A motorized covering system

Abstract

The present invention discloses a motorized covering system for covering a structural opening comprising a covering material, a motor drive assembly operatively connected to a roller tube attached to raise and lower the covering material to uncover and cover the structural opening, a housing adapted to conceal the motor drive assembly including an opening, an elongate bottom bar coupled to the covering material at a bottom end, the elongate bottom bar including at least one magnetic member, and a catch assembly disposed at each lower end of the structural opening corresponding to the at least one magnetic member so that it magnetically retains the bottom bar when the covering material is fully extended. The system also includes a counterforce mechanism operatively connected to the roller tube, the counterforce mechanism including a block rotatably connected to each end of the roller tube through an opening on the block, wherein the block is slidably movable between a lower end of a first support and a second support and an upper end of the first support and the second support by at least one biasing member.

Description

A MOTORIZED COVERING SYSTEMTechnical Field

[0001] The present disclosure generally relates to covering systems More particularly, it relates to a motorized covering system for covering a structural opening.Background|0002| The following discussion of the background to the invention is intended to facilitate an understanding of the present invention. However, it should be appreciated that the discussion is not an acknowledgment or admission that any of the material referred to was published, known or part of the common general knowledge in any jurisdiction as at the priority date of the application

[0003] Prior art solutions in automated covering systems have addressed various aspects, such as motorized operation, energy efficiency, and compatibility with different types of coverings. However, they fall short when it comes to addressing creasing on fully extended coverings. The issue is not only an aesthetic concern but also impacts the overall performance and longevity of these systems. The aesthetic concern is not only an issue for smaller coverings but also poses a challenge for larger ones due to their length or weight.

[0004] The existing motorized covering systems employ a head rail, bottom rail, and covering material that extends between them. For instance, in horizontal blinds or shades applications, the system enables vertical movement to cover structural openings effectively. However, despite their functional benefits, these prior art designs fail to address creasing on fully extended coverings. The unsightly creases negatively impact the overall appearance of these systems.

[0005] The unyielding presence of creases along the sides of fully extended covering material can significantly impact the overall appearance and appeal of a room's interior design. This issue arises due to the prolonged contact between the covering material and the head rail or the uneven deformation that occurs over time, leading to permanent crease lines on the side edges.

[0006] The primary objective of the present invention is to address the aforesaid problems.Summary of the Invention

[0007] One aspect of the present invention includes a motorized covering system for covering a structural opening comprising a covering material having a top end and a bottom end, a motor drive assembly operatively connected to a roller tube attached to the top end of the covering material to raise and lower the covering material between an upper limit and a lower limit to uncover and cover the structural opening, a housing adapted to conceal the motor drive assembly including a side wall on each longitudinal end of the housing and an opening from which the covering material exits the housing, an elongate bottom bar coupled to the covering material at the bottom end, the elongate bottom bar including at least one magnetic member disposed at each proximate end of the elongate bottom bar, a catch assembly disposed at each lower end of the structural opening corresponding to the at least one magnetic member so that it magnetically retains the bottom bar when the covering material is fully extended and a counterforce mechanism operatively connected to the roller tube, the counterforce mechanism including a block rotatably connected to each end of the roller tube through an opening on the block, wherein the block is slidably movable between a lower end of a first support and a second support and an upper end of the first support and the second support by at least one biasing member.

[0008] According to various embodiments, the biasing member is configured to be in a compressed state when the covering material is fully retracted on the roller tube, and is configured to be in an extended state when the covering material is fully extended from the roller tube, causing the block to slidably move from the lower end of the first and second support to the upper end to the upper end of the first and second support as the biasing member is released from its compressed state to the extended state.

[0009] According to various embodiments, the first support and the second support each includes a longitudinal pocket configured to allow the block to slidably move from the lower end of the first and second support to the upper end of the first and second support to cause the covering material tobe pulled upwards while the at least one magnetic member remains in the magnetically retained position by the catch assembly.

[0010] According to various embodiments, the biasing member is a resilient member that exerts a reactionary push force when the block is imparting a load on it.

[0011] According to various embodiments, the system further comprises a base support for mounting the at least one biasing member, the first support and the second support.100121 According to various embodiments, the counterforce mechanism is attached to a side wall configured for enclosing the housing at each end of the housing.

[0013] Another aspect of the present invention relates to a motorized covering system for covering a structural opening. A "motorized covering system" refers to a mechanism comprising a moving component, which is the covering material itself, and a driving force responsible for its motion - the motor drive assembly. The covering material has distinct top and bottom ends, while the motor drive assembly is operatively connected to a roller tube attached to the top end of the covering material. The "housing" in this context can be defined as an enclosure designed to conceal the intricacies of the motor drive assembly. Tt features an opening through which the covering material exits the housing when it is being raised or lowered. Another essential component of this arrangement includes an elongate bottom bar, which is coupled to the bottom end of the covering material. This elongate bottom bar incorporates at least one magnetic member located near each end. The structural opening has a catch assembly disposed at its lower ends that correspond to the magnetic members on the elongate bottom bar. These assemblies are designed to magnetically retain the bottom bar when the covering material is fully extended, ensuring proper positioning and alignment of both components.

[0014] It may be provided that a rotational movement of the motor drive assembly is configured to reverse the direction of the roller tube when the covering material is fully extended such that an upward pull force is generated on the covering material to cause the covering material to be pulled upwards while the at least one magnetic member remains in the magnetically retained position by the catch assembly.

[0015] The unique feature that sets this arrangement apart is the reversal of the motor drive assembly's rotational movement when the covering material is fully extended. This change in direction generates an upward pull force on the covering material, which causes it to be pulled upwards while remaining magnetically secured by the catch assemblies.

[0016] According to various embodiments, the rotational movement of the motor drive assembly is configured to cause the roller tube to rotate by approximately 5 to 10 degrees from its fully extended position.

[0017] According to various embodiments, the determination of rotational movement of the motor drive assembly is associated with one or more of the following parameters: diameter of the roller tube, weight of the covering material and the upward pull force generated by the covering material.

[0018] According to various embodiments, the upward pull force generated on the covering material does not overcome magnetic forces between the at least one magnetic member and the catch assembly.

[0019] According to various embodiments, the at least one magnetic member is attached to a lower end of the bottom bar.

[0020] According to various embodiments, the at least one magnetic member is embedded into a lower end of the bottom bar.

[0021] According to various embodiments, the corresponding metal elements include a bracket assembly fixed to a lower end of the structural opening for receiving the bottom bar.

[0022] According to various embodiments, the at least one magnetic member comprises neodynium.

[0023] According to various embodiments, the catch assembly includes a catch bracket installed in a position adjacent to the structural opening.

[0024] In a third aspect of the present invention, there is provided a method for controlling a motorized covering system adapted to cover a structural opening, wherein the motorized covering system includes a covering material having a top end and a bottom end, a motor drive assembly operatively connected to a roller tube attached to the top end of the covering material to raise and lower the covering material between an upper limit and a lower limit to cover and uncover the structural opening, a housing adapted to conceal the motor drive assembly including an opening from which the covering material exits the housing, an elongate bottom bar coupled to the covering material at the bottom end, the elongate bottom bar including at least one magnetic member disposed at each proximate end of the elongate bottom bar, a catch assembly disposed adjacent to the structural opening corresponding to the at least one magnetic member so that it magnetically retains the bottom bar when the covering material is fully extended. It may be provided that the method comprises the steps of configuring the lower limit for the bottom bar based on a position of the catch assembly such that a pull down force is generated to straighten the covering material when the at least one magnetic member is magnetically retained by the catch assembly at the lower limit; and configuring a rotational movement of the motor drive assembly in a reverse direction to cause the roller tube to reverse its direction resulting in an upward pull force applied to the covering material and maintaining the at least one magnetic member in the magnetically retained position.

[0025] According to various embodiments, the rotational movement comprises an amount of degree of rotation of the roller tube from its position at the lower limit.

[0026] According to various embodiments, the rotational movement of the motor drive assembly is configured to cause the roller tube to rotate by approximately 5 to 10 degrees from its fully extended position.

[0027] According to various embodiments, a determination of rotational movement of the motor drive assembly is associated with one or more of the following parameters: diameter of the roller tube, weight of the covering material and the upward pull force generated by the covering material.

[0028] According to various embodiments, the upward pull force generated on the covering material does not overcome the magnetic forces between the at least one magnetic member and the catch assembly.

[0029] According to various embodiments, the motor drive assembly includes a motor and a motor control module communicatively coupled to the motor drive assemblyBrief Description of the Drawings10030| In the drawings, like reference characters generally refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead generally being placed upon illustrating the principles of the invention. The dimensions of the various features or elements may be arbitrarily expanded or reduced for clarity. In the following description, various embodiments of the invention will be better understood with reference to the detailed description when considered in conjunction with the non-limiting examples and the accompany drawings, in which:[ 00311 Figure 1 illustrates a side view of a covering system according to various embodiments;

[0032] Figure 2a illustrates a perspective view of a covering system according to various embodiments;

[0033] Figure 2b illustrates a partial perspective view of a bottom bar on a bottom end of a covering material according to various embodiments,

[0034] Figure 2c illustrates a side view of example bottom bars on the bottom end of the covering material according to various embodiments;10035| Figure 3 illustrates a side view of a motor drive assembly within a shade housing according to various embodiments;

[0036] Figure 4 shows a front view of a counterforce mechanism and its components according to various embodiments;

[0037] Figure 5 shows a perspective view of the counterforce mechanism operatively connected to the roller tube according to various embodiments;

[0038] Figure 6 shows another perspective view of the counterforce mechanism operatively connected to the roller tube according to various embodiments;

[0039] Figure 7 shows an overview of a motor drive assembly and its components according to various embodiments; and[ 00401 Figure 8 illustrates a flow diagram of a method for controlling a motorized covering system according to various embodiments.Detailed Description

[0041] Reference will now be made in detail to an exemplary embodiment of the present invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the embodiment, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications, and equivalents, which may be included within the spirit and scope of the invention as defined by the appended description Furthermore, in the following detailed description of embodiments of the present invention, numerous specific details are set forth in order to provide a thorough understanding of the present invention. However, it will be recognized by one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail as not to unnecessarily obscure aspects of the embodiments of the present invention.

[0042] In the specification the term “comprising” shall be understood to have a broad meaning similar to the term “including” and will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. This definition also applies to variations on the term “comprising” such as “comprise” and “comprises”.

[0043] In the specification, the term “engage” and its variants including “engagement”, “engages”, “engaging” and “engaged” as used herein are to be interpreted to include engagement by touching, rubbing or abutting including engagement in one or more of an axial, radial, tangential and circumferential direction, and includes engagement through an intermediary such as a component positioned or sandwiched between the e.g. counter face and head of the blind-sided fastener.

[0044] Reference throughout this specification to “one embodiment,” “an embodiment,” “one example,” or “an example” means that a particular feature, structure, or characteristic described in connection with the embodiment or example is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” “one example,” or “an example” in various places throughout this specification are not necessarily all referring to the same embodiment or example Furthermore, the particular features, structures, databases, or characteristics may be combined in any suitable combinations and / or sub-combinations in one or more embodiments or examples. In addition, it should be appreciated that the figures provided herewith are for explanation purposes to persons ordinarily skilled in the art and that the drawings are not necessarily drawn to scale.

[0045] Accordingly, in one or more example embodiments, the functions described may be implemented in hardware, software, or any combination thereof. If implemented in software, the functions may be stored on or encoded as one or more instructions or code on a computer-readable medium.

[0046] Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrase “in one embodiment” as used herein does not necessarily refer to the same embodiment, though it may. Furthermore, the phrase “in another embodiment” as used herein does not necessarily refer to a different embodiment, although it may. Thus, as described below, various embodiments of the invention may be readily combined, without departing from the scope or spirit of the invention.

[0047] Certain terminology used in the description is for convenience in reference only and shall not be limiting. For example, up, down, front, back, right, and left refer to the disclosed subject matter as orientated in the view being referred to. The words, “inwardly”, “inner”, “outwardly” and “outer” refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. The terminology will include the words specifically mentioned, derivatives thereof, and words of similar meaning. Like references numbers denote like features, components, or elements throughout the various embodiments.

[0048] In addition, as used herein, the term “or” is an inclusive “or” operator, and is equivalent to the term “and / or,” unless the context clearly dictates otherwise. The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a, ’’an,” and “the” include plural references The meaning of “in” includes “in” and “on.”

[0049] Features that are described in the context of an embodiment may correspondingly be applicable to the same or similar features in the other embodiments. Features that are described in the context of an embodiment may correspondingly be applicable to the other embodiments, even if not explicitly described in these other embodiments. Furthermore, additions and / or combinations and / or alternatives as described for a feature in the context of an embodiment may correspondingly be applicable to the same or similar feature in the other embodiments.

[0050] To achieve the stated features, advantages and objects, the present invention is directed to a motorized covering system for covering a structural opening.100511 As will be understood in the below discussion, the present invention aims to overcoming the shortcomings and limitations of existing motorized covering systems by providing a novel solution to address the problem of creasing or fabric bagging when a covering material is extended.

[0052] These technical advantages not only improve the functionality and aesthetics of motorized covering systems but also contribute to their durability by mitigating creasing.

[0053] Figure 1 illustrates a side view of a covering system according to various embodiments. Figures 2a, 2b and 2c illustrate a perspective view of a motorized covering system, a perspective view and a side perspective view of a bottom bar according to various embodiments. Referring to the aforesaid figures, the motorized covering system 100 comprises a motor drive assembly 120, shade housing 110 for housing the motor drive assembly 120, a covering material 140 having a top end and a bottom end, and a bottom bar 150 coupled to the bottom end. The covering material 140 is connected at its top end to a roller tube 130 where the covering material 140 is wrapped or unwrapped around the roller tube 130. Shade housing 110 includes an opening for allowing the covering material to exit or enter the shade housing 110. The motor drive assembly 120 is configured to raise or lower the shadematerial to adjustably cover or uncover a structural opening between an upper and a lower limit, such as a window, a door, a wall opening, or the like. The upper limit is the maximum limit that the covering material can be retracted to the shade housing, and the lower limit is the maximum limit that the covering material can be extended from the shade housing. In various embodiments, the covering material 140 comprises fabric, vinyl, or other materials known to those skilled in the art. The shade housing 110 can be made of various materials including but not limited to, plastics or metals, such as, aluminium.

[0054] In various embodiments, the motorized covering system 100 is installed together with a frame surrounding the structural opening, for example, a window. The frame includes vertical slats 145 surrounding each side of the structural opening, and the shade housing 110 is mounted on the frame. The vertical slats 145 are aligned with the covering material such that when the covering material is extended, the vertical slats 145 are adjacent the sides of the covering material 140. In some embodiments, horizontal slats can be used with the vertical slats to border the frame. Conventional mounting brackets can be used to mount the shade housing 110 to secure the shade housing above the structural opening.

[0055] In various embodiments, the bottom bar 150 coupled to the bottom end of the covering material 140 extends laterally across the width of the covering material and the structural opening. Referring to figures 2b and 2c, the bottom bar 150 has an opening for receiving the covering material 140 and a catch so as to attach the covering material 140 to an interior of the bottom bar 150. At each end of the bottom bar 150 (location A in the aforesaid figures), a magnetic member 160 is disposed at each proximate end of the bottom bar 150. In some embodiments, the magnetic member 160 can be disposed at any location of the bottom bar. The magnetic members 160 can be located partially within the bottom bar, embedded within the bottom bar or at the lowest end of the bottom bar Once the magnetic members 160 are inserted into the bottom bar 1 0, an end cap is provided to close the side of the bottom bar so as to conceal the magnetic members and internal components of the bottom bar.

[0056] Referring to figure 1, the location of the magnetic members 160 is positioned so as to be able to attract and to releasably retain a corresponding catch assembly 200 located at or close to the lower limit when the covering material 140 is fully extended. When the covering material is fully extended,the magnetic members 160 housed within the bottom bar 150 are located adjacent to the corresponding catch assembly 200. The magnetic forces pulling in opposite directions on the ends of the bottom bar ensures that the bottom bar remains in a centered position in the structural opening. The catch assembly 200 includes a forward portion comprising a main elongate body of a generally flat profile for receiving the a portion of the bottom bar 150 and / or the magnetic member 160. The catch assembly 200 includes a rear portion perpendicular to the forward portion. The rear portion includes mounting holes for installing the catch assembly adjacent to the lower end of the structural opening. The catch assembly 200 can also be installed on a lower horizontal slat that defines a frame for the covering material to entirely cover the structural opening.

[0057] The magnetic members 160 used in the present invention can be of various types. For example, the magnets could be of a neodymium-based alloy, magnetic metal alloys, iron, cobalt or steel and could be mounted in both the bottom bar 150 and the corresponding catch assembly 200 such that opposite poles of the magnets are positioned adjacent to each other for the desired attraction. The magnetic members 160 can be installed within the bottom bar 150. The magnets can also be installed in the catch assembly with metallic objects installed in the bottom bar. The catch assembly includes a catch bracket that can be located at different locations on the frame to releasably secure the bottom bar at a different position than a fully extended position. The catch assembly is made of metal that is capable of attracting the magnetic members 160. Further, additional magnetic members could be installed in the bottom bar to cooperate with corresponding additional catch brackets.

[0058] The motor drive assembly 120 includes a motor that drives a drive wheel which in turn engages and rotates the roller tube. In various embodiments, the motor drives a gear mechanism that includes various gears that can be configured to provide speed reduction and torque increase to achieve efficient operation of the motor. A motor control module (not shown) is communicatively coupled to the motor drive assembly 120 and is configured to control and direct the motor, including its direction, speed and position. Details of the aforesaid components will be explained in more detail hereinafter.

[0059] A power source (not shown) is provided for supplying electrical power to operate the motor drive assembly. A person skilled in the art will readily understand that the power source can be an alternating current source, such as the electrical system of the building in which the covering systemis installed. In other embodiments, a solar powered system can be incorporated into the motorized covering system for continuously recharging rechargeable batteries, and photovoltaic pads for the solar powered system can be provided on surfaces of the covering material, surfaces of the shade housing, or bottom bar. Alternatively, photovoltaic cells can be provided in other locations and electrically connected to rechargeable batteries in the power source.

[0060] The roller tube 130 is generally cylindrical in shape and longitudinally extends from a first end to a second end. In various embodiments, the roller tube comprises aluminium, stainless steel, plastic, fiberglass, or other materials known to those skilled in the art. As mentioned previously, the roller tube 130 is coupled to the motor drive assembly 120 so that any rotational movement of the motor within the motor drive assembly causes a corresponding rotational movement of the roller tube in either direction. For example, depending on the configuration of the motorized covering system, a rotational movement in an anti-clockwise direction of the drive wheel will cause the roller tube to move correspondingly by the same rotational movement of the drive wheel.

[0061] When the covering material is fully extended, the magnetic members 160 are attracted to the corresponding catch assemblies such that the covering material exerts a downward pull-down force to straighten any potential creases at the sides of the covering material. In this fully extended position, the bottom bar 150 is releasably secured in position by the catch assembly 200 by the magnetic forces created between the magnetic components within the bottom bar and the catch assembly 200. When the covering material is in the fully extended position, the motor drive assembly 120 is configured to rotationally move in a reverse direction (from that of extending the covering material) such that the motor rotates in an opposite direction to retract the covering material into the shade housing. The motor drive assembly 120 is configured so that the motor rotates in an opposite direction by approximately 5 to 10 degrees to generate an upward pull force on the covering material so that both sides of the covering material become tighter and straighten out the creases as much as possible. The amount of rotational movement of the motor drive assembly 120 in a reverse direction is determined by the diameter of the roller tube size, weight of the covering material, and / or the upward pull force generated by the covering material such that it does not overcome the magnetic forces between the magnetic member 160 and the catch assembly 200. In other words, the maximum amount of rotational movement (i.e. the maximum number of degrees of rotation of the motor driveassembly) of the motor drive assembly should not generate an upward pull force that will overcome the magnetic forces between the magnetic member and the catch assembly.

[0062] The present invention thus combines the use of magnetic members at each end of the bottom bar with corresponding catch assemblies to releasably secure the covering material at the lower limit and a motorized drive assembly programmed to reverse its direction to generate an upward pull force to be applied to the covering material while maintaining the magnetic members and the corresponding catch assemblies in the releasably retained position. This design addresses the shortcoming of creasing on extended coverings by providing an effective solution that naturally tightens and extends the sides, enhancing both functionality and aesthetics.

[0063] The present invention therefore provides technical advantages for motorized covering systems. Firstly, it addresses the issue of creasing on extended covering material by incorporating magnets at each end of the window covering and corresponding catch assemblies on both ends of the bottom bar. This design allows the sides of the window covering to extend and tighten when fully deployed, thereby eliminating unsightly creases. Secondly, and especially for larger window coverings that may require additional support due to their extensive lengths or significant heights, a motor drive assembly can be programmed to rotate in a reverse direction when the covering material reaches its lower limit or is fully extended while maintaining the bottom bar in the releasably retained position. By reversing the direction of rotation under these conditions, it effectively pulls the window covering upwards towards the shade housing while tightening it, further enhancing the overall performance and longevity of the covering system.

[0064] By reversing the direction of rotation of the motor drive assembly under these conditions, it will effectively generate an upward pull force on the covering material towards the shade housing while tightening it and at the same time ensuring that the upward pull force does not overcome the magnetic forces between the magnetic member and the catch assembly. This counter-rotation mechanism complements the magnetic members on the bottom bar to naturally and uniformly tighten the covering material in both directions.

[0065] Figure 3 illustrates a side view of a motor drive assembly within a shade housing according to various embodiments. The motor drive assembly 120 is concealed within the shade housing 110. The roller tube 130 is coupled to the motor drive assembly 120 which in turn is attached to the covering material so that any rotational movement of the motor drive assembly 120 in either a clockwise direction or an anti -clockwise direction will cause a corresponding rotational movement of the roller tube in the same direction. Referring to Figure 3, the shade housing includes an opening 111 from which the covering material (not shown) exits the shade housing for retractably covering the structural opening. When the rotational movement of the motor drive assembly 120 in a clockwise direction causes the covering material to exit the shade housing, the covering material is fully extended to the lower limit such that the magnetic members 160 are attracted and releasably retained by the corresponding catch assemblies and the covering material exerts a downward pull-down force to straighten any potential creases at the sides of the covering material. At this point, or where the line Y-Y is indicative of when the lower limit is reached, the motor drive assembly is programmed to rotationally move in a reverse direction, i.e. anti-clockwise direction, such that the motor drive assembly rotates in an opposite direction to cause the covering material to retract into the shade housing. The motor drive assembly 120 is configured to rotationally move in a reverse direction (from that of extending the covering material) such that the motor rotates in the anti-clockwise direction to retract the covering material into the shade housing. In some embodiments, the motor drive assembly 120 is configured so that the motor rotates in an opposite direction by approximately 5 to 10 degrees to generate an upward pull force on the covering material so that both sides of the covering material become tighter and straighten out the creases as much as possible. The amount of rotational movement of the motor drive assembly 120 in a reverse direction is determined by the diameter of the roller tube size, weight of the covering material, and / or the upward pull force generated by the covering material such that it does not overcome the magnetic forces between the magnetic member 160 and the catch assembly 200. In other words, the maximum amount of rotational movement (i.e. the maximum number of degrees of rotation of the motor drive assembly) of the motor drive assembly should not generate an upward pull force that will overcome the magnetic forces between the magnetic member and the catch assembly.

[0066] Figure 4 shows a front view of a counterforce mechanism 300 and its components according to various embodiments. Figures 5 and 6 show perspective views of the counterforce mechanism 300operatively connected to a roller tube according to various embodiments. Referring to the aforesaid figures, the aforesaid figures show an embodiment of a counterforce mechanism 300 that generates an upward push force generated by a biasing member and causes the roller tube 130 to move linearly upwards when the covering material 140 has reached the lower limit or the bottom bar in in the releasably retained position The roller tube 130 is slidably movable upwards from the upward push force and this tightens the top end of the covering material it and at the same time ensuring that the upward push force does not overcome the magnetic forces between the magnetic member and the catch assembly. This counterforce mechanism complements the magnetic members on the bottom bar to naturally and uniformly tighten the covering material in both directions. It provides the advantage of effectively pulling the covering material upwards while tightening it, further enhancing the overall performance and longevity of the covering system.

[0067] In various embodiments, the counterforce mechanism 300 is attached to each side wall 112 configured for enclosing the shade housing 110 at each end of the shade housing 110. The counterforce mechanism 300 includes a first support 310 and a second support 350 that is supported on a base support 330. Each of the first support 310 and the second support 350 includes a longitudinal pocket configured to accommodate a block 320 between the first support and the second support that is slidably movable within the longitudinal pockets of the first support 310 and the second support 350. The block 320 includes an opening 325 configured for fitting one end of the roller tube so that it is rotatably movable within the opening 325 of the block 320. In other words, each end of the roller tube 130 is rotatably movable within the openings 325 of the blocks 320 at each end of the shade housing. The roller tube 130 is coupled to the motor drive assembly 120 which in turn is attached to the covering material so that any rotational movement of the motor drive assembly 120 in either a clockwise direction or an anti-clockwise direction will cause a corresponding rotational movement of the roller tube in the same direction within the opening 325 of the block 320. In various embodiments, the block 320 is attached to at least one biasing member 340 Each biasing member 340 is attached to the block 320 at one end and mounted on the base support 330 at the other end The biasing member 340 is capable of generating an upward push force or a counterforce when a load is imparted on the biasing member 340 from the block 320. As will be described in more detail below, the biasing member 340 engages with the base support 330 of the counterforce mechanism and transfers a biasing force or upward push force when a load is applied to the biasing member and is urged upwards to cause theblock 320 to slidably move upwards. The block 320 may be made of a metal, wood or plastic or any suitable material that is capable of withstanding the forces exerted by the roller tube on the block.

[0068] As used herein, the term “biasing member” refers to a resilient member or assembly that may be elastically deformed when placed under load (e g., compression, tension, deflection, torsion, etc ), and that exerts a reactionary force to resist such deformation. The term biasing member includes springs (e.g., coiled spring, leaf springs, torsion springs, etc.).

[0069] The counterforce mechanism 300 will now be discussed in further detail with reference to Figure 5 and 6. Figure 5 shows a perspective view of the counterforce mechanism 300 in operation as the covering material is extended downwards according to various embodiments. Referring to Figure 5, the shade housing (not shown) includes an opening (also not shown) from which the covering material exits the opening of the shade housing for retractably covering the structural opening. When the rotational movement of the motor drive assembly 120 in a clockwise direction (when seen from the right side) causes the covering material to exit the shade housing, the covering material is fully extended to the lower limit such that the magnetic members 160 are attracted and releasably retained by the corresponding catch assemblies and the covering material exerts a downward pull-down force to straighten any potential creases at the sides of the covering material. During this time, when the covering material is extended downwards to the lower limit, the block 320 is slidably movable downwards along the longitudinal pockets of the first support 310 and the second support 350. In other words, the block is imparting a load on the biasing member 340 by the weight of the covering material on the roller tube causing it to deform or compress. The biasing member 340 is in a state of compression when the covering material is fully retracted. This is due to the weight of the covering material on the roller tube 130 which is at its greatest when fully retracted. The weight of the covering material on the roller tube 130 decreases as the covering material is fully extended.

[0070] Figure 6 shows a perspective view of the counterforce mechanism 300 in operation when the covering material is fully extended according to various embodiments. At this point, the covering material is fully extended to the lower limit such that the magnetic members 160 are attracted and releasably retained by the corresponding catch assemblies and the covering material exerts a downward pull-down force to straighten any potential creases at the sides of the covering material. Atthe same time, as the weight of the covering material 140 on the roller tube 130 is at its lowest, the biasing member 340 is slowly released from its compressed state to an extended state where the block 320 is slidably movable upwards in a linear direction along the longitudinal pockets of the first support and the second support. In other words, the block 320 is slidably movable between a lower end of the first support and the second support to the upper end of the first and second support as the biasing member 340 is released from its compressed state to its extended state. Each of the first support 310 and the second support 350 includes a stopper (not shown) at the top end of the first support and second support to prevent the block 320 from leaving the longitudinal pockets. The biasing member 340 therefore provides an upward push force on the block 320 when it is being released from its compressed state to the extended state.

[0071] In various embodiments, the counterforce mechanism is a separate embodiment from the motorized drive assembly programmed to reverse its direction to generate an upward pull force applied to the covering material while maintaining the magnetic members and the corresponding catch assemblies in the releasably retained position. In other words, the counterforce mechanism complements the magnetic members on the bottom bar to naturally and uniformly tighten the covering material in both directions. The counterforce mechanism therefore provides some technical advantages for motorized covering systems. Firstly, it addresses the issue of creasing on extended covering material by incorporating magnets at each end of the window covering and corresponding catch assemblies on both ends of the bottom bar. This design allows the sides of the window covering to extend and tighten when fully deployed, thereby eliminating unsightly creases. Secondly, the counterforce mechanism provides a reactionary push force upwards that causes the roller tube to move upwards in a linear direction when the covering material reaches its lower limit or is fully extended while maintaining the bottom bar in the releasably retained position. When the roller tube moves upwards due to the upward push force, it effectively pulls the covering material upwards towards the shade housing while tightening it, further enhancing the overall performance and longevity of the covering system.

[0072] Figure 7 illustrates a high-level overview diagram of a motorized covering system and its components. According to various embodiments, the motorized covering system 100 comprises a motor drive assembly 120 that includes a motor 121 that drives a drive wheel 123 through a gearmechanism 122. The drive wheel 123 is operatively connected to the roller tube 130 which is in turn coupled to a covering material 140 having a top end and a bottom end, and a bottom bar 150 coupled to the bottom end. The covering material 140 is connected at its top end to a roller tube 130 where the covering material 140 is wrapped or unwrapped around the roller tube 130. The motor drive assembly 120 and its corresponding components are concealed within a shade housing 1 10 that includes an opening for allowing the covering material to exit or enter the shade housing 110. The motor drive assembly 120 is configured to raise or lower the shade material to adjustably cover or uncover a structural opening between an upper and a lower limit, such as a window, a door, a wall opening, or the like. The upper limit is the maximum limit that the covering material can be retracted to the shade housing, and the lower limit is the maximum limit that the covering material can be extended from the shade housing.

[0073] In various embodiments, the motor drive assembly 1 0 is electrically coupled to a motor control module 124. The motor control module 124 operates to control the operations of the motor 121, including its direction, speed and position. It also allows an administrator, manufacturer or a user to configure the operations of the motor through the motor control module 124. The motor control module 124 includes a controller 126, a memory 125, and a communication interface 127 which are communicatively coupled to one another. In some embodiments, the motor control module 124 includes a user interface (not shown) In various embodiments, the user interface may include buttons to allow a user to configure the upper limit, the lower limit, angle of rotation of reverse motor direction and other operations of the motor. The buttons may be arranged on the outside of the shade housing 110 so that they are visible and accessible to the user.[ 00741 In various embodiment, the motorized covering system includes a counterforce mechanism 300 that is attached to the roller tube 130. The counterforce mechanism 300 includes a block 320 rotatably connected to the roller tube 130 at each end of the roller tube 130 The block 320 is slidably movable in a linear direction between a first support and a second support and is movable between a lower end of the first and second support to an upper end of the first and second support by a biasing member. As the covering material 140 on the roller tube 130 is fully retracted, the weight of the roller tube 130 is at its highest, the block 320 is therefore at the lower end of the first support and second support and the biasing member 340 is fully compressed. As the covering material is extended fromthe roller tube, the weight of the roller tube 130 on the block 320 decreases, and the biasing member 340 is slowly released from its compressed state to an extended state where the block 320 is slidably movable upwards along the longitudinal pockets of the first support and the second support towards the upper end of the first support and second support. In other words, the block 320 is slidably movable between a lower end of the first support and the second support to the upper end of the first and second support as the biasing member 340 is released from its compressed state to its extended state.

[0075] As used herein, the term ‘controller’ provides processing capability for one or more functions described herein, and broadly refers to and is not limited to single or multi-core general purpose processor, a special purpose processor, a conventional processor, a graphical processing unit, a digital signal processor (DSP), a plurality of microprocessors, one or more microprocessors in association with a DSP core, a controller, a microcontroller, one or more Application Specific Integrated Circuits (ASICs), one or more Field Programmable Gate Array (FPGA) circuits, any other type of integrated circuit, a system on a chip (SOC), and / or a state machine.

[0076] The memory 125 stores data and executable code and may be a volatile memory, for example a DRAM (Dynamic Random Access Memory) or a non-volatile memory, for example a PROM (Programmable Read Only Memory), an EPROM (Erasable PROM), EEPROM (Electrically Erasable PROM), or a flash memory, e g., a floating gate memory, a charge trapping memory, an MRAM (Magneto resistive Random Access Memory) or a PCRAM (Phase Change Random Access Memory).100771 In various embodiments, the communication interface 127 comprises a wireless communication interface configured for bidirectional communication with other electronic devices, for example, a remote control device 300, over a communication network In one embodiment, the wireless interface can include a radio frequency (RF) transceiver, an infrared (IR) transceiver, or other communication technologies known to a skilled person in the art.

[0078] In various embodiments, the remote control device 300 may be remotely controlled by the user and communicate wirelessly with the communication interface 127 to send control commands to the motor control module 124. In other words, the motor control module 124 is configured for receiving control commands from the remote control device 300. In an embodiment, the remote control device300 is configured to transmit control commands via RF signals in response to an actuation of one or more buttons of the remote control device 300. The buttons on the remote control device 300 may be physical buttons or buttons on a touch panel screen. The remote control device 300 is also configured to allow the user to configure the upper limit, the lower limit, reverse rotational movement of motor and other operations of the motor including but not limited to lowering and raising the covering material

[0079] FIG. 8 shows a flow diagram of a method for controlling a motorized covering system for preventing creasing on a covering material according to various embodiments. The method outlines a process for configuring the motor control module in a motorized covering system. In some embodiments, the method described within the flowchart is designed to operate within the context of an automated covering system.

[0080] At step 410, a user configures a lower limit for a bottom bar based on a position of a catch assembly corresponding to a magnetic member attached to the bottom bar such that a pull down force is generated to straighten the covering material when the magnetic member is releasably retained by the catch assembly at the lower limit. In various embodiments, the user is the manufacturer, a supplier or a distributor, or the end user of the motorized covering system. In practice, the manufacturer or the distributor can configure the lower limit based on specific configuration of the individual structural openings, for example, doors, balconies or windows, located in a premise before it is installed. Alternatively, it is also possible for the end user, i.e. the home owner, to configure or to adjust the lower limit to a desired lower limit if the pre-configured lower limit is not satisfactory or sufficient. The lower limit can be done manually on the remote control device where options are provided to the user to configure the lower limit.

[0081] At step 420, the user next configures a rotational movement of the motor drive assembly in a reverse direction to cause a roller tube attached to the covering material to reverse its direction resulting in an upward pull force applied to the covering material while maintaining the at least one magnetic member in the releasably retained position. As explained previously, the roller tube is coupled to the motor drive assembly so that any rotational movement of the motor within the motor drive assembly causes a corresponding rotational movement of the roller tube in either direction. Forexample, depending on the configuration of the motorized covering system, a rotational movement in an anti-clockwise direction of the drive wheel will cause the roller tube to move correspondingly by the same rotational movement of the drive wheel, and to cause the covering material to exit the shade housing. When the rotational movement of the drive wheel is in a clockwise direction, or in a reverse direction, it will cause the covering material to retract back into the housing. This reversal in rotational movement of the motor drive assembly causes an upward pull force to be applied to the covering material provided the magnetic members are releasably retained by the catch assemblies. If the magnetic members are released completely from the catch assemblies, no upward pull force will be applied to the covering material and the covering material will be suspended by gravitational forces. It is therefore essential that the rotational movement is configured carefully and precisely to ensure that any reverse rotational movement of the motor drive assembly will not cause the magnetic members to be released from the catch assemblies. In various embodiments, the rotational movement of the motor drive assembly 120 is the degree of rotation of the motor or the degree of rotation of the roller tube from the point when the covering material is at its lower limit.

[0082] In some embodiments, the motor drive assembly 120 is configured so that the motor rotates in an opposite direction by approximately 5 to 10 degrees to generate an upward pull force on the covering material so that both sides of the covering material become tighter and straighten out the creases as much as possible The amount of rotational movement of the motor drive assembly 120 in a reverse direction is determined by the diameter of the roller tube size, weight of the covering material, and / or the upward pull force generated by the covering material such that it does not overcome the magnetic forces between the magnetic member 160 and the catch assembly 200. In other words, the maximum amount of rotational movement (i.e. the maximum number of degrees of rotation of the motor drive assembly) of the motor drive assembly should not generate an upward pull force that will overcome the magnetic forces between the magnetic member and the catch assembly.

[0083] While the invention has been particularly shown and described with reference to specific embodiments, it should be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. The scope of the invention is thus indicated by the appended claims and allchanges which come within the meaning and range of equivalency of the claims are therefore intended to be embraced.

Claims

CLAIMS1. A motorized covering system for covering a structural opening comprising: a covering material having a top end and a bottom end; a motor drive assembly operatively connected to a roller tube attached to the top end of the covering material to raise and lower the covering material between an upper limit and a lower limit to uncover and cover the structural opening; a housing adapted to conceal the motor drive assembly including a side wall on each longitudinal end of the housing and an opening from which the covering material exits the housing; an elongate bottom bar coupled to the covering material at the bottom end, the elongate bottom bar including at least one magnetic member disposed at each proximate end of the elongate bottom bar; a catch assembly disposed at each lower end of the structural opening corresponding to the at least one magnetic member so that it magnetically retains the bottom bar when the covering material is fully extended; a counterforce mechanism operatively connected to the roller tube, the counterforce mechanism including a block rotatably connected to each end of the roller tube through an opening on the block, wherein the block is slidably movable between a lower end and an upper end of a first support and a second support by at least one biasing member.

2. The motorized covering system according to claim 1 wherein the biasing member is configured to be in a compressed state when the covering material is fully retracted on the roller tube, and configured to be in an extended state when the covering material is fully extended from the roller tube, causing the block to slidably move from the lower end of the first and second support to the upper end to the upper end of the first and second support as the biasing member is released from its compressed state to the extended state.

3. The motorized covering system according to claim 1, wherein the first support and the second support each includes a longitudinal pocket configured to allow the block to slidably move from the lower end of the first and second support to the upper end of the first and second support to cause thecovering material to be pulled upwards while the at least one magnetic member remains in the magnetically retained position by the catch assembly.

4. The motorized covering system according to claim 1, wherein the biasing member is a resilient member that exerts a reactionary push force when the block is imparting a load on it.

5. The motorized covering system according to claim 1, further comprising a base support for mounting the at least one biasing member, the first support and the second support.

6. The motorized covering system according to claim 1, wherein the counterforce mechanism is attached to a side wall configured for enclosing the housing at each end of the housing.

7. A motorized covering system for covering a structural opening comprising: a covering material having a top end and a bottom end; a motor drive assembly operatively connected to a roller tube attached to the top end of the covering material to raise and lower the covering material between an upper limit and a lower limit to uncover and cover the structural opening; a housing adapted to conceal the motor drive assembly including an opening from which the covering material exits the housing; an elongate bottom bar coupled to the covering material at the bottom end, the elongate bottom bar including at least one magnetic member disposed at each proximate end of the elongate bottom bar; a catch assembly disposed at each lower end of the structural opening corresponding to the at least one magnetic member so that it magnetically retains the bottom bar when the covering material is fully extended; wherein a rotational movement of the motor drive assembly is configured to reverse the direction of the roller tube when the covering material is fully extended such that an upward pull force is generated on the covering material to cause the covering material to be pulled upwards while the at least one magnetic member remains in the magnetically retained position by the catch assembly.

8. The motorized covering system according to claim 7, wherein the rotational movement of the motor drive assembly is configured to cause the roller tube to rotate by approximately 5 to 10 degrees from its fully extended position.

9. The motorized covering system according to claim 7, wherein the determination of rotational movement of the motor drive assembly is associated with one or more of the following parameters: diameter of the roller tube, weight of the covering material and the upward pull force generated by the covering material.

10. The motorized covering system according to claim 7, wherein the upward pull force generated on the covering material does not overcome magnetic forces between the at least one magnetic member and the catch assembly.

11. The motorized covering system according to claim 7, wherein the at least one magnetic member is attached to a lower end of the bottom bar.

12. The motorized covering system according to claim 7, wherein the at least one magnetic member is embedded into a lower end of the bottom bar.

13. The motorized covering system according to claim 7, wherein the corresponding metal elements include a bracket assembly fixed to a lower end of the structural opening for receiving the bottom bar.

14. The motorized covering system according to claim 7, wherein the at least one magnetic member comprises neodynium.

15. The motorized covering system according to claim 7, wherein the catch assembly includes a catch bracket installed in a position adjacent to the structural opening.

16. A method for controlling a motorized covering system adapted to cover a structural opening, wherein the motorized covering system includes:a covering material having a top end and a bottom end; a motor drive assembly operatively connected to a roller tube attached to the top end of the covering material to raise and lower the covering material between an upper limit and a lower limit to cover and uncover the structural opening; a housing adapted to conceal the motor drive assembly including an opening from which the covering material exits the housing; an elongate bottom bar coupled to the covering material at the bottom end, the elongate bottom bar including at least one magnetic member disposed at each proximate end of the elongate bottom bar; a catch assembly disposed adjacent to the structural opening corresponding to the at least one magnetic member so that it magnetically retains the bottom bar when the covering material is fully extended; wherein the method comprises the steps of: configuring the lower limit for the bottom bar based on a position of the catch assembly such that a pull down force is generated to straighten the covering material when the at least one magnetic member is magnetically retained by the catch assembly at the lower limit; and configuring a rotational movement of the motor drive assembly in a reverse direction to cause the roller tube to reverse its direction resulting in an upward pull force applied to the covering material and maintaining the at least one magnetic member in the magnetically retained position.

17. The method for controlling a motorized covering system according to claim 16, wherein the rotational movement comprises an amount of degree of rotation of the roller tube from its position at the lower limit.

18. The method according to claim 16, wherein the rotational movement of the motor drive assembly is configured to cause the roller tube to rotate by approximately 5 to 10 degrees from its fully extended position.

19. The method according to claim 16, wherein a determination of rotational movement of the motor drive assembly is associated with one or more of the following parameters: diameter of the roller tube, weight of the covering material and the upward pull force generated by the covering material.

20. The method according to claim 16, wherein the upward pull force generated on the covering material does not overcome the magnetic forces between the at least one magnetic member and the catch assembly.

21. The method for controlling a motorized covering system according to claim 17, wherein the motor drive assembly includes a motor and a motor control module communicatively coupled to the motor drive assembly.

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