A motorised fabric sunshade and an assembly method

Abstract

A motorised fabric sunshade comprising: a housing; two side guides; a screen roller (40) rotatably mounted in the housing; a screen that can be wound on and unwound from the screen roller; a bottom bar fixedly mounted on the screen, wherein the bottom bar is guided at its end in one of the side guides; and a tensioning system for keeping the screen under tension. The tensioning system comprises: one belt (26); two spools which are positioned in line with the screen roller and on which the ends of the belt are mounted; and a guide for guiding the belt through the side guides and the bottom bar. Using a single belt avoids the need to use two separate tensioning systems to each tension one side of the screen. Moreover, the use of a belt also achieves improved rolling on the spool compared to a cord.

Description

[0001] A motorised fabric sunshade and an assembly method

[0002] Technical field

[0003] The present invention relates to a motorised fabric sunshade, particularly to a non-vertical fabric sunshade. The present invention further relates to a method for assembling a belt in the motorised fabric sunshade.

[0004] Prior art

[0005] Motorised non-vertical fabric sunshades are typically installed to shield a specific area from sunlight. For example, such fabric sunshades are often installed at homes, restaurants, shops, etc., to shield a window, skylight, veranda, terrace, or the like from sun rays. Such fabric sunshades comprise a fabric (also referred to as a "screen") that is provided with a bottom bar at its lower side. In a vertically installed fabric sunshade , additional weighting of the bottom bar (typically at least 10 kg per 3 metres of screen width), due to gravity, provides tension on the fabric. Vertically installed means that the fabric sunshade is in a vertical plane and moves in that plane, with the bottom bar located on the side of the fabric sunshade facing the ground surface.

[0006] However, in non-vertical fabric sunshades, fabric tension via gravity is not possible, and a separate tensioning system is used. Non-vertically installed means that the fabric sunshade is in one of the following situations: the fabric sunshade is in a non-vertical plane and moves in that plane; the fabric sunshade is in a vertical plane and moves in a horizontal direction in this plane (e.g. the Slidefix® marketed by Renson); or the fabric sunshade is in a vertical plane and moves in this plane with the bottom bar on the side of the fabric sunshade facing away from the ground surface. If a screen cannot be wound and down in a substantially vertical plane, such a tensioning system ensures that the bottom bar is inclined away from the screen roller, e.g. pushed or pulled. Such a tensioning system helps prevent a screen from moving excessively or flapping or being damaged by wind. Moreover, such a tensioning system prevents a screen, which is, for example, mounted on a slope towards a window or arranged as a roof of a terrace canopy without glazing, from sagging under its own weight and coming into contact with the window or the terrace canopy.

[0007] Furthermore, a tensioning system can also be used for vertical fabric sunshades. This can be useful if high wind loads on the fabric sunshade are expected, causing a weighted bottom bar not to maintain the necessary tension. This mainly occurs in high-rise buildings where wind loads can be greater due to the height at which the fabric sunshade is located. The tensioning system can also be used in vertical fabric sunshades as a replacement for the bottom bar.

[0008] A known motorised fabric sunshade comprises: a frame provided with a housing, a first side guide and a second side guide; a screen roller rotatably mounted in the housing and extending between a first end and a second end; a screen fixedly mounted at a first edge on the screen roller, wherein the screen can be wound on and unwound from the screen roller; a bottom bar fixedly mounted on a second edge of the screen, which second edge is opposite said first edge, wherein the bottom bar has a first end part and a second end part, which are each guided in one of said side guides; and a tensioning system for keeping the screen under tension.

[0009] Such a fabric sunshade is disclosed in DE 198 07 541 C1. The tensioning system comprises two separate components, namely one on each side of the screen roller. More specifically, on each side of the screen roller, a cord is provided that is wound on a spool and extends through the side guide into the bottom bar and is kept under tension there.

[0010] A first disadvantage of this tensioning system is the use of a cord when rolling up on a spool. In the wound state, there are in particular multiple layers of cord wound on top of each other, which, due to the tension, can lead to the cord shifting to a deeper layer. This causes noise, vibrations, small shifts of the screen, etc., and can lead to the cord breaking. A second disadvantage of this tensioning system is the use of two separate cords. If one of the two cords breaks, the other remains under tension. This causes the screen to skew, which is undesirable.

[0011] The first disadvantage has already been addressed in DE 93 09 350 U1 and CN 1 1 1945969 A. Both documents disclose the use of a belt instead of a cord. A belt is advantageous in this respect due to the width thereof, which prevents the wound belt from shifting to a deeper layer due to the tension.

[0012] The tensioning system disclosed in DE 93 09 350 U1 has a further problem concerning the torsion of the belt. The tread of the belt undergoes in particular a 90° rotation to fit into the bottom bar. However, this torsion is disadvantageous and causes wear.

[0013] This problem has already been addressed in EP 3 048 213 A1 , which also addresses the second disadvantage described above. EP 3 048 213 A1 discloses in particular the use of a woven tube that extends from one end of the screen roller through the side guides and bottom bar to the other end of the screen roller. A break in the woven tube thus results in the loss of the tension on the entire fabric. The problem of belt torsion is solved in EP 3 048 213 A1 by the woven tube winding up in a plane like a fire hose.

[0014] The problem of the tensioning system disclosed in EP 3 048 213 A1 is mainly wear. Due to the frequent winding and unwinding, there is also a frequent change in shape of the tube from flat to cylindrical and back. This change is particularly noticeable at the transition from the spools near the screen roller to the side guides.

[0015] Description of the invention

[0016] It is an object of the present invention to provide an improved tensioning system for a motorised fabric sunshade.

[0017] This object is achieved in that the tensioning system comprises: one belt extending between a first end and a second end; a first spool which is positioned in line with the screen roller near the first end thereof and on which the first end of the belt is mounted, wherein the belt can be wound on and unwound from the first spool; a second spool which is positioned in line with the screen roller near the second end thereof and on which the second end of the belt is mounted, wherein the belt can be wound on and unwound from the second spool; and a guide for guiding the belt between its first end and its second end through the side guides and the bottom bar.

[0018] The use of a single belt firstly achieves the same advantages as the woven tube in EP 3 048 213 A1 , namely avoiding the need to use two separate cords to each tension one side of the screen. Moreover, the use of a belt also achieves the same advantages as disclosed in DE 93 09 350 U1 and CN 1 1 1945969 A, namely improved winding on the spool compared to a cord.

[0019] The use of one belt as opposed to the woven tube has the further advantage that there is much less wear during use. The belt is dimensionally stable unlike the woven tube, resulting in significantly less wear on the belt.

[0020] An embodiment of the present invention is characterised in that the guide comprises: a first pulley inside the first side guide near the end thereof opposite the housing; and a second pulley inside the second side guide near the end thereof opposite the housing, wherein the belt is rotated 90° around its longitudinal direction between the first spool and the first pulley and wherein the belt is rotated 90° around its longitudinal direction between the second spool and the second pulley.

[0021] As already addressed in EP 3 048 213 A1 , torsion is a potential disadvantage of using a belt. Torsion of the belt is typically unavoidable in a tensioning system as the tread of the belt from the spools to the screen guide and the tread of the belt through the bottom bar are perpendicular to each other.

[0022] In this embodiment, the necessary torsion is intentionally introduced between the spool adjacent to the screen guide and the pulley near the far end of the side guide. These spools and pulleys are in particular static with respect to each other in the sense that their mutual distance does not vary as a result of the movement of the bottom bar. Furthermore, the distance between these spools and pulleys is maximised as the spool is located at the screen roller and the pulley at the end of the side guide. This means that the torsion occurs over the longest possible section of the belt, thereby significantly limiting the adverse effects.

[0023] An embodiment of the present invention is characterised in that said 90° rotations of the belt cancel each other out as viewed over the entire length of the belt.

[0024] In other words, the two rotations of the belt are in opposite rotational directions with respect to each other. This ensures that the belt winds up on both spools adjacent to the screen guide with its same forward-facing plane.

[0025] An embodiment of the present invention is characterised in that the guide further comprises: a first guide, in particular a static guide, inside the bottom bar near the first end part thereof; and a second guide, in particular a static guide, inside the bottom bar near the second end part thereof, wherein each guide bends the belt at an angle of approximately 90°.

[0026] Such guides allow the belt to be completely concealed from view by running it through the bottom bar. A static guide is also simpler and more robust than a non-static guide (such as a pulley).

[0027] An embodiment of the present invention is characterised in that the portion of the belt between the guides is substantially static.

[0028] This limits potential wear and is therefore desirable.

[0029] An embodiment of the present invention is characterised in that the guide further comprises: a third pulley near the end of the first side guide adjacent to the housing; and a fourth pulley near the end of the second side guide adjacent to the housing, wherein said 90° rotations of the belt are located between the first pulley and the third pulley, and between the second pulley and the fourth pulley. The third and fourth pulleys contribute to the correct alignment of the belt with respect to the spools. The placement of the 90° rotations between the pulleys is still advantageous as their mutual distance is static and relatively large.

[0030] An embodiment of the present invention is characterised in that the first spool and / or the second spool is provided with a clamping buckle for mounting the first end of the belt on the first spool, which clamping buckle is movable between a closed position in which the first end is mounted in a clamped manner on the first spool and an open position.

[0031] A clamping buckle is a simple and reliable way to attach a belt to a spool. The use of adhesives and other binding agents is thus avoided.

[0032] An embodiment of the present invention is characterised in that each clamping buckle is formed by an eccentric tensioning lever.

[0033] This allows an installer to easily secure the belt to the spool, while the eccentricity prevents the tensioning lever from accidentally coming loose by itself.

[0034] An embodiment of the present invention is characterised in that the first spool and / or the second spool is provided with a toothed surface that cooperates with a respective clamping buckle for clamped mounting of a respective one of the first end and the second end on the spool in the closed position of the clamping buckle.

[0035] A toothed surface increases the friction between the spool, belt, and clamping buckle, thereby reducing the risk of the belt unintentionally coming loose.

[0036] An embodiment of the present invention is characterised in that each spool is provided with a tread around which the belt can be wound and unwound, wherein the outer side of the clamping buckle in its closed position forms a part of the tread. Preferably, each tread substantially coincides with a cylindrical sheath.

[0037] The tread for the belt is therefore substantially continuous without interruptions. This avoids accumulations, ridges, etc. on the belt or at least reduces the risk thereof. Such accumulations, ridges, etc. can in particular lead to the belt not unwinding or winding up smoothly. A cylindrical sheath contributes to smooth winding or unwinding at a continuous speed, while, for example, an elliptical tread can cause additional stresses.

[0038] An embodiment of the present invention is characterised in that the tensioning system further comprises at least one spring means arranged between the screen roller and a motor of the screen device for keeping the belt under tension.

[0039] Such a method of keeping the screen under tension is known per se (e.g. the Topfix Max® or Lapure® marketed by Renson). The advantage is that the spring means is completely concealed within the screen roller and is therefore not exposed to atmospheric conditions.

[0040] An embodiment of the present invention is characterised in that the screen device is not vertical.

[0041] The object of the invention is also achieved by a terrace canopy comprising a roof device that comprises the motorised fabric sunshade as described above.

[0042] The object of the invention is also achieved by a method for assembling a belt in a motorised fabric sunshade, the method comprising: mounting the first end of the belt on the first spool or the second end of the belt on the second spool; guiding the belt through the guide; mounting the second end of the belt on the second spool or the first end of the belt on the first spool; and tensioning the belt.

[0043] The method results in a motorised, in particular non-vertical, fabric sunshade provided with the single-belt tensioning system described above and therefore achieves the same advantages.

[0044] Brief description of the drawings

[0045] The invention will hereinafter be explained in further detail on the basis of the following description and the accompanying drawings.

[0046] Figure 1 shows a schematic representation of a motorised fabric sunshade according to the present invention.

[0047] Figure 2 shows a tensioning system used in the motorised fabric sunshade according to the present invention.

[0048] Figures 3A and 3B show details from Figure 2.

[0049] Figures 4A and 4B show the mounting of a belt end on a spool.

[0050] Embodiments of the invention

[0051] The present invention will hereinafter be described with reference to specific embodiments and with reference to certain drawings, but the invention is not limited thereto and is only defined by the claims. The drawings shown here are only schematic representations and are not restrictive. In the drawings, the dimensions of certain parts may be shown enlarged, which means that the parts in question are not shown to scale and this is for illustrative purposes only. The dimensions and relative dimensions do not necessarily correspond to actual practical embodiments of the invention.

[0052] In addition, terms such as “first”, “second”, “third”, and the like are used in the description and in the claims to distinguish between similar elements and not necessarily to indicate a sequential or chronological order. The terms herein are interchangeable in appropriate circumstances, and embodiments of the invention may operate in different sequences than those described or illustrated herein.

[0053] In addition, terms such as "top," "bottom," "above," "below," "left," "right," and the like are used in the description and in the claims for descriptive purposes. The terms so used are interchangeable in appropriate circumstances, and the embodiments of the invention may operate in other orientations than those described or illustrated herein.

[0054] The term “comprising” and derivative terms, as used in the claims, shall not be construed as being limited to the means set forth in each case thereafter; the term does not exclude other elements or steps. The term shall be interpreted as a specification of the stated properties, integers, steps, or components referred to, without excluding the presence or addition of one or more additional properties, integers, steps, or components, or groups thereof. Therefore, the scope of an expression such as "a device comprising the means A and B" is not limited to devices consisting solely of components A and B. On the contrary, what is meant is that, as far as the present invention is concerned, the only relevant components are A and B.

[0055] The term "substantially" comprises variations of + / - 10% or less, preferably + / -5% or less, more preferably + / -1 % or less, and even more preferably + / -0.1 % or less, from the specified condition, in so far as the variations are applicable for operation in the present invention. It should be understood that the term "substantially A" is intended to also comprise "A".

[0056] Figure 1 illustrates a motorised fabric sunshade 10 according to the present invention. The fabric sunshade 10 is typically arranged non- vertically, but can also be used in the conventional vertical application. Non-vertically installed means that the fabric sunshade is in one of the following situations: the fabric sunshade is in a non-vertical plane and moves in that plane; the fabric sunshade is in a vertical plane and moves in a horizontal direction in this plane (e.g. the Slidefix® commercialised by Renson); or the fabric sunshade is in a vertical plane and moves in this plane with the bottom bar on the side of the fabric sunshade facing away from the ground surface.

[0057] The fabric sunshade 10 generally comprises a frame formed by a housing 12, a left side guide 14, and a right side guide 16. The side guides 14, 16 serve, among other things, to guide a bottom bar 18. These elements (i.e. the housing 12, the side guides 14, 16, and the bottom bar 18) are typically made from a rigid material. This can be aluminium, for example. Aluminium has many advantages as a material, as it is simultaneously robust and light, resistant to adverse weather conditions and requires little maintenance. However, other materials are also suitable and their advantages or disadvantages are assumed to be known by the person skilled in the art. These different elements can be produced using different techniques depending on the material, including extrusion, milling, setting, casting, welding and so on. The appropriate production technique is assumed to be known by the person skilled in the art. Preferably, these elements are manufactured by an extrusion process. These elements are typically hollow and thus allow various other components to be placed inside them, concealing them from view. The frame is typically placed on an existing structure, for example on the outside or inside of a window or as a roof infill of a terrace canopy. The various elements of the frame can comprise multiple components and do not need to be manufactured as an integral whole. Therefore, although Figure 1 shows that the housing extends above the side guides, it is also possible for the side guides to extend to the top of the frame with the housing in between, wherein the spools 26a, 28a are then located in the housing, which is conceptually formed as comprising the upper parts of each side guide.

[0058] The motorised fabric sunshade 10 further comprises a screen or fabric 20 that extends between the side guides 14, 16. The left and right sides of the screen 20 are preferably also guided in a corresponding side guide 14, 16 and tensioned therebetween, for example by a zip system. The screen 20 is mounted in a windable and unwindable manner on a screen roller 40 (shown in Figure 2) located inside the housing 12. At the end of the screen 20 opposite the screen roller, the bottom bar 18 is mounted. A motor (not shown) is also provided for driving the screen roller. This motor is typically built into the screen roller 40. In the wound-up state of the screen 20, it is located almost entirely in the housing. Figure 1 illustrates the (partially) unwound state of the screen 20. The screen 20 primarily serves as a sunshade. The screen 20 can be made from various materials, such as plastic-based, for example polyester or polymethyl methacrylate (PMMA) or fibreglass, and can be manufactured using various techniques. The person skilled in the art is assumed to be familiar with the possible materials and manufacturing methods of screens. A tensioning system is provided for keeping the screen 20 under tension. This tensioning system is better shown in Figure 2. According to the present invention, the tensioning system comprises one belt 26 extending between a first end 26a and a second end 26b. The belt 26 is a mainly flat narrow band and can be made from various materials. It is crucial that the belt is different from a cord, rope, or the like, which are not mainly flat but rather cylindrical in nature.

[0059] Various elements are provided for guiding the belt 26. Specifically, a wheel (or spool) 22, 24 is provided at opposite ends of the housing 12 on which the ends 26a, 26b are wound. Typically, these wheels 22, 24 are fixedly mounted on the motor shaft (not shown) and thus also driven by the motor. In each screen guide 14, 16, a first pulley 30, 32 is provided, in particular near the end of the screen guides 14, 16 opposite the housing 12.

[0060] Furthermore, two guides 34, 36 are provided at opposite ends of the bottom bar 18, and guide the belt 26 from the screen guide 14, 16 to the bottom bar 18. Note that the bottom bar 18 is only partially shown in Figure 2 and that it normally extends across the entire width between the guides 34, 36. The belt 26 extends through the bottom bar 18. In Figure 1 , these guides 34, 36 are formed by pulleys, but they can also be static guides as shown in Figure 2. This is possible and advantageous since the portion of the belt 26 inside the bottom bar 18 does not shift relative to the bottom bar 18.

[0061] Furthermore, two pulleys 42, 44 are provided at the top of each screen guide 14, 16 for guiding the belt 26 from the spool 22, 24 to the screen guide 14, 16. These pulleys 42, 44 can be omitted in other embodiments.

[0062] As shown in Figure 2, the axis of rotation of the spools 22, 24 is perpendicular to that of the pulleys 30, 32, so the belt 26 must undergo a 90° rotation. In the shown embodiment, this rotation is deliberately placed between pulleys 30, 42 and 32, 44, thus inside the side guides 14, 16. In this way, as described above, the distance over which the belt 26 undergoes this rotation is maximised and unchangeable.

[0063] Figure 3A shows the bottom bar 18 in more detail and illustrates that this bottom bar 18 is constructed from different profiles. Namely, a base profile 18a in which a recess is provided for accommodating the belt 26. A seal 18b is then applied in order to seal the recess in which the belt 26 is located and thereby secure the belt 26.

[0064] Figure 3B shows a detail of the guide 36 at the end of the bottom bar 18. This is a static guide 36 in which a recess is arranged for placing the belt 26 therein. In this way, the belt 26 is bent at an angle of about 90°. The guides 34, 36 are arranged at the ends of the bottom bar 18.

[0065] The tensioning system further comprises a spring means (not shown) for keeping the belt 26 under tension. In the shown embodiment, this spring means is arranged between the motor (not shown) and the screen roller 40. The motor is therefore a tubular motor in this embodiment. Such a spring means is known per se and is therefore not further described.

[0066] Figures 4A and 4B show the mounting of a belt end 26 on a spool 24. The spool 24 is provided for this purpose with a tensioning lever 50, in particular an eccentric tensioning lever. In the open position of the tensioning lever 50 (see Figure 4A), the belt end is placed between the tensioning lever 50 and the spool 24. The belt 26 can be pulled through until there is no more play through the side guides 14, 16 and bottom bar 18. The excess end can then be cut off. By closing the tensioning lever 50 (see Figure 4B), the belt end is secured on the spool 24. The tensioning lever 50 and spool 24 thus form a clamping buckle. Figure 4A further illustrates the presence of a toothed part 52 for increasing the clamping on the belt end. In the closed position, the tensioning lever 50 together with the spool 24 forms a substantially cylindrical tread 54, the advantages of which have already been described above. Although certain aspects of the present invention have been described with respect to specific embodiments, it is apparent that these aspects may be implemented in other forms within the scope of the claims.

Claims

CLAIMS1 . A motorised fabric sunshade (10) comprising:- a frame provided with a housing (12), a first side guide (14), and a second side guide (16);- a screen roller (40) rotatably mounted in the housing and extending between a first end and a second end;- a screen (20) fixedly mounted at a first edge on the screen roller, wherein the screen can be wound on and unwound from the screen roller;- a bottom bar (18) fixedly mounted on a second edge of the screen, which second edge is opposite said first edge; and- a tensioning system for keeping the screen under tension, characterised in that the tensioning system comprises:- one belt (26) extending between a first end (26a) and a second end (26b);- a first spool (22) which is positioned in line with the screen roller near the first end thereof and on which the first end of the belt is mounted, wherein the belt can be wound on and unwound from the first spool;- a second spool (24) which is positioned in line with the screen roller near the second end thereof and on which the second end of the belt is mounted, wherein the belt can be wound on and unwound from the second spool; and- a guide for guiding the belt between its first end and its second end through the side guides and the bottom bar.

2. The motorised screen device according to claim 1 , characterised in that the guide comprises:- a first pulley (30) inside the first side guide near the end thereof opposite the housing; and- a second pulley (32) inside the second side guide near the end thereof opposite the housing, wherein the belt is rotated 90° around its longitudinal direction between the first spool and the first pulley and wherein the belt is rotated 90° around itslongitudinal direction between the second spool and the second pulley.

3. The motorised screen device according to claim 2, characterised in that said 90° rotations of the belt cancel each other out as viewed over the entire length of the belt.

4. The motorised screen device according to claim 2 or 3, characterised in that the guide further comprises:- a first guide (34), in particular a static guide, inside the bottom bar near the first end part thereof; and- a second guide (36), in particular a static guide, inside the bottom bar near the second end part thereof, wherein each guide bends the belt at an angle of approximately 90°.

5. The motorised screen device according to claim 4, characterised in that the portion of the belt between the guides is substantially static.

6. The motorised screen device according to any one of claims 2 to 5, characterised in that the guide further comprises:- a third pulley (42) near the end of the first side guide adjacent to the housing; and- a fourth pulley (44) near the end of the second side guide adjacent to the housing, wherein said 90° rotations of the belt are located between the first pulley (30) and the third pulley (42), and between the second pulley (32) and the fourth pulley (44).

7. The motorised screen device according to any one of the preceding claims, characterised in that the first spool is provided with a clamping buckle for mounting the first end of the belt on the first spool, which clamping buckle is movable between a closed position in which the firstend is mounted in a clamped manner on the first spool and an open position.

8. The motorised screen device according to any one of the preceding claims, characterised in that the second spool is provided with a clamping buckle for mounting the second end of the belt on the second spool, which clamping buckle is movable between a closed position in which the second end is mounted in a clamped manner on the second spool and an open position.

9. The motorised screen device according to claim 7 or 8, characterised in that each clamping buckle is formed by an eccentric tensioning lever (50).

10. The motorised screen device according to any one of claims 7 to 9, characterised in that the first spool and / or the second spool is provided with a toothed surface (52) that cooperates with a respective clamping buckle for clamped mounting of a respective one of the first end and the second end on the spool in the closed position of the clamping buckle.1 1 . The motorised screen device according to any one of claims 7 to 10, characterised in that each spool is provided with a tread (54) around which the belt can be wound and unwound, wherein the outer side of the clamping buckle in its closed position forms a part of the tread.

12. The motorised screen device according to claim 11 , characterised in that each tread substantially coincides with a cylindrical sheath.

13. The motorised screen device according to any one of the preceding claims, characterised in that the tensioning system further comprises at least one spring means arranged between the screen roller and a motor ofthe screen device for keeping the belt under tension.

14. A terrace canopy comprising a roof device, characterised in that the roof device comprises the motorised fabric sunshade (10) according to any one of the preceding claims.

15. A method for assembling the belt (26) in the motorised screen device (10) according to any one of claims 1 to 13, wherein the method comprises: - mounting the first end (26a) of the belt on the first spool (22) or the second end (26b) of the belt on the second spool (24);- guiding the belt through the guide;- mounting the second end of the belt on the second spool or the first end of the belt on the first spool; and - tensioning the belt.

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