CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. § 119(e) of
U.S. Provisional Application No. 61/834,080, filed June 12, 2013, and entitled "Covering for an Architectural Opening Having Nested Rollers", and
this application also claims priority to
U.S. Patent Application No. 14/213,449, filed March 14, 2014, and entitled "Covering For an Architectural Opening Having Nested Rollers", and
this application further claims priority to
U.S. Patent Application No. 14/212,387, filed March 14, 2014 and entitled "Covering For an Architectural Opening Having Nested Rollers", which
application claims the benefit under 35 U.S.C. § 119(e) of
U.S. Provisional Application No. 61/834,080, filed June 12, 2013, and entitled "Covering for an Architectural Opening Having Nested Rollers", which
are all hereby incorporated by reference herein in their entireties.
FIELD
[0002] The present disclosure relates generally to coverings for architectural openings,
and more particularly to apparatus and methods for operating a covering for an architectural
opening having nested rollers.
BACKGROUND
[0003] Coverings for architectural openings, such as windows, doors, archways, and the like,
have taken numerous forms for many years. Some coverings include a retractable shade
that is movable between an extended position and a retracted position. In the extended
position, the shade of the covering may be positioned across the opening. In the retracted
position, the shade of the covering may be positioned adjacent one or more sides of
the opening.
[0004] Some coverings, when in the fully extended position, transmit light through the material
from which the covering is constructed. In some instances, even when the covering
has operable vanes that open and close to control the amount of light passing through
the covering, a greater amount of darkening is desired. Additionally, or alternatively,
in some instances a user may desire a different pattern or appearance of the covering
when in the fully extended position. Typically, these goals are accomplished by having
a separate roller positioned behind the primary roller for separate actuation by the
user. These separate rollers for the supplemental function or appearance increase
the size of the head rail, and may require the use of a second set of control cords
and operating mechanisms, thus increasing size and weight of the covering structure.
SUMMARY
[0005] Examples of the disclosure may include a covering for an architectural opening having
nested rollers. In some examples, the covering may include a rotatable outer roller
defining an elongated slot extending along a length of the outer roller and opening
to an interior of the outer roller, a rotatable inner roller received within the outer
roller and defining a central longitudinal axis, a first shade secured to the outer
roller, the first shade retractable onto and extendable from the outer roller, and
a second shade secured to the inner roller, with the second shade extending through
the elongated slot and retractable onto and extendable from the inner roller. The
elongated slot may be substantially horizontally aligned with the central longitudinal
axis of the inner roller when the first shade is in a fully extended position.
[0006] In some examples, the inner and outer rollers are concentric about the central longitudinal
axis of the inner roller. In some examples, the first and second shades have the same
width. In some examples, the width of the first shade extends along the entire length
of the outer roller, and the width of the second shade extends along the entire length
of the inner roller. In some examples, the slot is oriented orthogonally to a direction
of extension of the first shade.
[0007] In some examples, the covering includes a bottom rail secured to the second shade
and engaging the outer roller when the second shade is in a fully retracted position.
In some examples, the outer roller defines a longitudinal seat formed along the slot,
and the bottom rail is received in the seat when the second shade is in the fully
retracted position. In some examples, the covering includes a mounting system supporting
the inner and outer rollers for rotative movement about the central longitudinal axis
of the inner roller. In some examples, the covering includes an operating mechanism
for selectively rotating the inner roller.
[0008] In some examples, the outer roller includes a first shell and a second shell each
having a longitudinally-extending terminal edge, and the edges of the first and second
shells are peripherally spaced apart from one another to define the elongated slot.
In some examples, the covering includes a first bushing locked into one end of the
first and second shells, and a second bushing locked into an opposing end of the first
and second shells; wherein the first and second bushings maintain a constant width
of the slot.
[0009] In some examples, the covering includes a lock mechanism movable between a first
position restricting the rotation of the outer roller and a second position permitting
rotation of the outer roller. In some examples, the lock mechanism moves from the
first position to the second position upon engagement of the bottom rail with the
lock mechanism. In some examples, the outer roller defines an elongated groove formed
in the sidewall, the lock mechanism includes a bearing, and in the first position
of the lock mechanism, the bearing is received in the groove. In some examples, the
lock mechanism includes a pin, and the lock mechanism is actuated upon engagement
of the pin by the bottom rail to remove the bearing from the groove. In some examples,
the bearing movably engages the outer surface of the outer roller in the second position.
[0010] In some examples, the lock mechanism includes a locking member that pivots between
the first and second positions. In some examples, the lock mechanism includes a locking
member that axially translates between the first and second positions. In some examples,
the lock mechanism includes a rotatable shaft positioned external to the outer roller
and oriented substantially parallel to the central longitudinal axis of the inner
roller. In some examples, the covering includes an end cap, the inner and outer rollers
are rotatably coupled to the end cap, the lock mechanism includes a housing cantilevered
from the end cap, and the rotatable shaft is journaled to the housing. In some examples,
the lock mechanism includes a gear mechanism that couples rotation of the rotatable
shaft and the outer roller.
[0011] In some examples, the covering may include a rotatable outer roller defining an elongated
slot, a first shade secured to and wrappable around the outer roller, a lock mechanism
positioned external to the outer roller and at least partially defining a bottom stop
for the first shade, a rotatable inner roller received within the outer roller, a
second shade secured to and wrappable around the inner roller, the second shade extendable
and retractable through the elongated slot, and a non-rotatable shaft extending within
the inner roller and at least partially defining a bottom stop for the second shade.
[0012] In some examples, the lock mechanism includes a rotatable shaft positioned external
to the outer roller, and a locking member that axially translates along the rotatable
shaft. In some examples, the lock mechanism includes a pivotable locking member positioned
external to the outer roller.
[0013] Examples of the disclosure may include a method of operating a covering for an architectural
opening. In some examples, the method includes unwrapping a first shade from a periphery
of an outer roller, upon the first shade reaching a fully extended position, unwrapping
a second shade from a periphery of an inner roller positioned within the outer roller,
wherein unwrapping the second shade comprises extending the second shade through an
elongated slot formed in the outer roller and positioned in substantial horizontal
alignment with a central longitudinal axis of the inner roller.
[0014] In some examples, the method includes pivoting a locking member into locking engagement
with the outer roller to lock rotation of the outer roller, rotating the inner roller
relative to the outer roller to retract the second shade onto the inner roller through
the elongated slot formed in the outer roller, pivoting the locking member out of
locking engagement with the outer roller at a fully retracted position of the inner
roller to allow the outer roller to rotate, and rotating the outer roller by driving
the inner roller to retract the first shade onto the outer roller.
[0015] In some examples, the method includes during extension of the first shade, axially
traversing a locking member external to the periphery of the outer roller, restricting
rotation of the outer roller with the locking member upon the first shade reaching
the fully extended position, during extension of the second shade, axially traversing
a nut positioned within the inner roller, and restricting rotation of the inner roller
with the nut upon the second shade reaching a fully extended position.
[0016] The disclosure is given to aid understanding, and one of skill in the art will understand
that each of the various aspects and features of the disclosure may advantageously
be used separately in some instances, or in combination with other aspects and features
of the disclosure in other instances. Accordingly, while the disclosure is presented
in terms of examples, it should be appreciated that individual aspects of any example
can be claimed separately or in combination with aspects and features of that example
or any other example.
[0017] The present disclosure is set forth in various levels of detail in this application
and no limitation as to the scope of the claimed subject matter is intended by either
the inclusion or non-inclusion of elements, components, or the like in this summary.
In certain instances, details that are not necessary for an understanding of the disclosure
or that render other details difficult to perceive may have been omitted. It should
be understood that the claimed subject matter is not necessarily limited to the particular
examples or arrangements illustrated herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The accompanying drawings, which are incorporated into and constitute a part of the
specification, illustrate examples of the disclosure and, together with the general
description given above and the detailed description given below, serve to explain
the principles of these examples.
FIG. 1 is an isometric view of a covering with first and second shades in fully-retracted
positions in accordance with some examples of the present disclosure.
FIG. 2 is an isometric view of the covering of FIG. 1 with a first shade in a partially-extended
position and a second shade in a fully-retracted position in accordance with some
examples of the present disclosure.
FIG. 3 is an isometric view of the covering of FIG. 1 with a first shade in a fully-extended
position and a second shade in a fully-retracted position in accordance with some
examples of the present disclosure.
FIG. 4 is an isometric view of the covering of FIG. 1 with a first shade in a fully-extended
position and a second shade in a partially-extended position in accordance with some
examples of the present disclosure.
FIG. 5 is an isometric view of the covering of FIG. 1 with first and second shades
in fully-extended positions in accordance with some examples of the present disclosure.
FIG. 6 is an isometric, partially-exploded view of head rail components of a covering
in accordance with some examples of the present disclosure. The head rail cover and
the first and second shades are not shown for clarity.
FIG. 7 is a lengthwise cross-sectional view of a covering taken along line 7-7 of
FIG. 1 with the head rail components of FIG. 6 in accordance with some examples of
the present disclosure.
FIG. 8 is a transverse cross-sectional view of a covering taken along line 8-8 of
FIG. 2 with the head rail components of FIG. 6 in accordance with some examples of
the present disclosure.
FIG. 9 is a transverse cross-sectional view of a covering taken along line 9-9 of
FIG. 3 with the head rail components of FIG. 6 in accordance with some examples of
the present disclosure.
FIG. 10 is a transverse cross-sectional view of a covering taken along line 10-10
of FIG. 4 with the head rail components of FIG. 6 in accordance with some examples
of the present disclosure.
FIG. 11 is a transverse cross-sectional view of a covering taken along line 11-11
of FIG. 5 with the head rail components of FIG. 6 in accordance with some examples
of the present disclosure.
FIG. 12 is an isometric view of head rail components of a covering in accordance with
some examples of the present disclosure. The head rail cover is not shown for clarity.
FIG. 13 is an isometric, partially-exploded view of the head rail components of FIG.
12 in accordance with some examples of the present disclosure.
FIG. 14 is a transverse cross-sectional view of the head rail components of FIG. 12
taken along line 14-14 of FIG. 12 in accordance with some examples of the present
disclosure.
FIG. 15 is a side elevation view of some of the head rail components of FIG. 12 depicting
three intermeshed gears rotatably supported on an end cap of a covering in accordance
with some examples of the present disclosure.
FIG. 16 is an isometric view of a lock mechanism of the head rail components of FIG.
12 in accordance with some examples of the present disclosure.
FIG. 17 is a side elevation view of the lock mechanism of FIG. 16 in accordance with
some examples of the present disclosure.
FIG. 18 is another isometric view of the lock mechanism of FIG. 16 in accordance with
some examples of the present disclosure.
FIG. 19 is a side elevation view of a dual roller unit attached to the lock mechanism
of FIG. 16 in accordance with some examples of the present disclosure.
FIG. 20 is a detail view of a locking interface between first and second shells of
an outer roller of the dual roller unit of FIG. 19 in accordance with some examples
of the present disclosure.
FIG. 21 is a front elevation view of a housing of the lock mechanism of FIG. 16 in
accordance with some examples of the present disclosure.
FIG. 22 is a side elevation view of the housing of FIG. 21 in accordance with some
examples of the present disclosure.
FIG. 23 is a shaft of the lock mechanism of FIG. 16 in accordance with some examples
of the present disclosure.
FIG. 24 is an isometric view of a nut of the lock mechanism of FIG. 16 in accordance
with some examples of the present disclosure.
FIG. 25 is another isometric view of the nut of FIG. 24 in accordance with some examples
of the present disclosure.
FIG. 26 is a front elevation view of the shaft of FIG. 23 rotatably supported in the
housing of FIG. 21 and the nut of FIG. 24 threadedly mounted onto the shaft, with
the housing and nut shown in lengthwise cross-section, in accordance with some examples
of the present disclosure.
FIG. 27 is a transverse cross-sectional view of the housing, the nut, and the shaft
of FIG. 26 taken along line 27-27 of FIG. 26 in accordance with some examples of the
present disclosure.
FIG. 28 is an isometric, partially-exploded view of head rail components of a covering
in accordance with some examples of the present disclosure. The head rail cover and
the second shade are not shown for clarity.
FIG. 29 is another isometric, partially-exploded view of the head rail components
of FIG. 28 in accordance with some examples of the present disclosure.
FIG. 30 is a transverse cross-sectional view of a covering taken along line 30-30
of FIG. 5 with the head rail components of FIG. 28 in accordance with some examples
of the present disclosure.
FIG. 31 is a transverse cross-sectional view of a covering taken along line 31-31
of FIG. 3 with the head rail components of FIG. 28 in accordance with some examples
of the present disclosure.
FIG. 32 is a transverse cross-sectional view of the covering of FIG. 31 with a bottom
rail seated against the outer roller and a lock mechanism unseated from the outer
roller in accordance with some examples of the present disclosure.
FIG. 33 is a transverse cross-sectional view of the covering of FIG. 32 with the outer
roller rotated counterclockwise relative to the position of the outer roller in FIG.
32 in accordance with some examples of the present disclosure.
FIG. 34 is a transverse cross-sectional view of a covering taken along line 34-34
of FIG. 4 with the head rail components of FIG. 28 in accordance with some examples
of the present disclosure.
FIG. 35 is a transverse cross-sectional view of the covering of FIG. 31 with the inner
roller and second shade removed for clarity in accordance with some examples of the
present disclosure.
FIG. 36 is a transverse cross-sectional view of the covering of FIG. 32 with the inner
roller and second shade removed for clarity in accordance with some examples of the
present disclosure.
FIG. 37 is a transverse cross-sectional view of the covering of FIG. 33 with the inner
roller and second shade removed for clarity in accordance with some examples of the
present disclosure.
FIG. 38 is an isometric view of a lock mechanism of the head rail components of FIG.
28 in accordance with some examples of the present disclosure.
FIG. 39 is another isometric view of the lock mechanism of FIG. 38 in accordance with
some examples of the present disclosure.
FIG. 40 is an isometric view of a bracket of the head rail components of FIG. 28 in
accordance with some examples of the present disclosure.
FIG. 41 is an isometric view of the lock mechanism of FIG. 38 rotatably mounted onto
the bracket of FIG. 40 in accordance with some examples of the present disclosure.
FIG. 42 is a fragmentary isometric view of some of the head rail components of FIG.
28 and depicts the interface of the lock mechanism of FIG. 38 with a bottom rail of
the covering in accordance with some examples of the present disclosure.
FIG. 43 is a fragmentary isometric view of some of the head rail components of FIG.
28 and depicts the interface of the lock mechanism of FIG. 38 with a bottom rail of
the covering in accordance with some examples of the present disclosure.
FIG. 44 is a fragmentary view of an end of the bottom rail of FIGS. 42 and 43 in accordance
with some examples of the present disclosure.
FIG. 45 is an isometric view of an actuator rim of the bottom rail of FIG. 44 in accordance
with some examples of the present disclosure.
FIG. 46 is a lengthwise cross-sectional view of one end of a covering taken along
line 7-7 of FIG. 1 with the head rail components of FIG. 28 in accordance with some
examples of the present disclosure.
FIG. 47 is a lengthwise cross-sectional view of another end of a covering taken along
line 7-7 of FIG. 1 with the head rail components of FIG. 28 in accordance with some
examples of the present disclosure.
DETAILED DESCRIPTION
[0019] The present disclosure provides a covering for an architectural opening. In general,
the covering may include a first shade and a second shade both suspended from the
same head rail by a pair of nested rollers forming a dual roller unit. The first shade
(front shade in this configuration) is engaged with an outer roller for retraction
onto and extension therefrom by wrapping around and unwrapping from the outer roller
as actuated by a user. The second shade (rear shade in this configuration) is engaged
with an inner roller, which is positioned inside the outer roller, for retraction
onto and extension therefrom by wrapping around and unwrapping from the inner roller
as actuated by the user. The inner roller may be positioned inside the outer roller
and collectively the inner and outer rollers may form a roller unit, as further described
below. The second shade may be extended and retracted as directed by the user when
the first shade is in the fully extended position. The operating unit that causes
the rollers to rotate as directed by the user may be operated by, for example, a motor
or a single control cord. The operating unit may engage and control the rotation of
the inner roller, which in turn may control the rotation of the outer tube.
[0020] Referring to FIGS. 1-5, a retractable covering 10 for an architectural opening is
provided. The retractable covering 10 may include a head rail 14, a first bottom rail
18, a second bottom rail 20, a first shade 22, and a second shade 24. The first shade
22 may extend between the head rail 14 and the first bottom rail 18. The second shade
24 may extend between the head rail 14 and the second bottom rail 20. The head rail
14 may include two opposing end caps 26a, 26b, which may enclose the ends of the head
rail 14 to provide a finished appearance. The first bottom rail 18 may extend horizontally
along a lower edge of the first shade 22 and may function as a ballast to maintain
the first shade 22 in a taut condition. The second bottom rail 20 may extend horizontally
along a lower edge of the second shade 24 and may function as a ballast to maintain
the second shade 24 in a taut condition.
[0021] The first shade 22 may include vertically suspended front 30 and rear 34 sheets of
flexible material (such as sheer fabric) and a plurality of horizontally-extending,
vertically-spaced flexible vanes 38. Each of the vanes 38 may be secured along horizontal
lines of attachment with a front edge attached to the front sheet 30 and a rear edge
attached to the rear sheet 34. The sheets 30, 34 and vanes 38 may form a plurality
of elongated, vertically-aligned, longitudinally-extending cells, which collectively
may be referred to as a cellular panel. The sheets 30, 34 and/or the vanes 38 may
be constructed of continuous lengths of material or may be constructed of strips of
material attached or joined together in an edge-to-edge, overlapping, or other suitable
relationship. The second shade 24 may be a single panel and may be constructed of
strips of material attached or joined together in an edge-to-edge, overlapping, or
other suitable relationship.
[0022] The first and second shades 22, 24 may be constructed of substantially any type of
material. For example, the shades 22, 24 may be constructed from natural and/or synthetic
materials, including fabrics, polymers, and/or other suitable materials. Fabric materials
may include woven, non-woven, knits, or other suitable fabric types. The shades 22,
24 may have any suitable level of light transmissivity. For example, the first and
second shades 22, 24 may be constructed of transparent, translucent, and/or opaque
materials to provide a desired ambience or decor in an associated room. In some examples,
the first shade 22 includes sheets 30, 34 that are transparent and/or translucent,
and vanes 38 that are translucent and/or opaque. In some examples, the second shade
24 is made of a single sheet of material with zero light transmissivity, often referred
to as a black-out shade. The second shade 24 may include patterns or designs so that
when the second shade 24 is extended behind the first shade 22, the second shade 24
creates a different aesthetic appearance than the first shade 22 by itself.
[0023] Referring to FIGS. 1-6, the covering 10 may include a drive or operating mechanism
40 configured to raise or retract the first shade 22, the second shade 24, or both.
The operating mechanism 40 may be controlled mechanically and/or electrically. The
operating mechanism 40 may include a speed governing device to control or regulate
the extension or lowering speed of the shades 22, 24.
[0024] In some examples, the operating mechanism 40 may include an operating element 42
(such as a ball chain, a cord, or a wand) to allow the user to extend or retract the
first and/or second shades 22, 24. To move the shades 22, 24, an operator may manipulate
the operating element 42. For example, to raise or retract the shades 22, 24 from
an extended position, the operator may pull the operating element 40 in a downward
direction. To extend or lower the shades 22, 24 from a retracted position, the operator
may manipulate the operating element 42 to release a brake, which may allow the shades
22, 24 to automatically lower under the influence of gravity.
[0025] Additionally, or alternatively, the operating mechanism 40 may include an electric
motor 44 configured to extend or retract the shades 22, 24 upon receiving an extension
or retraction command. The motor 44 may be hard-wired to a switch and/or operably
coupled to a receiver that is operable to communicate with a transmitter, such as
a remote control unit 46, to permit a user to control the motor 44 and thus the extension
and retraction of the shades 22, 24. The motor 44 may include a gravity lower state
to permit the shades 22, 24 to lower via gravity without motor intervention, thereby
reducing power consumption.
[0026] Referring to FIG. 6, the covering 10 may include a dual roller unit 46, which may
be disposed within the head rail 14. The dual roller unit 46 may include an inner
roller 48 and an outer roller 50. The inner roller 48 may be positioned inside the
outer roller 50, and the rollers 48, 50 may be coaxially aligned about the same rotational
axis 52. The rollers 48, 50 may be concentric about a central axis of the inner roller
48.
[0027] Referring to FIGS. 6 and 7, the inner roller 48 may be generally cylindrical in shape
and may be formed as a tube. The second shade 24 may be attached at a top edge to
the inner roller 48 by adhesive, corresponding retention features, or other suitable
attachment means. In some examples, a longitudinally-extending recess 52 is formed
in the circumferential wall of the inner roller 48 and may receive an adhesive bead
configured to adhere the top edge of the second shade 24 to the inner roller 48.
[0028] The outer roller 50 may be generally cylindrical in shape and may surround the inner
roller 48. The outer roller 50 may be formed of two pieces that interlock with one
another. Referring to FIG. 6, the outer roller 50 may include a first shell 54 and
a second shell 56 that nest together. Referring to FIGS. 6 and 8-11, longitudinally-extending
edge portions 58, 60 of the first and second shells 54, 56, respectively, may overlap
and interlock with one another. The first shade 22 may be attached at a top edge to
the outer roller 50 by adhesive, corresponding retention features, or other suitable
attachment means. In some examples, a pair of channels 62 is formed in the circumferential
wall of the outer roller 50 and configured to receive and secure the top edges of
the first shade 22. Referring to FIGS. 8-11, inserts 64 may be positioned in a hem
formed on each of the top edges and may act to retain the top edges in the respective
channels 62.
[0029] Referring to FIG. 7, the inner and outer rollers 48, 50 may extend substantially
the entire distance between the right and left end caps 26a, 26b. The inner and outer
rollers 48, 50 may have the same or substantially the same length. The first and second
shades 22, 24 may have the same or substantially the same width, which may be equivalent
to the length of the rollers 48, 50. In some examples, the first and second shades
22, 24 have equivalent widths that match the length of the inner and outer rollers
48, 50, which may eliminate the existence of a light gap between the edges of the
shades 22, 24 and the sides of the architectural opening.
[0030] Referring to FIGS. 6 and 7, the dual roller unit 50 may be rotatably supported by
the opposing end caps 26a, 26b. The operating mechanism 40 may be anchored to the
right end cap 26a and may be actuated, for example, by the operating element 42 or
the remote control unit 46. The operating mechanism 40 may be operably associated
with the inner roller 48 to cause it to rotate. The operating mechanism 40 may include
an internal fitting 64, which may be received within the inner roller 48 and may tightly
engage the wall of the inner roller 48. The internal fitting 64 may be driven in rotation
by the operating mechanism 40, such as the motor 44, and thus may drive the inner
roller 48 in rotation. The operating mechanism 40 may include a planetary gear drive
often utilized in window covering applications.
[0031] Continuing with FIGS. 6 and 7, a limit screw 66 may be positioned inside the inner
roller 48 and may be fixed to the left end cap 26b such that the limit screw 66 does
not rotate. A limit nut 68 may be threadedly engaged with the limit screw 66 and may
be rotationally keyed to the wall of the inner roller 48. The key structure may allow
movement of the limit nut 68 along the length of the inner roller 48. As the inner
roller 48 rotates, the limit nut 68 may move along the threaded limit screw 66, and
may engage a limit stop formed on the limit screw 66 to define the lowermost extended
position of the second shade 24 (see FIG. 5). Additionally, or alternatively, a top
limit stop may be employed on the limit screw 66 if desired.
[0032] Referring to FIG. 6, right and left bushings 70a, 70b may be axially aligned with
the inner roller 48 and may be disposed adjacent opposing ends of the inner roller
48. The right bushing 70a may be rotatably mounted onto the operating mechanism 40,
and the left bushing 70b may be rotatably mounted onto the limit screw 66. The bushings
70a, 70b may lock into the ends of the outer roller 50 to maintain a desired spatial
relationship between the shells 54, 56. The bushings 70a, 70b each may include a pair
of axial projections 72a, 72b. One of the projections 72a may engage the first shell
54, and the other projection 72b may engage the second shell 56. When the bushings
70a, 70b are engaged with the opposing ends of the outer roller 50, the bushings 70a,
70b and the outer roller 50 may rotate in unison about the rotation axis 52 of the
inner and outer rollers 48, 50.
[0033] Referring to FIGS. 8-11, the first and second shells 54, 56 of the outer roller 50
each may define a retention feature that snugly receives the axial projections 72a,
72b of the bushings 70a, 70b. The retention feature may be formed as circumjacently-spaced
shelves 74 that extend inwardly from the outer roller 50 into an interior space defined
by the outer roller 50. When the bushings 70a, 70b are engaged with the ends of the
outer roller 50, the axial projections 72a, 72b may be snugly received between the
shelves 74 and the circumferential wall of the outer roller 50 to prevent relative
movement between the first and second shells 54, 56.
[0034] Continuing with FIGS. 8-11, the first and second shells 54, 56 may define a slot
76 extending along a length of the outer roller 50 and in communication with the interior
of the outer roller 50. The slot 76 permits passage of the second shade 24 during
extension and retraction of the second shade 24. When the first end portions 58, 60
of the first and second shells 54, 56, respectively, are interlocked together, second
longitudinally-extending edge portions 78, 80 of the first and second shells 54, 56
may be peripherally spaced apart from one another to define the slot 76. The confronting
second edge portions 78, 80 of the first and second shells 54, 56 may be spaced a
sufficient distance from one another to permit passage of the second shade 24 yet
prevent passage of the bottom rail 20 of the second shade 24. The axial projections
72a, 72b of the bushings 70a, 70b may maintain the width of the slot 76 during operation
of the covering 10. The slot 76 may be positioned on the outer roller 50 so as to
be located above and adjacent to the rearward most of the pair of channels 62 when
the first shade 22 is in its extended, vane-open configuration.
[0035] With continued reference to FIGS. 8-11, the outer roller 50 may define a recessed
seat 81 in the circumferential wall on both sides of the slot 76. The seat 81 may
be formed as a recess extending along the length of the slot 76. The seat 81 may include
a generally vertically-oriented base wall 84 spanning the slot 76 and formed by the
opposing edge portions 78, 80 of the outer roller 50. The seat 81 may be configured
to receive the second bottom rail 20 when the second shade 24 is in the fully retracted
position (see FIG. 8). The base wall 84 may allow a relatively vertical-tangential
engagement and disengagement between the second bottom rail 20 and the outer roller
50. The slot 76 and the seat 81 may be positioned on the circumference of the outer
roller 50 above the attachment point 62 of the rear sheet 34 of the first shade 22,
and the position of the slot 76 and the seat 81 may be referred to in FIGS. 9-11 as
3 o'clock. The location of the seat 81 and the slot 76 near the furthest rearward
position on the circumference of the outer roller 50, along with the shape of the
seat 81, may allow for secure receipt of the second bottom rail 20 as it is pulled
vertically up and into the seat 81 during retraction (see FIGS. 8-10).
[0036] The shape of the seat 81 and its orientation on the outer roller 50 may encourage
smooth and predictable disengagement of the second bottom rail 20 from the seat 81
to begin the extension of the second shade 24. The shape and orientation of the seat
81 may allow the bottom rail 20 to drop vertically out of the seat 81, which takes
advantage of the force of gravity on the relatively heavy bottom rail 20. The generally
tangential orientation of the seat 81 on the outer roller 50 may assist in this regard.
The lower free edge of the slot 76 (defined by the edge portion 80 of the second shell
56 of the outer roller 50) may be curved or rounded to allow for smooth travel of
the second shade 24 over the edge portion 80 as the second shade 24 is extended and
retracted through the slot 76.
[0037] The second bottom rail 20 may be an elongated member, having relatively high mass,
and defining a groove running along its length to receive and retain a lower edge
of the second shade 24. The lower edge of the second shade 24 may be held in the groove
of the bottom rail 20 by an insert 82 positioned in a hem formed in the lower edge
of the second shade 24. A portion of the profile of the second bottom rail 20 may
generally match the shape of the seat 81 formed in the outer roller 50 to conform
thereto when the second shade 24 is in the retracted position.
[0038] Referring to FIGS. 7-11, the first shade 22 may be coupled to and wrappable about
the outer roller 50. An upper edge of each of the front and rear sheets 30, 34 may
be attached to the outer roller 50 at circumferentially-spaced locations. The first
shade 22 may be wrapped about or unwrapped from a rear side of the outer roller 50,
with the rear side of the roller 50 positioned between a front side of the roller
50 and a street side of an associated architectural opening (in FIGS. 8-11, the rear
side of the roller 50 is to the right). Generally, rotation of the outer roller 50
in a first direction (counterclockwise in FIGS. 8-11) retracts the first shade 22
by winding it about the outer roller 50 to a position adjacent one or more sides (such
as the top side) of an associated architectural opening, and rotation of the outer
roller 50 in a second, opposite direction extends the first shade 22 across the opening
(such as to the bottom side).
[0039] Referring still to FIGS. 7-11, the second shade 24 may be coupled to and wrappable
about the inner roller 48. An upper edge of second shade 24 may be attached to the
inner roller 48, as discussed previously. The second shade 24 may be wrapped about
or unwrapped from a rear side of the roller unit 46, with the rear side of the roller
unit 46 positioned between a front side of the roller unit 46 and a street side of
an associated architectural opening (in FIGS. 8-11, the rear side of the roller unit
46 is to the right). Generally, rotation of the inner roller 48 in a first direction
(counterclockwise in FIGS. 8-11) retracts the second shade 24 by winding it about
the inner roller 48 to a position adjacent one or more sides (such as the top side)
of an associated architectural opening, and rotation of the inner roller 48 in a second,
opposite direction extends the second shade 24 across the opening (such as to the
bottom side).
[0040] The operation of the covering is described below with reference to FIGS. 1-5 and
7-11. As shown in FIGS. 1 and 7, the first and second shades 22, 24 are in fully-retracted
positions and concealed within the head rail 14. In this configuration (see FIG. 7),
the second shade 24 is fully wrapped about the inner roller 48 and the first shade
22 is fully wrapped about the outer roller 50. In some examples, the first bottom
rail 18 engages a portion of the head rail 14 to define a top limit stop.
[0041] To extend the first shade 22 from the head rail 14, the user may actuate the operating
mechanism 40 to cause the inner roller 48 to rotate in an extension direction (clockwise
in FIGS. 8-11), which in turn causes the outer roller 50 to rotate in an extension
direction (clockwise in FIGS. 8-11) due at least in part to the weight of the first
bottom rail 18 applying a downward force to the first shade 22. As the first shade
22 extends off of the rear of the outer roller 50, the outer roller 50 generally rotates
in unison with the inner roller 48. The dual roller unit 46 generally rotates in the
direction the user controls the inner roller 48 to rotate.
[0042] Referring to FIGS. 2 and 8, the first shade 22 extends off of the rear of the outer
roller 50 in a closed or collapsed configuration in which the front and rear sheets
30, 34 are relatively close together and the vanes 38 extend vertically in an approximately
coplanar, contiguous relationship with the front and rear sheets 30, 34. Once the
first shade 22 is substantially unwrapped from the outer roller 50, continued rotation
of the outer roller 50 in the extension direction moves the front and rear sheets
30, 34 generally vertically relative to each other to shift the vanes 38 from a closed
position (FIGS. 2 and 8) to an open position (FIGS. 3 and 9). A rear portion of the
first bottom rail 18 may be weighted more than a front portion of the bottom rail
18 to facilitate the full opening of the vanes 38.
[0043] Referring to FIGS. 3 and 9, the covering 10 is shown with the first shade 24 in a
fully extended position with the vanes 38 in an open or expanded configuration. In
this position, the front and rear sheets 30, 34 are horizontally spaced with the vanes
38 extending substantially horizontally therebetween, and the attachment points 62
of the front and rear sheets 30, 34 with the outer roller 50 may be disposed at the
same height. In FIG. 9, for instance, the positions of the attachment points 62 may
be referred to as being at 4 o'clock and 8 o'clock, and are disposed at substantially
the same level with each other. Rotation of the outer roller 50 in either direction
from that shown in FIG. 9 causes the front and rear sheets 30, 34 to move toward one
another and the vanes 38 to re-orient into more vertical alignment.
[0044] When the first shade 22 is fully unwrapped from the outer roller 50, the slot 76
in the outer roller 50 is rotationally oriented within the head rail 14 such that
the bottom rail 20 of the second shade 24 may drop vertically out of the seat 81 upon
further rotation of the inner roller 48 in the extension direction. The generally
tangential orientation and generally vertical positioning of the seat 81, with a relatively
vertical base wall 84 (see FIGS. 10 and 11), allows the weight of the second bottom
rail 20 to unseat the bottom rail 20 from the outer roller 50 when the tension in
the second shade 24 is decreased due to continued rotation of the inner roller 48
in the extension direction. The operating mechanism 40 may include a brake system
operably coupled to the inner roller 48 to restrict unwanted downward movement of
the second shade 24, and thus of the first shade 22.
[0045] In order to extend the second shade 24, the operating mechanism 40 is further actuated
by the user to rotate the inner roller 48 in the extension direction. During extension
of the second shade 24 (see FIGS. 4 and 10), the outer roller 50 and the first shade
22 may remain stationary due to the weight of the first shade 22 and the weight of
the first bottom rail 18 maintaining the rotational position of the outer roller 50,
without a positive lock. In some examples, as discussed below, a positive lock may
be used to prevent rotation of the outer roller 50 upon full extension of the first
shade 22. As shown in FIGS. 10 and 11, during extension of the second shade 24, the
slot 76 defined in the outer roller 50 may be directed rearwardly and may be substantially
horizontally aligned with the rotational axis 52 (see FIG. 6) of the inner and outer
rollers 48, 50. In other words, the second shade 24 may deploy off of the rear side
of the inner and outer rollers 48, 50.
[0046] During extension of the second shade 24, the inner roller 48 rotates relative to
the outer roller 50, with the fitting 64 and the limit nut 68 supporting the respective
ends of the inner roller 48. As the inner roller 48 rotates in the extension direction,
the second shade 48 is unwound from the inner roller 48 as it is extended through
the slot 76 formed in the outer roller 50. The rotation of the inner roller 48 in
the extension direction moves the limit nut 68 along the limit screw 66 towards the
bottom limit stop.
[0047] Referring to FIGS. 5 and 11, the covering 10 is shown with the first and second shades
22, 24 both in the fully extended positions with the vanes 38 in an open or expanded
configuration. In this position, the front and rear sheets 30, 34 are horizontally
spaced with the vanes 38 extending substantially horizontally therebetween. The second
shade 24 may be a blackout shade and inhibit light from passing through the second
shade 24, and thus through the first shade 22. When the second shade 24 is fully extended
(see FIGS. 5 and 11), the second shade 24 may be offset rearwardly from the first
shade 22, but may extend coextensively in length and width with the first shade 22.
To control the amount of light passing through the first shade 22, the second shade
24 may be withdrawn into the head rail 14 and wrapped about the inner roller 48 of
the dual roller unit 46.
[0048] When the second shade 24 is in the fully extended position (lowermost extension),
the limit nut 68 may be positioned on the limit screw 66 (see FIG. 6) in engagement
with a lower limit stop formed on the limit screw 66 to prevent further rotation of
the inner roller 48. The limit screw 66 also may include an upper limit stop to define
the upper limit of the covering 10. Alternatively, the bottom rail 18 of the first
shade 22 may engage a portion of the head rail 14 when the first shade 22 is fully
retracted to serve as the upper limit stop of the covering 10.
[0049] At any point during the extension process, the user may stop the operating mechanism
40 or reverse the direction of the operating mechanism 40 to move the first and second
shades 22, 24 into a desired position. In examples including a motorized covering
10, preprogrammed commands may be used to control the motor 44 and thus control the
position of the first and second shades 22, 24. The commands may instruct the motor
44 to move the first and second shades 22, 24 into predetermined shade positions,
such as a first position in which the first and second shades 22, 24 are fully retracted,
a second position in which the first shade 22 is fully extended and the second shade
24 is fully retracted, and a third position in which the first and second shades 22,
24 are fully extended. The commands may be transmitted to the motor 44 by the remote
control unit 46.
[0050] Retraction of the first and second shades 22, 24 may be accomplished in reverse order
as compared to the extension sequence described above, such as generally following
FIG. 11 to FIG. 8. In FIGS. 5 and 11, the first and second shades 22, 24 are disposed
in fully extended positions. When both the first and second shades 22, 24 are in the
fully extended position, the limit nut 68 (see FIG. 6) may be engaged with a lower
limit stop, which may be formed on the limit screw 66. Actuation of the operating
mechanism 40, such as by the operating element 42 and/or the motor 44, from this position
moves the limit nut 68 axially away from the lower limit stop and begins the retraction
process of the covering 10. The retraction process generally involves actuation of
the operating mechanism 40 to first rotate the inner roller 48 in a retraction direction
(counterclockwise in FIG. 11) to retract the second shade 24, and when the second
shade 24 is fully retracted, the outer roller 50 is then rotated in a retraction direction
(counterclockwise in FIG. 11) to retract the first shade 22 onto the outer roller
50. This sequence is described further below.
[0051] To retract the second shade 24 from the fully extended position of FIGS. 5 and 11,
the user actuates the operating mechanism 40 to cause the inner roller 48 to rotate
in a retraction direction (counterclockwise in FIGS. 8-11), which in turn wraps the
second shade 24 about the inner roller 48 and raises the second bottom rail 20 upwardly
along a rear face of the rear sheet 34 of the first shade 22. During retraction of
the second shade 24, the inner roller 48 rotates relative to the outer roller 50,
with the fitting 64 and the limit nut 68 supporting the respective ends of the inner
roller 48. As the inner roller 48 rotates in the retraction direction, the second
shade 24 is wound onto the inner roller 48 as it is pulled through the slot 76 formed
in the outer roller 50. The rotation of the inner roller 48 in the retraction direction
moves the limit nut 68 along the limit screw 66 towards the opposite end of the limit
screw 66. Also during the retraction of the second shade 24, the first shade 22 remains
in the fully extended, open position due to the weight of the first bottom rail 18
and the weight of the portion of the first shade 22 suspended from the outer roller
50 acting upon the outer roller 50 to inhibit rotation of the outer roller 50. This
allows the user to move the second shade 24 between fully extended and fully retracted
positions without affecting the position or orientation of the first shade 22.
[0052] Referring to FIGS. 9 and 10 in reverse order, as the second shade 24 is further withdrawn
into the outer roller 50, the second bottom rail 20 becomes securely positioned in
the seat 81. Upon the bottom rail 20 engaging the seat 81 of the outer roller 50,
the driving force of the operating mechanism 40 may be transferred through the second
shade 24 to the outer roller 50. That is, the operating mechanism 40 may apply a rotational
force to the inner roller 48, which in turn may be applied to the outer roller 50
through the engagement of the bottom rail 20 in the seat 81 under the tension of the
second shade 24. Referring to FIGS. 8 and 9, when the second shade 24 is fully wrapped
onto the inner roller 48 and the second bottom rail 20 is received in the seat 81
of the outer roller 50, the outer roller 50 may be driven in a retraction direction
(counterclockwise in FIGS. 8 and 9) by the operating mechanism 40, through rotation
of the inner roller 48 in the same retraction direction. As such, when the bottom
rail 20 is received in the seat 81 and a retraction force (counterclockwise in FIGS.
8 and 9) is applied to the inner roller 48 by the operating mechanism 40, the outer
roller 50 generally rotates in conjunction with the inner roller 48.
[0053] Referring to FIG. 8, as the outer roller 50 continues to rotate in the retraction
direction, the first shade 22 wraps around the outer roller 50. The first shade 22
is under tension as it is wrapped around the outer roller 50 due to the suspended
portion of the first shade 22 and the weight of the bottom rail 18.
[0054] When the first shade 22 is fully retracted, the first bottom rail 18 may engage a
portion of the head rail 14, such as an abutment, to serve as a top limit stop for
the dual roller unit 46. It is contemplated that other mechanisms may be utilized
to define the top retraction position, including a top limit stop positioned on the
limit screw 66 opposite the bottom limit stop. For example, a top limit stop may be
formed on the limit screw 66 and positioned along the screw 66 such that the nut 68
engages the top limit stop upon full retraction of the first shade 22.
[0055] As explained above, the retraction of the second shade 24 and then the first shade
22 from the fully extended position occurs with the user actuating a single operating
element 42 or a motor 44 for the retraction of both shades 22, 24. The limit screw
66 includes a sufficient length to allow the limit nut 68 to move along the screw
66 from the bottom limit stop until the top retracted position is attained. It is
contemplated that the first shade 22 may be wrapped about or unwrapped from the front
side of the outer roller 42. Accompanying modifications to the structure described
herein would be necessary to facilitate the implementation of the dual roller shade
technology as applied to a front-descending shade structure.
[0056] The covering may include a lock mechanism that restricts rotation of the outer roller
50 when the first shade 22 is in the fully extended position, thereby ensuring the
first shade 22 remains in the fully extended position and is substantially unaffected
by rotation of the inner roller 48 during extension of the second shade 24. The lock
mechanism may be movable (such as pivotable, translatable, or other suitable movements)
between a first position that restricts rotation of the outer roller 50 and a second
position that permits rotation of the outer roller 50. In one example, the lock mechanism
includes a locking member positioned external to the outer roller 50 that translates
longitudinally along an outer periphery of the outer roller 50 and engages a stop
to restrict rotation of the outer roller 50. In another example, the lock mechanism
includes a locking member positioned external to the outer roller 50 that pivots into
engagement with the outer roller 50 to restrict rotation of the outer roller 50.
[0057] Referring to FIGS. 12-27, a covering for an architectural opening is provided that
uses a lock mechanism to positively lock rotation of the outer roller upon full extension
of the first shade 22. With the exception of a lock mechanism and retaining clips,
the covering depicted in FIGS. 12-27 generally has the same features and operation
as the covering depicted in FIGS. 1-11. Accordingly, the preceding discussion of the
features and operation of the covering depicted in FIGS. 1-11 should be considered
generally applicable to the covering depicted in FIGS. 12-27, except as noted in the
following discussion. The reference numerals used in FIGS. 12-27 generally correspond
to the reference numerals used in FIGS. 1-11 to reflect the similar parts and components,
except the reference numerals are incremented by one hundred.
[0058] Referring to FIG. 12, the covering 110 includes an axially movable lock mechanism
186 that, similar to the pivotally movable lock mechanism discussed below in connection
with FIGS. 28-47, restricts rotation of the outer roller 50 when the first shade 22
is in the fully extended position. The axially movable lock mechanism 186 may include
a housing 187, a rotatable shaft 188 journaled to the housing 187, and a nut 189 threadedly
engaged with and travelable axially along the shaft 188. Although the axially movable
lock mechanism 186 is depicted in conjunction with the left end cap 126b, the lock
mechanism 186 may be used in conjunction with the right end cap 126a.
[0059] Referring to FIGS. 12, 16, and 18, the housing 187 may be cantilevered from the left
end cap 126b and extend axially away from the left end cap 126b along an outer periphery
of the outer roller 150 towards the right end cap 126a. One end 187a of the housing
187 may be removably connected to the left end cap 126b with a fastener 190, and an
opposing, free end 187b of the housing 187 may be positioned laterally outward of
the outer roller 150. The housing 187 may be laterally separated from the periphery
of the outer roller 150 by a sufficient distance so as to not interfere with the wrapping
or unwrapping of the first shade (not shown) about or from the outer roller 150. The
housing 187 may be laterally separated from the periphery of the outer roller 150
by a uniform distance.
[0060] With reference to FIGS. 16, 18, 21, and 26, the opposing end portions 187a, 187b
of the housing 187 may include axially-extending collars 191 and abutment flanges
192 extending outward from the collars 191. The collars 191 may include an internal
wall 193 (see FIGS. 22 and 26) that defines a shaft aperture 194 that receives a journal
portion 195 of the rotatable shaft 188, which rotatably bears against the internal
wall 193. The internal wall 193 of the collar 191 also may define a key hole 196 that
permits passage of the rotatable shaft 188 (particularly the stops 197 formed on the
rotatable shaft 188) during axial insertion or removal of the shaft 188 into or out
of the housing 187. The abutment flanges 192 each may define a fastener aperture configured
to receive a fastener 190 that connects the housing 187 to a respective end cap 126a,
126b (see FIGS. 12, 14, 16, 18, and 22). The end portions 187a, 187b of the housing
187 may be mirror images of one another to facilitate interconnection of the housing
187 to either the left or right end caps 126a, 126b.
[0061] With continued reference to FIGS. 12, 16, 18, 21, and 26, the housing 187 may include
an intermediate portion 187c that interconnects the end portions 187a, 187b. The intermediate
portion 187c may extend longitudinally along an outer periphery of the outer roller
150 in a laterally spaced relationship. The intermediate portion 187c of the housing
187 may include a base 198 and a guide rail 199 each spanning the distance between
the opposing end portions 187a, 187b of the housing 187. The base 198 of the housing
187 may define stop receiving apertures 200 proximate to the end portions 187a, 187b
to permit passage of the shaft 188 stops during rotation of the shaft 188 relative
to the housing 187, thereby reducing the transverse profile of the housing 187. The
base 198 of the housing 187 also may include a stiffening rib 201 extending longitudinally
between the end portions 187a, 187b that stiffens the housing 187 and reduces lateral
displacement or buckling of the intermediate portion 187c of the housing 187. As shown
in FIG. 27, the stiffening rib 201 may include at least one transversely-extending
buttress 202 that further increases the stiffness of the longitudinally-extending
rib 201.
[0062] Referring to FIGS. 12, 16-19, 23, and 26, the shaft 188 of the axially movable lock
mechanism 186 may be offset from, but parallel or substantially parallel to, a rotation
axis 152 of the inner roller 148. The shaft 188 may be positioned external to the
outer roller 150 and extend longitudinally along an outer periphery of the outer roller
150 in a spaced relationship. The shaft 188 may include journal portions 195 rotatably
received within the collars 191 of the housing 187. The journal portions 195 of the
shaft 188 may include recessed circumferential areas that reduce the contact areas
(and thus the friction) between the bearing surface 193 of the collars 191 and the
journal portions 195 of the shaft 188. The shaft 188 may include a threaded portion
203 extending between the journal portions 195 of the shaft 188 and between the collars
191 of the housing 187. Stops 197 may be formed on the shaft 188 near the terminal
ends of the threaded portion 203 of the shaft 188. The stops 197 may extend radially
outward from the shaft 188 and may be axially aligned with the apertures 200 formed
in the base 198 of the housing 187 (see FIG. 21) so that during rotation of the shaft
188 relative to the housing 187 the stops 197 rotationally pass in and out of the
apertures 200. A gear 204 may be non-rotatably attached to one end of the shaft 188
and may define a central cavity for laterally locating the gear (and thus the shaft
188) relative to the end cap 126b.
[0063] Referring to FIGS. 12, 16, 18, and 24-27, the nut 189 of the axially movable lock
mechanism 186 is positioned at least partially within the housing 187 and travels
axially along the shaft 188 within the intermediate portion 187c of the housing 187.
The nut 189 is keyed to the housing 187 so that as the shaft 188 rotates the nut 189
translates along, rather than rotates about, the shaft 188. The nut 189 includes a
body 205 that extends only partially around the shaft 188 and may be referred to as
a half-nut 189. In an alternative design, the nut 189 may extend around the entire
circumference of the shaft 188.
[0064] Referring to FIGS. 24 and 25, the nut 189 includes an internal thread 206 that projects
inward from the body 205 and threadedly engages the external thread of the threaded
portion 203 of the shaft 188. To maintain engagement of the threads and restrict rotation
of the nut 189 about the shaft 188, the nut 189 may include two longitudinally-extending
wings 207 that project radially outward from the body of the nut 189. The wings 207
may include axially-extending fins 208 that slidably contact confronting faces of
the base 198 of the housing 187 (see FIG. 27) and guide the nut 189 axially along
the intermediate portion 187c of the housing 187 while reducing the contact area (and
thus the friction) between the nut 189 and the housing 187.
[0065] One of the wings 207 may define a longitudinally-extending slot 208 that at least
partially receives the guide rail 199. As shown in FIG. 27, portions of the wing 207
defining the slot 208 may slidably abut different sides of the guide rail 199. As
such, the wings 207 of the nut 189 may substantially prevent the nut 189 from rotating
about the shaft 188, thereby facilitating translation of the nut 189 along the shaft
188 during rotation of the shaft 188 relative to the housing 187. To laterally stiffen
the wings 207, the nut 189 may include a transversely-extending rib 209 positioned
outwardly of the internal thread 206 and extending between the wings 207. In an alternative
design, the nut 189 and the housing 187 may include various other corresponding keying
structures so that the nut 189 travels axially along the shaft 188 upon rotation of
the shaft 188 relative to the housing 187.
[0066] As described, rotation of the shaft 188 relative to the housing 187 generally moves
or translates the nut 189 axially along the shaft 188. To limit the axial range of
the nut 189, the shaft 188 may include stops 197 extending outward from a periphery
of the shaft 188. Upon contact with the nut 189, the stops 197 generally restrict
or limit translation of the nut 189 relative to the shaft 188, thereby restricting
or limiting further rotation of the shaft 188 relative to the housing 187. To ensure
a solid engagement between the nut 189 and a respective stop 197, the nut 189 may
include a longitudinally-extending abutment wall 211 that interacts with the shaft
188 stop upon the nut 189 reaching a desired stopping position corresponding to a
full extension of the first shade 22. As shown in FIG. 24, the abutment wall 211 may
be formed at a terminal end of the internal thread 206 of the nut 189.
[0067] Additionally or alternatively, the body 205 of the nut 189 (which may resemble an
axially-extending sleeve) may abut the abutment flange 192 of the housing 187 to stop
translation of the nut 189 along the shaft 188. The body 205 of the nut 189 may be
radially spaced from an outer periphery of the shaft 188 by a sufficient distance
to permit passage of the shaft stop 197 in an annular space defined between the shaft
188 and the body 205. The shaft 188 and the nut 189 may include two stops 197 and
abutment walls 211, respectively, to facilitate interoperability of the lock mechanism
186 with the right or left end caps 126a, 126b, thereby providing a robust design
capable of accommodating left and right hand assemblies.
[0068] Referring to FIGS. 15-17, the axially movable lock mechanism 186 may include a gear
mechanism or train 213 positioned external to the inner and outer rollers 148, 150.
The gear mechanism or train 213 may include a first gear 215 non-rotatably coupled
to the outer roller 150, a second gear 204 non-rotatably coupled to the shaft 188,
and an idler gear 217 intermeshed with the first and second gears 215, 204. The idler
gear 217 may be rotatably supported on a mounting plate 219 that includes locator
pins 221 projecting axially from the mounting plate 219 (see FIG. 17) toward the associated
end cap 126. The locator pins 221 may be receivable within the end cap 126 to restrict
rotation of the mounting plate 219 relative to the end cap 126.
[0069] The gear mechanism 213 may be altered depending on the size, weight, or other characteristics
of the shade members. In one example, the gear mechanism 213 provides a three-to-one
gear ratio between the first and second gears 215, 204. That is, for every revolution
of the outer roller 150, the shaft 188 completes three revolutions. In one example,
the external thread of the shaft 188 has sixteen threads per inch (or a pitch of 1/16
of an inch). Generally, the length of the threaded portion 203 of the shaft 188 may
be oversized relative to the operative range of the nut 189 so that the shaft 188
may accommodate many different shade lengths. Thus, in some examples, the nut 189
only interacts with one of the stops 197 on the rotatable shaft 188 during operation
and the other stop is provided so that the lock mechanism 186 may be used with either
of the right or left end caps 126a, 126b.
[0070] Referring to FIG. 15, the gear mechanism 213 is depicted in association with the
left end cap 126b. The external gears 204, 215, 217 are rotatably supported by stub
shafts projecting axially from the left end cap 126b. The idler gear 217 is positioned
forwardly of the first gear 215, and the second gear 204 is positioned forwardly of
the idler gear 217, with all three gears 215, 204, 217 disposed in the same plane
adjacent to the end cap. The idler gear 217 is positioned upwardly of the first gear
215, and the second gear 204 is positioned upwardly of the idler gear 217. The first
gear 215 and the idler gear 217 may be received within a rim 223 projecting axially
from the end cap 126b.
[0071] Referring to FIG. 13, a partially exploded view of the head rail components (with
the exception of the right side components which are generally the same as those shown
and discussed in relation to FIGS. 6-11) is provided. The components include a left
end cap 126b, a non-rotatable limit screw 166 that attaches to the left end cap 126b,
a left bushing 170b that mounts onto and rotates relative to a bearing surface of
the limit screw 166, an inner roller 148 that internally receives a portion of the
limit screw 166 (including the limit nut 168) and mounts onto a boss 167 of the left
and right bushings 170a, 170b, an outer roller 150 that internally receives the inner
roller 148, and the axially movable lock mechanism 186 that attaches to the left end
cap 126b.
[0072] Referring to FIGS. 13, 14, 19, and 20, the outer roller 150 may include a split shell
design. In particular, the outer roller 150 may include first and second shells 154,
156. To secure the first and second shells 154, 156 together and maintain a desired
spatial relationship relative to one another, the first and second shells 154, 156
of the outer roller 150 each may snugly receive an axial projection 172a, 172b of
the left and right bushings 170a, 170b (see FIGS. 14, 18, and 19). The axial projections
172a, 172b may couple the outer roller 150 to the bushings 170a, 170b so that the
outer roller 150 and bushings 170a, 170b rotate in unison about a rotation axis 152
of the outer roller 150. The first gear 215 may be non-rotatably secured to an opposing
face of the left bushing 170b relative to the axial projections 172a, 172b, thereby
ensuring the first gear 215 rotates in unison with the outer roller 150. To further
secure the first and second shells 154, 156 together, the shells 154, 156 may be clamped
together by at least one retaining clip 225 (FIGS. 12-13 depict two retaining clips,
although more or less clips may be used as desired to securely fasten the shells together).
As shown in FIG. 20, the retaining clip 225 may be resiliently snapped around an interlocked
region 227 of the first and second shells 154, 156.
[0073] Referring to FIG. 20, the end portions 158, 160 of the first and second shells 154,
156 may overlap one another and extend into corresponding longitudinally-extending
receiving channels 229, 231 defined at least partially by longitudinally-extending
lips 233, 235. The lip 233 of the first shell 158 may be positioned internal to a
terminal, longitudinally-extending edge 237 of the second shell 160, while the lip
235 of the second shell 160 may be positioned external to a terminal, longitudinally-extending
edge 239 of the first shell 158 (although this arrangement may be flipped). The retaining
clip 225 may resiliently snap around external detents 241, 243 formed in the interlocked
region of the first and second shells 154, 156, respectively, to clamp the first and
second shells 154, 156 together.
[0074] Referring to FIGS. 14 and 19, the split-shell design of the outer roller 150 defines
a longitudinally-extending slot 176 that permits passage of the second shade 24 during
extension and retraction of the second shade 24. When the edge portions 158, 160 of
the first and second shells 154, 156 are interlocked together, opposing or second
longitudinally-extending terminal edge portions 178, 180 of the first and second shells
154, 156 are peripherally spaced apart from one another and define the longitudinally-extending
slot 176. The confronting second terminal edge portions 158, 160 of the first and
second shells 154, 156 may be spaced a sufficient distance from one another to permit
passage of the second shade 24 yet prevent passage of the bottom rail 20 of the second
shade 24. The function of the outer roller 150 is generally the same as that discussed
in relation to FIGS. 6-11 and thus will not be repeated here for the sake of brevity.
[0075] During operation of the covering, as the outer roller 150 extends the first shade
22 across the architectural opening, the first gear 215 drives the idler gear 217,
which in turn drives the second gear 204, which traverses the nut 189 axially along
the shaft 188 toward a bottom end position. Once the nut 189 reaches the bottom end
position (which may be defined by a stop 197 on the shaft 188), the nut 189 restricts
further rotation of the shaft 188 in the extension direction of the first shade 22,
which in turn inhibits further rotation of the outer roller 150 in the extension direction.
With the outer roller 150 restricted from further rotation in the extension direction
and the first shade 22 unwrapped from the periphery of the outer roller 150, the second
shade 24 may be unwrapped from the inner roller 148, passed through the slot 176 in
the outer roller 150, and extended across the architectural opening. As the inner
roller 148 rotates during extension of the second shade 24, the internal limit nut
168 rotates in unison with the inner roller 148 and travels axially along the limit
screw 166 toward a bottom end stop formed on the non-rotatable limit screw 166. The
internal limit nut 166 generally contacts the bottom end stop upon the second shade
24 being fully extended across the architectural opening to define a bottom stop of
the dual roller unit 146.
[0076] During retraction of the covering from a fully extended position, the inner roller
148 pulls the second shade 24 through the slot 176 defined between the opposing longitudinally-extending
edge portions 178, 180 of the shells 154, 156 of the outer roller 150 and wraps the
second shade 24 about a periphery of the inner roller 148 until the bottom rail 20
of the second shade 24 seats against an outer periphery of the outer roller 150. During
retraction of the second shade 24, the weight of bottom rail 18 of the first shade
22 maintains the bushings 170a, 170b in a stationary condition and thus the inner
roller 148 rotates relative to the bushings 170a, 170b and the outer roller 150.
[0077] Once seated, the bottom rail 20 of the second shade 24 transfers the rotational torque
from the inner roller 148 to the outer roller 150, thereby rotating the outer roller
150 in a retraction direction and wrapping the first shade 22 about a periphery of
the outer roller 150. The inner and outer rollers 148, 150 continue to rotate in a
retraction direction until the bottom rail 18 of the first shade 22 contacts a top
limit stop, which may be associated with one or both of the end caps 126, at which
point the covering is retracted into a fully retracted position. During rotation of
the inner roller 148 in the retraction direction, the internal limit nut 168 traverses
along the non-rotatable limit screw 166 within the inner roller 148 away from the
bottom stop of the second shade 24. During rotation of the outer roller 150 in the
retraction direction, the external nut 189 traverses along the rotatable shaft 188
away from the bottom stop of the first shade 22.
[0078] Referring to FIGS. 28-47, a covering for an architectural opening is provided that
includes a pivotable lock mechanism. With the exception of the pivotable lock mechanism
and the multiple-piece outer roller, the covering depicted in FIGS. 28-47 generally
has the same features and operation as the covering depicted in FIGS. 6-27. Accordingly,
the preceding discussion of the features and operation of the covering depicted in
FIGS. 6-27 should be considered generally applicable to the covering depicted in FIGS.
28-47, except as noted in the following discussion. The reference numerals used in
FIGS. 28-47 generally correspond to the reference numerals used in FIGS. 12-27 to
reflect the similar parts and components, except the reference numerals are incremented
by one hundred.
[0079] Referring to FIGS. 28-34, the inner roller 248 is generally cylindrical in shape,
and forms a retaining member for securing the top edge of the second shade 24 thereto.
As noted above, the inner roller 248 is positioned inside the outer roller 250 to
define the dual roller unit, and in this example both rollers 248, 250 are coextensive
about the same rotational axis 252. An upper edge of the second shade 24 is attached
to the inner roller 248, and a lower edge of the second shade 24 is received in a
slot formed in the second bottom rail 220, and held in the slot by an insert 282 positioned
in a hem formed on the bottom edge of the second shade 24. Other attachment structures
may be used to attach the bottom rail 220 to the second shade 24.
[0080] Continuing with FIGS. 28-34, the second bottom rail 220 is an elongated member, having
relatively high mass, and defining a slot running along its length to receive and
retain, as noted above, the bottom edge of the second shade 24. The second bottom
rail 220 has a generally triangular cross section, a portion of which generally matches
the shape of the seat 281 formed on the outer roller 250 to conform thereto when the
second shade 24 is in the retracted position. An actuator rim 247 is defined at one
end of the second rail 220, and engages the lock mechanism 286 to disengage the lock
mechanism 286 from the outer roller 250, as is described in more detail below.
[0081] The outer roller 250 in this example is generally cylindrical, and defines several
features in its circumferential wall. The outer roller 250 defines a longitudinal
central axis 252 about which it rotates, and about which the inner roller 248 is coextensively
positioned also. A pair of channels 262 is formed to receive and secure the top edges
of the first shade 22, with the inserts 264 each being positioned in a hem formed
on each of the top edges, the inserts 264 acting to retain the top edge in the respective
channel 262. An anchor groove 245 is formed along the length of the outer roller 250
for receipt of a roller lock bearing, as is described below. A slot 276 is formed
along the length of the outer roller 250 and is in communication with the interior
of the outer roller 250, which may be formed as a tube. A recessed seat 281 is formed
on either side of the slot 276. The second shade 24 is extended and retracted through
the slot 276, and when in the fully retracted position, the second bottom rail 220
is received in the seat 281 and nests therein for at least one of many purposes, as
is described below. The slot 276 is positioned on the outer roller 250 so as to be
located above and adjacent to the rearward most of the two channels 262 when the first
shade 22 is in its extended position and vane-open configuration.
[0082] Referring to FIGS. 28, 29, 46, and 47, the dual roller unit is rotatably supported
between the right end cap 226a and the left end cap 226b, and the operating mechanism
240 is operably associated with the inner roller tube 248 to cause it to rotate. The
operating mechanism 240 is anchored to the right end cap 226a and is actuated by,
in one example, the operating element 242 as noted above. The operating mechanism
240 may, in one example, include a planetary gear drive often utilized in window covering
applications. The operating mechanism 240 may include an internal fitting 264 which
is rotated by the operating mechanism 240. The fitting 264 is sized to be received
within the inner roller 248, and tightly engages the inner wall of the inner roller
248. The inner roller 248 is driven in rotation by the internal fitting 264 as the
fitting is driven by the operating mechanism 240. The open right end of the outer
roller 250 receives a right end roller cap 270a, which includes a central aperture
having an axially extending collar rotatably receiving an axial bearing surface formed
on the housing of the operating mechanism 240. The bearing surface supports the right
end roller cap 270a as it rotates when the outer roller 250 rotates. The inner roller
248 is rotatably received on the collar. The collar rotatably supports the right end
of the inner tube 248 as it is driven by the operating mechanism 240 to rotate.
[0083] As shown in FIG. 46, right ends 248a, 250a of the inner and outer rollers 248, 250,
respectively, may be aligned with one another, and a right side edge 24a of the second
shade 24 may be aligned with the right ends 248a, 250a of the rollers 248, 250. As
shown in FIG. 47, left ends 248b, 250b of the inner and outer rollers 248, 250, respectively,
may be aligned with one another, and a left side edge 24b of the second shade 24 may
be aligned with the left ends 248b, 250b of the rollers 248, 250. The first shade
22 may be wrapped about the outer roller 250, and the edges of the first shade 22
may be aligned with the ends of the rollers 248, 250 and the edges of the second shade
24. The alignment of the ends of the rollers 248, 250 and the edges of the shades
22, 24 may reduce or eliminate light gaps between the edges of the shades and corresponding
sides of the architectural opening.
[0084] The outer roller 250 is driven in rotation by the inner roller 248 when the second
shade 24 is fully retracted onto the inner roller 248 and the second end rail 220
is received in the seat 281 of the outer tube 250. In this condition, as the inner
roller 248 rotates, the second shade 24 tensions the second end rail 220, which in
turn applies a force to the outer roller 250 at the interface between the second end
rail 220 and the seat 281. Thus the outer roller 250 is caused to rotate in conjunction
with the inner roller 248. The outer roller 250 does not rotate along with the inner
roller 248 unless the second shade 24 is fully retracted about the inner roller 248.
As noted above, the operating mechanism 240 may be actuated by an operating element
242 to extend or retract the first and second shades 22, 24 as desired by the user.
Many types of mechanisms for causing the rotation of the inner roller tube 248 upon
actuation of the operating element 242 are acceptable.
[0085] Continuing with FIGS. 28 and 29, a limit screw 266 is positioned inside the inner
roller 248, and is operably fixed to the left end cap 226b by a screw. The limit screw
266 does not rotate. A limit nut 268 is threadedly engaged with the limit screw 266,
and is rotationally keyed to the inside of the inner roller 248, the key structure
allowing movement of the limit nut 268 along the length of the inner roller 248. As
the inner roller 248 rotates, the limit nut 268 moves along the threaded limit shaft
266, and engages a limit stop defining the bottom most extended position of the second
shade 24 (see FIG. 5). The retracted position of the first shade 22 is defined by
the first shade 22, in this example, being wrapped entirely around the outer roller
250. In some examples, the first bottom rail 18 engages a portion of the head rail
14 to define this position. Alternatively or additionally, while a top limit stop
on the limit screw 266 is not used in this example, one may be employed on the limit
screw 266 if desired. The left end cap 226b, as best seen in FIGS. 28, 29, and 47,
rotatably supports the inner roller 248 and the outer roller 250.
[0086] Referring to FIGS. 28, 29, and 40, a pivot bracket 249 is attached to the inside
surface of the left end cap 226b and defines a centrally positioned annular boss 251
and a post 253 extending toward the right end cap 226a that serves as an axle on which
the roller lock 255 is pivotally mounted. The annular boss 251 on the pivot bracket
249 is rotatably received in the central aperture of the left outer roller cap 270b,
which is itself received in the open left end of the outer roller 250. A collar extends
axially from around the central aperture of the cap 270b, and serves as a bearing
surface for the relative rotation between the outer roller 250 and the left end bracket.
The open left end of the inner roller 248 is rotatably received upon the outer surface
of the collar, which acts as a bearing surface for the rotation of the roller 248
relative to the collar, which rotation is under the selective control through the
operating mechanism 240.
[0087] The roller lock 255, as shown in FIGS. 28, 29, 38, and 39, is pivotally attached
to the post 253 on the pivot bracket 249 (see FIGS. 40 and 41), and secured thereto
by a fastener 257 (see FIG. 41). The roller lock 255 is pivotable relative to the
pivot bracket 249 about the axis defined by the post 253. A spring member 259 (see
FIG. 43) is positioned around the post 253 of the pivot bracket 249, the spring 259
having two legs, one of which engages the roller lock 255 to bias the roller lock
255 into engagement with the outer surface of the outer roller 250, and the other
leg operably engages a portion of the left end cap 226b.
[0088] Referring to FIGS. 38 and 39, the roller lock 255 includes a frame plate 261 having
a central body 263 from which extend an upper leg 265 and a lower leg 267, each leg
265, 267 lying in the same plane as the central body 263. The upper and lower legs
265, 267 extend at near right angles to one another, and it is contemplated that this
relative positioning may be adjusted as needed given the geometry of the particular
usage. The end of the lower leg 267 includes a pin 269 extending orthogonally from
the plate 261 toward the opposite end cap, the pin 269 having a cylindrical shape
and being relatively short. For instance, the pin 269 does not extend far enough to
interfere with the rotation of the roller 250. The length and shape of the pin 269
facilitate the moving engagement between the pin 269 and the actuator rim 247 on the
second end rail 220 as described below.
[0089] Continuing to refer to FIGS. 38 and 39, the end of the upper leg 265 rotatably supports
a relatively long cylindrical bearing 271 which extends orthogonally from the upper
leg 265 towards the opposite end cap 226a. The bearing 271 is rotatably supported
at its opposite end by an arm 273 extending at an angle from the central plate 261.
The arm 273 supports the distal end of the bearing 271 from a top side only, and does
not extend much beyond the center of the bearing 271. This configuration leaves the
lower portion of the bearing 271, along its length, unencumbered and able to be received
in the anchor groove 245 formed in the outer roller 250, as well as to engage the
outer surface of the outer roller 250 and ride along its surface, as described further
below.
[0090] The operation of one example of the covering is described below with primary reference
to FIGS. 30-34. As shown in FIG. 30, both the first and second shades 22, 24 are in
the extended position, and the vanes 38 are in an open configuration. With brief reference
to FIG. 30, the first shade 22 may be coupled to and wrappable about the outer roller
42. An upper edge of each of the front and rear sheets 30, 34 may be coupled to an
inwardly-directed, longitudinally extending gland or rib 275. The gland 275 may define
an internal cavity 262 that opens through a periphery of the outer roller 250. The
shade 22 may be wrapped about or unwrapped from a rear side of the roller 250, with
the rear side of the roller 250 positioned between a front side of the roller 250
and a street side of an associated architectural opening (in FIG. 30, the rear side
of the roller is to the right). Generally, rotation of the roller 250 in a first direction
(counterclockwise in FIG. 30) retracts the shade 22 by winding it about the outer
roller 250 to a position adjacent one or more sides (such as the top side) of an associated
architectural opening and rotation of the roller 250 in a second, opposite direction
may extend the shade 22 across the opening (such as to the bottom side).
[0091] The first shade 22 is maintained in this open position by positioning the engagement
points 262 of the rear and front sheets 30, 34 of the first shade 22 with the outer
roller 250 at the same height. In FIG. 30, for instance, the positions of these attachment
points 262 may be referred to as being at 4 o'clock and 8 o'clock, which puts them
at close to the same level with each other. If the outer roller 250 is rotated either
direction from that shown in FIG. 30, the front and rear sheets 30, 34 would move
toward one another and the vanes 38 would re-orient into more vertical alignment.
[0092] At this position with both the first and second shades 22, 24 at the fully extended
position, the limit nut 268 (see generally FIGS. 28 and 29) is engaged with the lower
limit. Actuation of the operating mechanism 240, such as by the operating element
242, from this position begins the retraction of the second shade 24 into the head
rail 14. The operating mechanism 240 first rotates the inner roller 248 in a counterclockwise
direction in FIG. 30 to retract the second shade 24, and when the second shade 24
is fully retracted, the outer roller 250 is then actuated to retract the first shade
22 onto the outer roller 250. This sequence is described further herein and below.
[0093] As noted above, and referring still to FIG. 30, the inner roller 248 is positioned
within the outer roller 250 to define the dual roller unit 246. The outer roller 250
defines an axis of rotation 252 defined by the portion of the outer roller 250 having
a circular shape (such as from 9 o'clock to 2 o'clock). The inner roller 248 is positioned
so as to be coextensive with or concentric about the same axis 252 as the outer roller
250.
[0094] During retraction of the second shade 24, the inner roller 248 rotates relative to
the outer roller 250, with the opposing collars in the left and right roller end caps
270a, 270b supporting the respective ends of the inner roller 248. The outer roller
250 is held in fixed rotational position relative to the inner roller 248 by the roller
lock 255. The roller lock 255 is oriented such that the bearing 271 is biased by the
spring 259 to be received in the anchor groove 245 (See FIGS. 28-30). This position
of the bearing 271 inhibits the rotation of the outer roller 250. As the inner roller
248 rotates in the retraction direction, the second shade 24 is wound onto the inner
roller 248 as it is pulled through the slot 276 formed in the outer roller 250. This
retraction rotation moves the limit nut 268 along the limit screw 266 towards the
opposite end of the limit screw 266.
[0095] The slot 276 through which the second shade 24 extends, and the seat 281 for receiving
the second end rail 220 is positioned on the circumference of the outer roller 250
above the attachment point 262 of the rear sheet 34 of the first shade 22. This may
be referred to in FIG. 30 as 3 o'clock. The slot 276 is defined by opposing free edges
formed in the seat 281. The seat 281 is a recess formed along the length of the slot
276, and includes two outer edges that define the boundaries of the seat 281 on the
circumference of the outer roller 250. The shape of the recess, as oriented in FIG.
30, is somewhat angular overall, with a generally vertically oriented base wall 284
allowing a relatively vertical-tangential engagement and disengagement between the
second bottom rail 220 and the outer roller 250. The location of the seat 281 and
slot 276 near the furthest rearward position on the circumference of the outer roller
250, along with the shape of the seat 281, allows for secure receipt of the second
bottom rail 220 as it is pulled vertically up and into the seat 281 during retraction
(see FIGS. 31 and 32).
[0096] The shape of the seat 281 and its orientation on the outer roller 250 encourages
smooth and predictable disengagement of the second bottom rail 220 from the seat 281
to begin the extension of the second shade 24 (from the position shown in FIG. 32).
The shape and orientation of the seat 281 allows the bottom rail 220 to drop vertically
out of the seat 281, which takes advantage of the force of gravity on the relatively
heavy bottom rail 220. The generally tangential orientation of the seat 281 on the
outer roller 250 assists in this regard. Referring to FIG. 35, the upper wall 277a
extends from the top edge of the recess downwardly and radially inwardly to a lip
277b, which extends directly downwardly to an upper free edge 277c. This portion of
the seat 281 is the deepest (as measured from the circumference toward the center
of the outer roller). The lower wall 279a extends from the bottom edge of the recess
upwardly and inwardly at a shallow angle, and transitions to a lip 279b which defines
the lower free edge 279c of the slot 276. The lower wall 279a is relatively vertical,
and remains so even in combination with the upper lip 277b. The lower free edge 279c
of the slot 276 is curved or rounded to allow for the smooth travel of the second
shade 24 over this feature as it is retracted onto the inner roller 248.
[0097] The secure engagement of the second bottom rail 220 in the seat 281 aids in consistent
actuation of the roller lock 255 to disengage the bearing 271 from the anchor groove
245. Referring to FIG. 31, when the second shade 24 is near fully wound around the
inner roller 248, the bottom rail 220 of the second shade 24 engages the roller lock
255 to disengage the roller lock 255 from the outside of the outer roller 250. The
second bottom rail 220 is shown in dash in FIGS. 31 and 35. At this position, the
actuator rim 247, which extends axially from the end of the second bottom rail 220,
contacts the pin 269 formed on the lower leg 267 of the roller lock 255. As the second
bottom rail 220 is pulled into the seat 281 by the second shade 24 being retracted,
the actuator rim 247 moves the pin 269 relative to the pivot axis of the post 253.
The pin 269 is moved radially inwardly relative to the inner roller 248, and is moved
circumferentially relative to the pivot axis of the roller lock 255. The movement
of the roller lock 255 about the post 253 moves the upper arm 265, which begins the
movement of the bearing 271 upwardly and out of engagement with the anchor groove
245, which frees the outer roller 250 to rotate (see FIGS. 32, 36, and 43).
[0098] As shown in FIGS. 42 and 43, the actuator rim 247 extends off of the end of the second
bottom rail 220 adjacent the roller lock 255. With reference to FIGS. 44 and 45, the
rim 247 is a thin, curved element that in this example conforms to the curved shape
of the bottom side of the second bottom rail 220. The rim 247 is curved along a dimension
consistent with the bottom side of the second bottom rail 220, and extends axially
away from the second bottom rail 220. As best seen in FIG. 43, the rim 247 extends
a distance sufficient to engage the pin 269 on the roller lock 255 but not contact
the central plate 261 of the roller lock 255. The inside, concave surface of the fin
247 engages the round outer surface of the pin 269. As the second bottom rail 220
is further retracted, the pin 269 and fin 247 maintain a sliding engagement. This
further movement of the second end rail 220 causes the roller lock 255 to pivot further
about the pivot axis of the post 253 and thus moves the roller lock bearing 271 out
of the anchor groove 245.
[0099] Referring to FIGS. 32 and 36, as the second shade 24 is further withdrawn into the
outer roller 250, the bottom rail 220 becomes securely positioned in the seat 281
and the fin 247 moves the pin 269 a sufficient amount inwardly to fully remove the
bearing 271 from the anchor groove 245, which frees the outer roller 250 to rotate.
Further actuation of the operating mechanism 240 applies the rotational motion of
the inner roller 248 to the outer roller 250, through the engagement of the bottom
rail 220 in the seat 281 under the tension of the second shade 24. This engagement
causes the outer roller 250 to rotate in conjunction with the rotation of the inner
roller 248. As the outer roller 250 begins to rotate in the retraction direction,
the actuator rim 247 on the second bottom rail 220 disengages from the pin 269 on
the roller lock 255. Referring to FIGS. 33 and 37, upon release the roller lock 255
is biased by the spring 259 to cause the bearing 271 to contact the outer surface
of the outer roller 250 at a circumferential location spaced away from the anchor
groove 245.
[0100] Referring to FIG. 34, as the outer roller 250 continues to rotate in the retraction
direction, the first shade 22 wraps around the outer roller 250, covering the anchor
groove 245. When the roller lock bearing 271 nears the anchor groove 245 as the outer
roller 250 continues to rotate, the roller lock bearing 271 passes over the groove
245 by riding on the first shade 22 which spans the groove 245. The first shade 22
is under tension as it is wrapped around the outer roller 250, thus making the span
of the shade 22 extending over the groove 245 relatively taut. The bearing 271 may
depress somewhat into the anchor groove 245 when only a single wrap of the first shade
22 is positioned over the anchor groove 245, but after another full rotation the bearing
271 rides over the surface of the first shade 22 wrapped around the outer roller 250
without interference from the anchor groove 245.
[0101] As the first shade 22 continues to retract, it wraps around the outer roller 250
many times, and the roller lock bearing 271 continues to ride on the outer surface
of the shade 22. The dual roller unit 246 reaches the top retraction position when
the first bottom rail 18 contacts an abutment on the head rail housing, for example.
It is contemplated that other mechanisms may be utilized to define the top retraction
position, including a top limit stop positioned on the limit screw 266 opposite the
bottom limit stop. As explained above, the retraction of the second shade 24 and first
shade 22 from the fully extended position may occur with the user actuating one operating
element (manually or automatically) for the retraction of both shades 22, 24. The
limit screw 266 is of sufficient length to allow the limit nut268 to move from the
bottom limit stop until the top retracted position is attained.
[0102] Extension of the first shade 22 and the second shade 24, if desired, is accomplished
in reverse order as described above, such as generally following FIGS. 34 to 30. This
allows the user to select whether to have just the first shade 22 extended or to also
have the second shade 24 extended (between fully retracted and fully extended). During
extension of the first shade 22, the user actuates the operating mechanism 240 to
cause the inner roller 248 to rotate in an extension direction (clockwise in FIGS.
34-30), which in turn causes the outer roller 250 to rotate in an extension direction.
The dual roller unit 246 rotates, in this example, in the direction the user controls
the inner roller 248 to rotate. As the first shade 22 extends off of the rear of the
outer roller 250, the roller lock bearing 271 rides on the outer surface of the outer
roller 250 until the first shade 22 is nearly fully extended. At this point, the outer
surface of the outer roller 250 is exposed.
[0103] As the outer roller 250 continues to rotate, the roller lock bearing 271 rides on
the outer surface of the outer roller 250 until it meets the anchor groove 245. The
bearing 271 is biased downwardly by the spring 259 to be positioned in the groove
245 and inhibit the rotation of the outer roller 250 and allow the continued rotation
of the inner roller 248 (if desired by the user). Since the roller lock 255 is biased
in a direction against the outer surface of the outer roller 250, the bearing 271
moves into the anchor groove 245 without further urging. At this point the first shade
22 is at its most extended position across the opening. It is contemplated that the
roller lock 255 may be biased by means other than a spring 259 in these examples.
For instance, the top aim 273of the roller lock 255 may be weighted such that the
roller lock 255 pivots as desired automatically under the weight of the top arm 273.
Where a spring 259 is used, it may be a wire spring, coil spring, resilient material
spring (such as rubber, elastic, and/or plastic) or the like.
[0104] When the bearing 271 of the roller lock 255 is seated in the anchor groove 245, the
slot 276 in the outer roller 250 is rotationally oriented within the head rail 14
such that the bottom rail 220 of the second shade 24 may drop vertically out of the
seat 281 when the tension in the second shade 24 is lessened by the operating system
240. The generally tangential orientation and generally vertical positioning of the
seat 281, with a relatively vertical base wall 284, allows the weight of the second
bottom rail 220 to be effective to extract the bottom rail 220 from the seat 281 when
the tension in the second shade 24 is released in the retraction position. However,
if the user does not intend to extend the second shade 24, then the second shade 24
may remain retracted. The operating mechanism 240 may include a brake system to restrict
unwanted downward movement of the second or first shades 24, 22.
[0105] In order to extend the second shade 24, the operating system 240 is further actuated
to the level as desired by the user. When the user extends the second shade 24 to
the lowest position (most extension), the limit nut 268 is positioned on the limit
screw 266 in engagement with the lower limit stop. Thus a single limit screw 266 may
be utilized to define the upper limit of the retracted first shade 22 attached to
the outer roller 250, and to define the lower limit of the extended second shade 24
attached to the inner roller 248.
[0106] It is contemplated that the first shade 22 of FIGS. 30-34 (which may be the same
as or different than that shown in FIGS. 1-5) may be wrapped about or unwrapped from
the front side of the outer roller 250. Accompanying modifications to the structure
described herein would be necessary to facilitate the implementation of the dual roller
shade technology as applied to a front-descending shade structure. It is also contemplated
that the roller lock mechanism and accompanying elements necessary for it to operate
may be employed on the right end of the head rail, in affiliation with the right end
cap 226a, either in conjunction with a roller lock mechanism on the left end of the
head rail, or by itself. Also, the second bottom rail 220 may have an actuating rim
247 on either end thereof.
[0107] The foregoing description has broad application. While the provided examples describe
a silhouette-type shade and a black-out type shade, it should be appreciated that
the concepts disclosed herein may equally apply to many types of shades. Accordingly,
the discussion of any embodiment is meant only to be explanatory and is not intended
to suggest that the scope of the disclosure, including the claims, is limited to these
examples. In other words, while illustrative embodiments of the disclosure have been
described in detail herein, it is to be understood that the inventive concepts may
be otherwise variously embodied and employed, and that the appended claims are intended
to be construed to include such variations, except as limited by the prior art.
[0108] The foregoing discussion has been presented for purposes of illustration and description
and is not intended to limit the disclosure to the form or forms disclosed herein.
For example, various features of the disclosure are grouped together in one or more
aspects, embodiments, or configurations for the purpose of streamlining the disclosure.
However, it should be understood that various features of the certain aspects, embodiments,
or configurations of the disclosure may be combined in alternate aspects, embodiments,
or configurations. Moreover, the following claims are hereby incorporated into this
Detailed Description by this reference, with each claim standing on its own as a separate
embodiment of the present disclosure.
[0109] The phrases "at least one", "one or more", and "and/or", as used herein, are openended
expressions that are both conjunctive and disjunctive in operation.
[0110] The term "a" or "an" entity, as used herein, refers to one or more of that entity.
As such, the terms "a" (or "an"), "one or more" and "at least one" can be used interchangeably
herein.
[0111] All directional references (e.g., proximal, distal, upper, lower, upward, downward,
left, right, lateral, longitudinal, front, back, top, bottom, above, below, vertical,
horizontal, radial, axial, clockwise, and counterclockwise) are only used for identification
purposes to aid the reader's understanding of the present disclosure, and do not create
limitations, particularly as to the position, orientation, or use of this disclosure.
Connection references (e.g., attached, coupled, connected, and joined) are to be construed
broadly and may include intermediate members between a collection of elements and
relative movement between elements unless otherwise indicated. As such, connection
references do not necessarily infer that two elements are directly connected and in
fixed relation to each other. Identification references (e.g., primary, secondary,
first, second, third, fourth, etc.) are not intended to connote importance or priority,
but are used to distinguish one feature from another. The drawings are for purposes
of illustration only and the dimensions, positions, order and relative sizes reflected
in the drawings attached hereto may vary.
[0112] The following statements correspond to the claims of the parent application:
- 1. A covering for an architectural opening, comprising:
an outer roller having a central longitudinal axis and an elongated slot formed through
a sidewall;
an inner roller having a central longitudinal axis;
a first shade secured to and adapted to be wrapped around the outer roller;
a second shade defining a bottom rail and secured to and adapted to be wrapped around
the inner roller;
the inner roller received within the outer roller;
a mounting system supporting the inner and outer rollers for rotative movement about
the central longitudinal axis of the inner roller;
the second shade extending through the elongated slot and being retractable onto and
extendable from the inner roller there through, the bottom rail engaging the outer
roller when the second shade is in the fully retracted position;
an operating mechanism for selectively rotating the inner roller; and
the rotation of the inner roller when in the retracted position causing the rotation
of the outer roller.
- 2. A covering as defined in claim 1, wherein:
the elongated slot extending between ends of the outer roller; and
the inner roller having ends that are aligned with the ends of the outer roller.
- 3. The covering as defined in claims 1 or 2, wherein the second shade has side edges
that are aligned with the ends of the inner and outer rollers.
- 4. The covering as defined in anyone of the preceding claims, comprising:
a lock mechanism movable between a first position restricting the rotation of the
outer roller and a second position permitting rotation of the outer roller; and
wherein the lock moves from the first position to the second position upon engagement
of the second bottom rail with the lock mechanism.
- 5. The covering as defined in anyone of the preceding claims, wherein:
the slot is oriented orthogonally to a direction of extension of the first shade.
- 6. The covering as defined in anyone of the preceding claims, wherein:
the outer roller defines a longitudinal seat formed along the slot; and
the second bottom rail is received in the seat when the inner roller is in the retracted
position.
- 7. The covering as defined in claim 6, wherein:
the seat defines a recess with an opening in a direction of extension of the first
shade.
- 8. The covering as defined in anyone of the preceding claims, wherein:
the outer roller defines an elongated groove formed in the sidewall;
the lock mechanism includes a bearing; and
in the first position of the lock mechanism, the bearing is received in the groove.
- 9. The covering as defined in claim 8, wherein:
the lock mechanism includes a pin; and
the lock mechanism is actuated upon engagement of the pin by the second bottom rail
and the bearing is removed from the groove.
- 10. The covering as defined in claims 8 or 9, wherein:
the bearing movably engages the outer surface of the outer roller in the second position.
- 11. The covering as defined in anyone of the preceding claims, wherein:
the lock mechanism includes a locking member that pivots between the first and second
positions.
- 12. The covering as defined in anyone of the preceding claims, wherein:
the lock mechanism includes a locking member that axially translates between the first
and second positions.
- 13. The covering as defined in anyone of the preceding claims, wherein:
the lock mechanism includes a rotatable shaft positioned external to the outer roller
and oriented substantially parallel to the central longitudinal axis of the inner
roller.
- 14. The covering as defined in claim 13, wherein:
the lock mechanism includes a housing; and
the rotatable shaft is journaled to the housing.
- 15. The covering as defined in claim 14, further comprising an end cap, wherein:
the housing is cantilevered from the end cap.
- 16. The covering as defined in anyone of claims 13 to 15, wherein the lock mechanism
includes a gear mechanism that couples rotation of the rotatable shaft and the outer
roller.
- 17. The covering as defined in anyone of the preceding claims, wherein:
the outer roller includes a first shell and a second shell each having a longitudinally-extending
terminal edge; and
the longitudinally-extending terminal edges of the first and second shells are peripherally
spaced apart from one another to define the elongated slot.
- 18. A covering for an architectural opening, comprising:
a rotatable outer roller;
a first shade secured to and wrappable around the outer roller;
a rotatable shaft positioned external to the outer roller and at least partially defining
a bottom stop for the first shade;
a rotatable inner roller received within the outer roller;
a second shade secured to and wrappable around the inner roller; and
a non-rotatable shaft extending within the inner roller and at least partially defining
a bottom stop for the second shade.
- 19. A method of operating a dual panel covering for an architectural opening, comprising:
providing an inner roller positioned inside an outer roller;
locking rotation of the outer roller;
rotating the inner roller relative to the outer roller to retract until fully retracted
an extended second shade onto the inner roller through a slot formed in the outer
roller;
actuating the rotation lock at the fully retracted position of the inner roller to
allow the outer roller to rotate; and
rotating the outer roller by driving the inner roller to retract a first shade onto
the outer roller.
- 20. A method of operating an architectural opening covering having nested rollers,
comprising:
unwrapping a first shade from a periphery of an outer roller;
during extension of the first shade, axially traversing a locking member external
to the periphery of the outer roller;
restricting rotation of the outer roller upon the locking member engaging a first
stop;
unwrapping a second shade from a periphery of an inner roller positioned within the
outer roller;
during extension of the second shade, axially traversing a nut positioned within the
inner roller; and
restricting rotation of the inner roller upon the nut engaging a second stop.
- 21. A covering for an architectural opening, comprising:
a rotatable outer roller defining an elongated slot extending along a length of the
outer roller and opening to an interior of the outer roller;
a rotatable inner roller received within the outer roller and defining a central longitudinal
axis;
a first shade secured to the outer roller, the first shade retractable onto and extendable
from the outer roller; and
a second shade secured to the inner roller, the second shade extending through the
elongated slot and retractable onto and extendable from the inner roller, wherein
the elongated slot is substantially horizontally aligned with the central longitudinal
axis of the inner roller when the first shade is in a fully extended position.
- 22. The covering as defined in claim 21, wherein the inner and outer rollers are concentric
about the central longitudinal axis of the inner roller.
- 23. The covering as defined in claims 21 or 22, wherein the first and second shades
have the same width.
- 24. The covering as defined in anyone of claims 21-23, wherein:
the width of the first shade extends along the entire length of the outer roller;
and
the width of the second shade extends along the entire length of the inner roller.
- 25. The covering as defined in anyone of claims 21-24, further comprising a bottom
rail secured to the second shade and engaging the outer roller when the second shade
is in a fully retracted position.
- 26. The covering as defined in claim 25, wherein:
the outer roller defines a longitudinal seat formed along the slot; and
the bottom rail is received in the seat when the second shade is in the fully retracted
position.
- 27. The covering as defined in anyone of claims 21-26, wherein the slot is oriented
orthogonally to a direction of extension of the first shade.
- 28. The covering as defined in anyone of claims 21-27, further comprising a mounting
system supporting the inner and outer rollers for rotative movement about the central
longitudinal axis of the inner roller.
- 29. The covering as defined in anyone of claims 21-28, further comprising an operating
mechanism for selectively rotating the inner roller.
- 30. The covering as defined in anyone of claims 21-29, wherein:
the outer roller includes a first shell and a second shell each having a longitudinally-extending
terminal edge; and
the edges of the first and second shells are peripherally spaced apart from one another
to define the elongated slot.
- 31. The covering as defined in claim 30, further comprising:
a first bushing locked into one end of the first and second shells; and
a second bushing locked into an opposing end of the first and second shells; wherein
the first and second bushings maintain a constant width of the slot.
- 32. The covering as defined in anyone of claims 21-31, further comprising a lock mechanism
movable between a first position restricting the rotation of the outer roller and
a second position permitting rotation of the outer roller.
- 33. The covering as defined in claim 32, wherein the lock mechanism moves from the
first position to the second position upon engagement of the bottom rail with the
lock mechanism.
- 34. The covering as defined in claims 32 or 33, wherein:
the outer roller defines an elongated groove formed in the sidewall;
the lock mechanism includes a bearing; and
in the first position of the lock mechanism, the bearing is received in the groove.
- 35. The covering as defined in claim 34, wherein the bearing movably engages the outer
surface of the outer roller in the second position.
- 36. The covering as defined in anyone of claims 32-35, wherein:
the lock mechanism includes a pin; and
the lock mechanism is actuated upon engagement of the pin by the bottom rail to remove
the bearing from the groove.
- 37. The covering as defined in anyone of claims 32-36, wherein the lock mechanism
includes a locking member that pivots between the first and second positions.
- 38. The covering as defined in anyone of claims 32-37, wherein the lock mechanism
includes a locking member that axially translates between the first and second positions.
- 39. The covering as defined in anyone of claims 32-38, wherein the lock mechanism
includes a rotatable shaft positioned external to the outer roller and oriented substantially
parallel to the central longitudinal axis of the inner roller.
- 40. The covering as defined in claim 39, further comprising an end cap, wherein:
the inner and outer rollers are rotatably coupled to the end cap;
the lock mechanism includes a housing cantilevered from the end cap; and
the rotatable shaft is journaled to the housing.
- 41. The covering as defined in claims 39 or 40, wherein the lock mechanism includes
a gear mechanism that couples rotation of the rotatable shaft and the outer roller.
- 42. A covering for an architectural opening, comprising:
a rotatable outer roller defining an elongated slot;
a first shade secured to and wrappable around the outer roller;
a lock mechanism positioned external to the outer roller and at least partially defining
a bottom stop for the first shade;
a rotatable inner roller received within the outer roller;
a second shade secured to and wrappable around the inner roller, the second shade
extendable and retractable through the elongated slot; and
a non-rotatable shaft extending within the inner roller and at least partially defining
a bottom stop for the second shade.
- 43. The covering as defined in claim 42, wherein the lock mechanism includes:
a rotatable shaft positioned external to the outer roller; and
a locking member that axially translates along the rotatable shaft.
- 44. The covering as defined in claim 42, wherein the lock mechanism includes a pivotable
locking member positioned external to the outer roller.
- 45. A method of operating a covering for an architectural opening, comprising:
unwrapping a first shade from a periphery of an outer roller;
upon the first shade reaching a fully extended position, unwrapping a second shade
from a periphery of an inner roller positioned within the outer roller; wherein unwrapping
the second shade comprises extending the second shade through an elongated slot formed
in the outer roller and positioned in substantial horizontal alignment with a central
longitudinal axis of the inner roller.
- 46. The method as defined in claim 45, further comprising:
pivoting a locking member into locking engagement with the outer roller to lock rotation
of the outer roller;
rotating the inner roller relative to the outer roller to retract the second shade
onto the inner roller through the elongated slot formed in the outer roller;
pivoting the locking member out of locking engagement with the outer roller at a fully
retracted position of the inner roller to allow the outer roller to rotate; and
rotating the outer roller by driving the inner roller to retract the first shade onto
the outer roller.
- 47. The method as defined in claim 45, further comprising:
during extension of the first shade, axially traversing a locking member external
to the periphery of the outer roller;
restricting rotation of the outer roller with the locking member upon the first shade
reaching the fully extended position;
during extension of the second shade, axially traversing a nut positioned within the
inner roller; and
restricting rotation of the inner roller with the nut upon the second shade reaching
a fully extended position.