How to Make a Shade Panel

Abstract

A method of making a shade panel includes the steps of forming a shade panel including a plurality of cells, each of the cells having opposing front and rear portions; stretching the shade panel, each of the cells including a bend in the front portion that protrudes away from the rear portion when the shade panel is stretched; and pressing the front and rear portions including the bends toward each other to form a crease in the front portion of each of the cells.

Description

[Technical field]

[0001] FIELD OF THEINVENTION This invention relates to window shades, and more particularly to a method of making shade panels for use in window shades.

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 341,818, filed May 13, 2022, the disclosure of which is incorporated herein by reference. [Background technology]

[0003] Some conventional window shades use panels composed of multiple cells to cover a window opening. For example, some approaches propose attaching multiple lateral strips to each other in an overlapping relationship to form cells, with each lateral strip arranged to form alternating front and rear portions of adjacent cells. These approaches require relatively complex and less cost-effective processing steps. Furthermore, the cells may not fold or expand as desired during use, which may affect the appearance of the panel and the ability of the cells to provide thermal insulation. Summary of the Invention

[0004] The present application describes a method of making a shade panel that can address at least some of the aforementioned problems.

[0005] According to one aspect, a method of making a shade panel includes the steps of: forming a shade panel including a plurality of cells, each cell having opposed front and rear portions; stretching the shade panel, each cell including a bend in the front portion that protrudes away from the rear portion when the shade panel is stretched; and pressing the front and rear portions including the bends toward each other to form a crease in the front portion of each cell. [Brief description of the drawings]

[0006] [Figure 1] FIG. 1 is a perspective view showing one embodiment of a window shade. [Diagram 2] FIG. 2 is a front view showing the window shade of FIG. [Diagram 3] FIG. 2 is a side view showing the window shade of FIG. [Figure 4] FIG. 2 is an exploded view of the window shade shown in FIG. [Diagram 5] 4 is a flow chart illustrating certain process steps in a method of making a shade panel. [Figure 6] 6 is a schematic diagram showing examples of intermediate steps in the method of FIG. 5. [Figure 7] 6 is a schematic diagram showing examples of intermediate steps in the method of FIG. 5. [Figure 8] 6 is a schematic diagram showing examples of intermediate steps in the method of FIG. 5. [Figure 9] 6 is a schematic diagram illustrating one embodiment of a shade panel formed in an initial step of the method illustrated in FIG. 5. [Figure 10] 10 is a schematic diagram showing the stretch strips used to form the shade panel shown in FIG. 9. [Figure 11] 6 is a schematic diagram illustrating an alternative embodiment of the shade panel formed in the initial steps of the method shown in FIG. 5. [Figure 12] 12 is a schematic diagram showing the stretch strips used to form the shade panel shown in FIG. 11. [Figure 13] 12 is a schematic diagram showing [some] examples of intermediate stages in the method of FIG. 5, the initial step of which is to form the shade panel shown in FIG. 11. [Figure 14] 12 is a schematic diagram showing [some] examples of intermediate stages in the method of FIG. 5, the initial step of which is to form the shade panel shown in FIG. 11. [Figure 15] 12 is a schematic diagram showing [some] examples of intermediate stages in the method of FIG. 5, the initial step of which is to form the shade panel shown in FIG. 11. [Figure 16]6 is a schematic diagram illustrating another alternative embodiment of the shade panel formed in the initial steps of the method shown in FIG. 5. [Figure 17] 17 is a schematic diagram showing [some] examples of intermediate stages in the method of FIG. 5, the initial step of which is to form the shade panel shown in FIG. 16. [Figure 18] 17 is a schematic diagram showing [some] examples of intermediate stages in the method of FIG. 5, the initial step of which is to form the shade panel shown in FIG. 16. [Figure 19] 17 is a schematic diagram showing [some] examples of intermediate stages in the method of FIG. 5, the initial step of which is to form the shade panel shown in FIG. 16. [Figure 20] FIG. 13 is a schematic diagram showing an additional processing step to remove the front portion of the bottom cell while leaving the rear portion for attachment to the rail. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0007] Figure 1 is a perspective view of one embodiment of a window shade 100. Figures 2 and 3 are front and side views, respectively, of the window shade 100. Figure 4 is an exploded view showing some structural details of the window shade 100. With reference to Figures 1-4, the window shade 100 may include a head frame 102, a shade panel 104, and an actuation system assembled to the head frame 102 for controlling movement of the shade panel 104.

[0008] The actuation system may include a roller 106 and a control device 108 having an operating member 110. The roller 106 is connected to an end 111A of the shade panel 104 and pivotally connected to the head frame 102. According to an example construction, the roller 106 may be connected to the shade panel 104 by inserting an anchor strip 112 coupled to the end 111A of the shade panel 104 into a slot in the roller 106. The head frame 102 may include two side brackets 102A and 102B attached to an extension rail 102C. The roller 106 may have one end, which is pivotally connected about a fixed shaft 114 fixedly connected to the side bracket 102A. The control device 108 is coupled to the other end of the roller 106 and is attached to the side bracket 102B with the operating member 110 extending outside the head frame 102. Examples of the operating member 110 may include, but are not limited to, a closed loop element such as a bead chain. With this structure, the roller 106 can be rotated to wind and unwind the shade panel 104. The operating member 110 is operable to drive the roller 106 in rotation in either direction.

[0009] 1-4, the shade panel 104 has a length L in a first direction and a width W in a second direction perpendicular to the first direction. The shade panel 104 includes a plurality of cells 122 disposed adjacent to one another along the length L, with each cell 122 extending along a width W and having a hollow interior. Each cell 122 has a front portion 122F and a rear portion 122R that are opposed to one another. When the shade panel 104 is unfolded, the rear portion of the cell 122 may be generally flat, while the front portion of the cell 122 may have a wavy profile. When the shade panel 104 is unfolded for use within a building, the front portion 122F of the cell 122 faces the interior, and the unfolded cells 122 may form a layer of air that can help provide insulation.

[0010] 1-4, an end 111A of the shade panel 104 may be adapted to connect to a roller 106, and another end 111B of the shade panel 104 opposite the end 111A may be connected to a rail 116. The rail 116 extends along a width W of the shade panel 104 and functions as a weighing element that may help spread and stabilize the shade panel 104 during use. According to an example construction, the end 111B of the shade panel 104 may be attached to an anchor strip 118. The anchor strip 118 may be disposed within a hollow interior of the rail 116, and a limiter 120 may be fitted into the rail 116 to hold a portion of the shade panel 104 within the rail 116.

[0011] In conjunction with Figures 1-4, Figure 5 is a flow chart illustrating process steps in a method 200 of making a shade panel 104. Figures 6-8 are schematic diagrams illustrating some example intermediate stages in the method 200 of Figure 5. With reference to Figures 5 and 6, a shade panel 104A is formed in an initial step 202, including cells 122, each of the cells 122 having opposed front and rear portions 122F, 122R.

[0012] In step 204, the shade panel 104A is stretched such that each cell 122 includes a bend 124 at a front portion 122F that protrudes away from the rear portion 122R when the shade panel 104A is stretched. Stretching the shade panel 104A causes the rear portion 122R of each cell 122 to extend generally along the same plane, while the bend 124 at the front portion 122F of the cell 122 may form a wavy profile.

[0013] 5 and 7, in the next step 206, the front portion 122F and the rear portion 122R, including the bend 124, are pressed toward each other to form a fold 126 in the front portion 122F of each cell 122. For example, step 206 may include passing the stretched shade panel 104A through a pressing roller 210 in a direction D, such that the pressing roller 210 contacts and presses the front portion 122F against the rear portion 122R of each cell 122. In particular, the shade panel 104A may be passed through the pressing roller 210 from an end 111A to an end 111B of the shade panel 104A. The end 111A of the shade panel 104A corresponds to an end that can be attached to the roller 106 of the window shade 100.

[0014] 7, the front portion 122F can be pressed against (towards) the rear portion 122R to flatten the bent portion 124. As the bent portion 124 is gradually flattened, the pressure roller 210 can urge the squeezed portion formed in the front portion 122F forward of the pressure roller 210 to fold it over the rear portion 122R, thereby forming the crease 126.

[0015] 8 illustrates the resulting shade panel 104 after step 206 is completed. Within the shade panel 104, each cell 122 includes a fold 126 at its front portion 122F. The fold 126 forms a hinge that can facilitate the folding and unfolding of the cell 122 when the shade panel 104 is unwound from the roller 106 and stretched.

[0016] In conjunction with Figures 5-8, Figures 9 and 10 are schematic diagrams illustrating one embodiment of a shade panel 104A formed in step 202. With reference to Figures 5, 9 and 10, step 202 of method 200 may include providing a support sheet 130, providing a plurality of extension strips 132, and adhering the extension strips 132 to the support sheet 130 to form cells 122 of the shade panel 104A. A front portion 122F of each cell 122 is formed by one of the extension strips 132 and a rear portion 122R of each cell 122 is formed by the support sheet 130.

[0017] The extension strips 132 are of similar construction. Each extension strip 132 may have two opposed longitudinal edges 134A and 134B and a main strip portion 136 located between two margins 138A and 138B. The margin 138A is adjacent to the main strip portion 136 along a fold line 140A and extends between the fold line 140A and the longitudinal edge 134A. The other margin 138B is adjacent to the main strip portion 136 along a fold line 140B and extends between the fold line 140B and the longitudinal edge 134B. The fold lines 140A and 140B are generally parallel to each other and extend along the longitudinal direction of the extension strip 132 (i.e., corresponding to the width W of the shade panel 104). Margin 138B further includes fold line 140C that is generally parallel to fold lines 140A and 140B and is located between fold line 140B and longitudinal edge 134B. Thus, margin 138B has margin portion 142A extending between longitudinal edge 134B and fold line 140C, and margin portion 142B extending between the two fold lines 140B and 140C.

[0018] Various methods may be applied to form the fold lines 140A, 140B, and 140C in each stretch strip 132. For example, each of the fold lines 140A, 140B, and 140C may be a line of perforations passing through the stretch strip 132 and including a plurality of spaced apart perforations. According to another example, each of the fold lines 140A, 140B, and 140C may be a crease formed by a rolling blade pressed against the stretch strip 132. The method applied to form the fold lines 140A, 140B, and 140C may be selected depending on the thickness of the stretch strip 132 and / or the material of the stretch strip 132.

[0019] 9 and 10, the cells 122 of the shade panel 104A may be formed by adhering the extension strips 132 to the support sheet 130. More specifically, a margin 138A of each extension strip 132 may be adhered to the support sheet 130, and a margin 138B of each extension strip 132 may be adhered to the support sheet 130 at a margin portion 142A between the longitudinal edge 134B and the fold line 140C. The margin 138B is non-adhered to the support sheet 130 at a margin portion 142B between the two fold lines 140B and 140C. Examples of techniques applied to adhere the extension strips 132 include, but are not limited to, adhesive bonding, ultrasonic welding, and the like.

[0020] 9, the elongated strip 132 may have two opposing strip surfaces 144A and 144B extending between two opposing longitudinal edges 134A and 134B. The margin 138A and the margin portion 142A may be adhered to the support sheet 130 at the same strip surface 144A. For example, the margin 138A of the elongated strip 132 may have a first layer of adhesive applied to its strip surface 144A, and the margin portion 142A of the elongated strip 132 may have a second layer of adhesive applied to its same strip surface 144A. The extension strips 132 may then be positioned such that margins 138A of the extension strips 132 are adhered to the support sheet 130 with a first layer of adhesive and margin portions 142A of the extension strips 132 are adhered to the support sheet 130 with a second layer of adhesive at a location spaced from the margins 138A. The extension strips 132 may likewise be adhered adjacent to one another to the support sheet 130 to form the cells 122 of the shade panel 104A.

[0021] It is understood that the manner of adhesion of the stretch strips 132 is not limited to the above-mentioned example. According to another example, the margin 138A and the margin portion 142A of each stretch strip 132 may be adhered to different ones of the strip surfaces 144A and 144B to the support sheet 130. According to another variation, the margin 138A of the stretch strip 132 may be adhered to the support sheet 130 and the margin portion 142A of the stretch strip 132 may be adhered to the other stretch strip 132 adjacent thereto.

[0022] 5, 8 and 9, step 206 may form a fold 126 in each of the elongated strips 132 between its two fold lines 140A and 140B. When the shade panel 104 thus formed is unfolded, the bottom end of each cell 122 may be defined by the fold 126. When one cell 122 is folded by winding the shade panel 104 around the roller 106, the front portion 122F may lie adjacent to the rear portion 122R.

[0023] In conjunction with Figure 5, Figures 11 and 12 are schematic diagrams illustrating alternate embodiments of the shade panel 104B that may be formed in step 202 of the method 200. With reference to Figures 5, 11 and 12, step 202 of the method 200 may include providing a plurality of elongated strips 150 and adhering the elongated strips 150 to one another to form the cells 122 of the shade panel 104B.

[0024] According to a construction example, each of the elongated strips 150 includes a central portion 152, two longitudinal edges 154A and 154B opposite each other, and two longitudinal portions 156A and 156B folded onto the central portion 152 along two fold lines 158A and 158B, respectively. In each of the elongated strips 150, the longitudinal portion 156A has a width W1 between the longitudinal edge 154A and the fold line 158A, and the longitudinal portion 156B has a width W2 between the longitudinal edge 154B and the fold line 158B, which is smaller than the width W1 of the longitudinal portion 156A. In other words, the ratio W1 / W2 is greater than 1.

[0025] The cells 122 of the shade panel 104B may be formed by adhering the extension strips 150 to one another. Two adjacent ones of the extension strips 150 are adhered to one another by adhering the longitudinal portions 156A and 156B of one of the two adjacent extension strips 150 to the central portion 152 of the other one of the two adjacent extension strips 150. For example, the two longitudinal portions 156A and 156B of the first extension strip 150 may be applied with a first adhesive layer 160A and a second adhesive layer 160B, respectively. Thereafter, the second extension strip 150 may be positioned such that the central portion 152 of the second extension strip 150 is adhered to the two longitudinal portions 156A and 156B of the first extension strip 150 with the first adhesive layer 160A and the second adhesive layer 160B. Similarly, the stretch strips 150 may be bonded together to form the cells 122 of the shade panel 104B. Within each cell 122 of the shade panel 104B, a front portion 122F of the cell 122 is formed by a portion of the stretch strip 150 including the longitudinal portion 156A and a first region 152A of the central portion 152 adjacent the fold line 158A. A rear portion 122R of the cell 122 is formed by a portion of the stretch strip 150 including the longitudinal portion 156B and a second region 152B of the central portion 152 adjacent the fold line 158B.

[0026] 13-15 are schematic diagrams illustrating some example intermediate steps in the method 200 of FIG 5. Step 202 of the method 200 forms the shade panel 104B shown in FIG 11.

[0027] 5 and 13, in step 204, the shade panel 104B is stretched such that each cell 122 includes a bend 124 at the front portion 122F that protrudes away from the rear portion 122R when the shade panel 104B is stretched. The bend 124 at the front portion 122F of the cell 122 may form a wavy profile, whereas the rear portion 122R of each cell 122 extends generally along the same plane when the shade panel 104B is stretched. In particular, within each stretch strip 150, the longitudinal portion 156B and the second region 152B of the central portion 152 (better shown in FIG. 11) may be stretched to extend generally along the same plane.

[0028] 5 and 14, in step 206, the front portion 122F can be pressed against the rear portion 122R to flatten the bent portion 124. As the bent portion 124 is gradually flattened, the pressure roller 210 can urge (drive) the squeezed portion formed in the front portion 122F forward of the pressure roller 210 to fold it over the rear portion 122R, thereby forming the crease 126.

[0029] 5 and 15, after step 206 is completed, each cell 122 of the formed shade panel 104 includes a fold 126 in a first region 152A of the central portion 152 of the extension strip 150. The fold 126 forms a hinge that can facilitate folding and unfolding of the cell 122 when the shade panel 104 is wrapped around and extended from the roller 106.

[0030] Depending on the ratio W1 / W2 (better shown in FIG. 12) in each stretch strip 150, the cells 122 of the shade panel 104 resulting from the method 200 may have different shapes. FIG. 16 shows a variation in which each stretch strip 150 used to form the shade panel 104C in step 202 has a ratio W1 / W2 greater than the ratio W1 / W2 of the example shown in FIGS. 11 and 12. FIGS. 17 and 18 show the shade panel 104C as steps 204 and 206 of the method 200 described above are performed. FIG. 19 shows the shade panel 104 resulting after completion of step 206.

[0031] 20, the method may further include removing a front portion 122F of the bottom cell 122' (shown in phantom in FIG. 20) while leaving a rear portion 122R of the bottom cell 122' to form an end 111B of the shade panel 104 that is attached to the rail 116 (better shown in FIG. 4). For example, the front portion 122F of the bottom cell 122' may be cut and removed. This allows the remaining rear portion 122R of the bottom cell 122' to form a tail adapted to be attached to the rail 116. This step may be applied optionally as needed. For example, the step of removing the front portion 122F of the bottom cell 122' may be performed when the shade panel 104 is made based on the structure shown in FIG. 11 or FIG. 16.

[0032] Advantages of the methods and structures described herein include the ability to provide shade panels with suitable creases to facilitate folding and unfolding of the cells of the shade panel. The creases may be added to the cells through a pressing process after the shade panel is formed. This accommodates shade panels with cells of different configurations and facilitates the manufacturing process.

[0033] Structural implementations are described only in the context of specific embodiments. These embodiments are exemplary and not limiting. Many variations, modifications, additions, and improvements are possible. Thus, components described herein as a single instance may be provided with multiple instances. Structures and functions presented as separate components in example configurations may be implemented as a combined structure or component. These and other variations, modifications, additions, and improvements may be included within the following claims.

Claims

1. 1. A method of making a shade panel, comprising: forming a shade panel including a plurality of cells, each cell having opposed front and rear portions; stretching the shade panel, each cell including a bend in the front portion that protrudes away from the rear portion when the shade panel is stretched; and pressing the front portion and the rear portion, including the bend, toward each other to form a crease in the front portion of each cell.

2. 2. The method of claim 1, wherein the step of pressing the front portion and the rear portion including the bend toward each other causes flattening of the bend, resulting in a squeezed portion of the front portion that is folded over the rear portion to form the crease.

3. The method of claim 1 , wherein the step of stretching the shade panel comprises causing the rear portion of each cell to extend generally along the same plane.

4. 2. The method of claim 1, wherein the step of pressing the front portion and the rear portion, including the bent portion, toward each other includes passing the stretched shade panel through a pressure roller, whereby the pressure roller contacts and presses the front portion against the rear portion.

5. The shade panel has opposed first and second ends; 5. The method of claim 4, wherein the shade panel is attachable to a roller of a window shade at the first end, and the shade panel passes through the pressure roller from the first end to the second end.

6. The step of forming a shade panel including a plurality of cells includes: providing a support sheet; Providing a plurality of elongated strips; and adhering the elongated strips to the support sheet to form the cells; 6. A method according to claim 1, wherein the front portion of each cell is formed by one of the elongated strips and the rear portion of each cell is formed by the support sheet.

7. each of the elongate strips having opposed first and second longitudinal edges and a main strip portion located between a first margin and a second margin; the first margin is adjacent the main strip portion along a first fold line and extends between the first fold line and the first longitudinal edge; the second margin is adjacent the main strip portion along a second fold line and extends between the second fold line and the second longitudinal edge; The method of claim 6 , wherein the second margin includes a third fold line generally parallel to the second fold line.

8. The step of adhering the elongated strip to the support sheet comprises: adhering the first margin of each elongation strip to the support sheet; and adhering the second margin of each elongated strip to the support sheet at a first margin portion between the third fold line and the second longitudinal edge; The method of claim 7 , wherein the second margin is non-adhered to the support sheet at a portion of the second margin between the second fold line and the third fold line.

9. 9. The method of claim 8, wherein the step of pressing the front and rear portions including the bends toward each other forms the crease in each of the elongated strips between the first fold line and the second fold line.

10. The step of forming a shade panel including a plurality of cells includes: providing a plurality of elongated strips, each elongated strip including a central portion, opposing first and second longitudinal edges, and first and second longitudinal portions folded over the central portion along first and second fold lines, respectively; and adhering the elongated strips together to form the cells; 6. The method according to claim 1, wherein two adjacent ones of the stretch strips are bonded to each other by bonding the first longitudinal portion and the second longitudinal portion of one of the two adjacent stretch strips to the central portion of the other one of the two adjacent stretch strips.

11. For each of the elongated strips, the first longitudinal portion has a width between the first longitudinal edge and the first fold line; 11. The method of claim 10, wherein the second longitudinal portion has a width between the second longitudinal edge and the second fold line that is less than the width of the first longitudinal portion between the first longitudinal edge and the first fold line.

12. the front portion of each cell is defined by the first longitudinal portion and a first region of the central portion of one of the elongate strips; The method of claim 11 , wherein the rear portion of each cell is defined by the second longitudinal portion and a second region of the central portion of one of the elongated strips.

13. 13. The method of claim 12, wherein the step of stretching the shade panel causes the second longitudinal portion of each elongated strip and the second region of the central portion to extend generally along the same plane.

14. The method of claim 12 , wherein the step of pressing the front and rear portions including the bends toward each other forms the crease in the first region of the central portion of each elongated strip.

15. 6. The method of claim 1, wherein the cells include a bottom cell, the method further comprising removing a front portion of the bottom cell while maintaining a rear portion of the bottom cell.

Images