (see FIG. 7) must be
removed prior to this stage to provide for the formation of another
looped portion of the shade fabric 28 within the top spline-receipt
channel 22. As shown, the creasing tool 48 forms the new (second)
looped fabric portion in the top channel 22 atop the previously
placed looped portion of the shade fabric 28 (i.e., in stacked
fashion).
[0047] Following the formation of the new (second) looped fabric
portion within the top spline-receipt channel 22 as shown in FIG.
8, the spline tool 50 is then used in the above-described manner to
pull a spline 26 into the top spline-receipt channel 22. As should
be understood, the replacement of the spline 26 into the top
channel 22 at this stage within both of the looped fabric portions
(i.e., the first-placed portion (FIG. 5) and the second-placed
portion (FIG. 8) functions to secure both of the looped fabric
portions within the top spline-receipt channel 22.
[0048] Referring to FIG. 10, there is shown an alternative spline
tool 60. In a similar fashion as spline tool 50, the spline tool 60
includes a fabric-engaging portion 62 having a tapered flange 66
facilitating insertion into the looped fabric portion and a post 64
extending from an upper surface of the flange 66 for receipt by a
hole 68 formed in the spline 26. The fabric-engaging portion 62 of
the spline tool 60 is preferably made from plastic instead of
metal.
[0049] The foregoing describes the invention in terms of
embodiments foreseen by the inventor for which an enabling
description was available, notwithstanding that insubstantial
modifications of the invention, not presently foreseen, may
nonetheless represent equivalents thereto.
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