NZ228024A

NZ228024A - Honeycomb cell panel retained in a slotted rail by a cell engaging rigid stiffener

Info

Publication number: NZ228024A
Application number: NZ22802485A
Authority: NZ
Inventors: Wendell B Colson; Richard S Steele; John T Schnebly
Original assignee: Hunter Douglas International
Priority date: 1984-08-07
Filing date: 1985-08-06
Publication date: 1991-03-26
Also published as: NZ228025A; NZ223943A

Description

<div class="application article clearfix" id="description"> I I 22 8 0 2 4 Pnority Date(s): ];. .V. (" a, o <~ Complete Specification Filed: V. Class: ... o *=?<? Publication Date: ....J99L... P.O. Journal, No: Divided Out of 3r the provisions of Regu- N.Z.No. 213002 >&3 (1) the C£a?m! Ration has been ante-dated Patents Act 3953 lL' *' 'J-S" I9?..f2. |j^ 17 FEB 1989 *"11 COMPLETE SPECIFICATION Initials "HONEYCOMB BLIND CONSTRUCTIONS AND METHOD OF ASSEMBLING HONEYCOMB BLIND CONSTRUCTIONS" We, HUNTER DOUGLAS INTERNATIONAL N.V., incorporated under the laws of the Netherlands Antilles, of Kaya Flamboyan 11, Rooi Catootje, Curacao, Netherlands Antilles, do hereby declare the invention, for which we pray that a Patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement : - - 1 - (followed by 1A) HONEYCOMB BLIND CONSTRUCTIONS AND METHOD 0 \ ASSEMBLING"HONEYCOMB BLIND"CONSTRUCTIONS BACKGROUND OF THE INVENTION The present invention is related to moveable insulation and decorative window coverings, and more particularly to method for assembling |"amounting moveable honeycomb blind constructions. 5 The increased cost of energy and general raising of energy consciousness over the past decade has resulted in a developing interest in methods and appiaratus for covering windows, not only for privacy and aesthetic effects, but also for insulation effect. Such window 10 coverings, of course, have to be moveable so that they can be raised and lowered during different times of the day and during different seasons. In order to satisfy the needs of most users, they also have to be aesthetically pleasing, durable, easy to install, adjustable, . and 15 relatively inexpensive. This combination of desirable features, including a moveable material having a significant insulating effect and being aesthetically pleasing in appearance has not been an easily attained goal. There have been a number of 20 different developments in this area, such as the L Specification inflatable curtains disclosed in U.S. Patent] No. lSpecification 4 , 187,896, issued to R. Shore and in U.S. Patent No.| 4,453, 584, issued to R. Steele. Another kind of development in this area includes the use of expandable honeycomb 25 panels having a plurality of cellular tubes fastened to- j Specification gether to form panels. O.S. Patent/No. 4,450,027, issued to W. Colson, is one example of such material. Such expandable honeycomb material appears at the present time £2 8024 228024 at least to hold the most promise for meeting the goals of moveable insulation that is both aesthetically pleasing and has a significant insulating effect- It also is more conducive to mass production and mass marketing to 5 consumers. There are a number of problems in the use of cellular honeycomb material for moveable insulation that have heretofore not been solved. For example, most of the past effort up to this time has been directed to developing 10 economical and suitable processes for fabricating honeycomb insulation panels that are capable of enduring long life and severe environments of high temperature and exposure to sunlight and moisture, while always maintaining an aesthetically pleasing appearance. However, 15 prior to this invention, the methods and apparatus utilized for mounting such expandable honeycomb insulation panels over windows have been rather crude and not conducive to mass marketing or installation by individual home owners or relatively unskilled persons. / 2 O 9 0 0 o ft L C ^ o £- T The present invention provides, in one aspect., a method of assembling a honeycomb blind construction, which is capable of expanding and collapsing, the construction comprising a plurality of elongate parallel, hollow, cell structures, the interiors of which are sealed from one another to form a honeycomb panel, the cells themselves being expandable in a direction transverse to their length and width, said method comprising the steps of: positioning two parallel, elongate members of a first elongate panel support rail and a first cell of the panel of said hollow cell structures at or adjacent one end of said honeycomb panel in parallel relationship, said two parallel members of the rail being spaced apart a distance from each other less than the width of the hollow cell structure; positioning said first hollow cell structure in a space in the rail behind said parallel members; inserting a rigid stiffener member that is wider than the gap between said two parallel members longitudinally through said first hollow cell structure within the space in the rail member; positioning a movable second elongate panel support rail parallel to and spaced from said first support rail; and connecting said second panel support rail with a second hollow cell structure of the honeycomb panel substantially over the full length thereof at or adjacent the other end of said honeycomb panel. In another aspect, the invention provides a honeycomb blind construction, which is capable of being expanded and collapsed, comprising a plurality of elongate parallel hollow cell structures, the interiors of which are sealed from one another, the cells themselves being expandable in a direction transverse to their length and width, a first elongate panel support rail having two parallel elongate members, the two parallel elongate members being spaced apart from each other by a distance less than the width of the hollow cell structures, one of said cell structures at or adjacent one end of said honeycomb panel being positioned in a space in the rail behind said parallel members, rigid stiffener means positioned in said one cell structure and being wider than the gap between said parallel members and preventing said one cell structure from collapsing and moving through the gap, a movable second elongate panel support rail at the opposite end of Preferably seals and side tracks are provided to close and seal the open ends of the honeycomb cells and to guide the panel during movement thereof. The edge seals and side track combinations include elongated web strips positioned against the lateral edges of the panel and inside the channel-shaped side tracks. The webs are biased toward the lateral edges of the panel by resilient or strut extensions from the web bearing against the web of the channel. An alternate embodiment shows notched bearing surfaces in the lateral edges of the panels with a protruding rib or. web-like edge track inserted into the notched bearing surfaces. Alternate edge seals and a lift drive rusable with this invention include concealed cords at the lateral edges of the honeycomb panel. BRIEF DESCRIPTION OF THE DRAWINGS The present invention will become more apparent as the description proceeds, taken in conjunction with the accompaning drawings, in which: Figure 1 is a perspective view of a honeycomb window covering unit according to the present invention; Figure 2 is a front elevation view of a honeycomb window covering unit according to the present invention mounted over a window, the illustration therein being with the insulating shade unit half drawn over the window; Figure 3 is a perspective exploded view of the preferred vertical drop embodiment of the honeycomb window covering unit according to the present invention; Figure 4 is a side elevation view of the honeycomb window covering unit of the present invention showing primarily the side track thereof; Figure 5 is a cross-sectional view of the honeycomb window covering unit taken along lines 5-5 of Figure 2; Figure 6 is a cross-sectional view of the side track and edge seal element taken along lines 6-6 of_JELijgiiX£_-4-^- i *vl\ 1._ N D • 22 8 02 4 5 10 Figure 7 is a perspective view of an alternate embodiment honeycomb window covering unit according to the present invention with a rail fastened to the sillboard of the window frame and moveable upwardly over the window; 15 Figure 3 is a partial perspective view of another alternate embodiment honeycomb window covering unit that is moveable horizontally over the window; Figure 9 is another alternate embodiment installation of the honeycomb window covering unit of the 20 present invention on an off-vertical or slanted window or skylight arrangement; Figure 10 is an exploded perspective view of an alternate preferred parallel bar system embodiment of the present invention suitable for use in installations such 25 as those shown in Figures 7. , 8 , and 9 ; Figure n is a perspective view of another preferred alternate continuous loop system honeycomb window covering unit mounted in a horizontal ceiling skylight installation; 30 Figure 12 is an exploded perspective view of the alternate embodiment continuous loop system honeycomb 5 22 8 0 2 4 window covering unit of the present invention; Figure 13 is a perspective view of another alternate embodiment notched bearing edge track embodiment suitable for non-vertical* or curved surface installations such as the 5 green house shown therein; Figure 14 is a perspective view of the honeycomb insulation panel with the notched end bearings therein for use in the notched bearing edge track embodiment shown in Figure 13; 10 Figure 15 is an enlarged perspective view of the edge track of the embodiment shown in Figure 13; Figure 16 is an enlarged perspective view of the notched opening in the sill rail of the embodiment shown in Figure 13. 15 Figure 17 is an enlarged perspective view of a drive pulley for the embodiment shown in Figure 13; Figure 13 is an enlarged perspective view of the top idler pulley of the embodiment shown in Figure 13; Figure 19 is a cross-sectional view of the sill rail 20 and edge track taken along lines 19-19 in Figure 16; Figure 20 is a cross-sectional view of an alternate edge seal embodiment adapted for use with the notched bearing .edge track embodiment shown in Figure 13 ; and Figure 21 is a cross-sectional view of another edge 25 seal embodiment for use with the notched bearing edge track embodiment shown in Figure 13. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT The first preferred embodiment of the present 30 invention is the vertical drop honeycomb window covering unit shown in Figure 1. An expandable honeycomb insulation panel 16 is comprised of a plurality of tubular 6 22 8 0 2 4 cell sections 210 adhered or fastened together in parallel relationship to each other so that they can be compressed and contracted together or expanded and extended apart. This honeycomb cellular panel 16 is mounted in and 5 suspended from a head rail 12. A moveable sill rail 14 is fastened to the bottom of the honeycomb panel 16 for weight and to provide structural integrity to the bottom-of the panel. A lift mechanism, several embodiments of which will be described below, is provided for pulling the 10 sill rail 14 upwardly to collapse the honeycomb panel between the sill rail 14 and head rail 12 when it is preferred to have the window uncovered and to drop the sill rail 14 downwardly to expand the honeycomb panel 16 over the window when it is desired to cover the window. A 15 pull cord 60, shown in Figure 1, is provided for this purpose as will be described in more detail below. In order to provide a significant insulating quality, the open ends of the tubular honeycomb cells 210 of the honeycomb panel 16 must be closed and sealed. With each 20 such tubular cell sealed at the ends, a plurality of dead air spaces are provided by the expanded honeycomb panel 16 between the window and the interior environment. Further, a suitable seal at the edges of the honeycomb panel 16 should prevent infiltration from the window behind the 25 honeycomb panel 16 into the interior environment of a room. Such edge seals are provided in the present invention by edge seal elements 22, 32 positioned respectively in left and right side tracks 18, 20, as will be described in 30 more detail below. Weather stripping 30 is also provided around the entire honeycomb window covering unit 10 to 7 further decrease the possibility of infiltration of air from one side of the honeycomb window covering unit to the other . A typical window W mounted in building frame F is 5 shown in Figure 2. Such a window typically includes one or more window panes 75 mounted in sash bars 74. The window sashes are typically mounted in a frame comprised of a head 70, left and right side jambs 71, 72, respectively, and the sill 73 at the bottom. The front 10 elevation view in Figure 2 shows the honeycomb window covering unit 10 of the present invention installed and in place over a window W in a building frame F. The head rail 12 is fastened to the head 70 of the window. The left side track 18 is fastened to the left side jamb 15 71, and the right side track 20 is fastened to the right side jamb 72. The sill rail 14 is moveable upwardly and downwardly over the window W by operating pull cord 60. Such upward and downward movement of the sill rail 14 expands and contracts the honeycomb panel 16 over the 20 surface of the window W. The honeycomb panel 16, illustrated in Figure 2, is shown in a partially drawn position with a part of the window W exposed. As shown in more detail in the exploded perspective view in Figure 3.and the enlarged cross-25 sectional view in Figure 5, the honeycomb panel 16 is mounted in and suspended by the head rail 12. The sill rail 14 is attached to the bottom of the honeycomb panel 16 and is suspended on two cords 62, 64. It should be noted here that in some embodiments having very wide 30 honeycomb panels 16 it may be desirable to provide more than two suspension cords; however, two suspension cords fvif'.'V 7. CALA^iO | ' g rATEt'j t OFrii.!; j o -i A no foor\ 22 8 0 2 4 are sufficient in most installations and are sufficient for purposes of this description. The head rail 12 is preferably comprised of an extruded channel having a web 82, front and rear flanges 5 84, 86, respectively, defining an interior chamber 80. The chamber 80 is partially closed on the bottom by a front lip 88 extending inwardly from the bottom of the front flange 84, and a rear lip 90 extending partially inward from the bottom of the rear flange 86. A 10 longitudinal rib 100 extends along the length of the inside of front flange 84, and a longitudinal channel 102 I extends along the length of the inside surface of the rear flange 86. This longitudinal rib 100 and longitudinal channel 102 are utilized for mounting components as will 15 be described in more detail below. The web 82 of head rail 12 has a recessed portion 92 toward the rear thereof for accommodating the mounting bracket 290, as will be described in more detail below. An elongated tongue 94 extends partially over the recessed 20 portion 92 to form a longitudinal slot 96. A shoulder 98 is formed at the rear edge of the web 82 adjacent the rear flange'86. This tongue 94, slot 96, and shoulder 98 are designed to engage the mounting bracket 290 as will be described in more detail below. A channel 104 is also 25 provided in the web 82 for having mounted therein a ^ weather stripping element 30. The honeycomb panel 16 is attached to the head rail 12 by inserting the top tubular cell 180 through the opening between lips 88, 90, as best shown in Figure 5. 30 The opening between lips 88, 90 should be of sufficient width to accommodate the full width of the glue line or 22 8 02 4 attachment surface area 184 between the top tubular cell 180 and the next adjacent tubular cell 182 so that distortion of the cells does not occur. The top tubular cell 180 is then flattened in the chamber 80 inside head rail 5 12 as shown. Since the tubular cells, such as the top cell 180 and next adjacent cell 182 of honeycomb panel 16 are typically fabricated of quite flexible thin film materials, they do not have sufficient structural rigidity to maintain them-10 selves in the mounted position in head rail 12. When any significant amount of weight is suspended on the panel 16, the upper tubular cell 180 would simply fold and be pulled downwardly through the opening between lips 88, 90 if some additional stiffener material is not provided. Therefore, 15 a significant feature of the present invention includes a flat, elongated stiffener member 186 inserted through the top tubular cell 180 inside the head rail 12. This stiffener member 186 is wider than the opening between lips 88, 90 and has sufficient structural resistance to 20 bending or folding in both normal and high temperature environments such that it easily b.olds the weight of the honeycomb panel 16 while preventing the upper tubular cell 180 from folding and being pulled down through the opening 25 between lips 88, 90. The sill rail 14 is also comprised of a channel-shaped extrusion having a web 132, front flange 134, and rear flange 136 enclosing a chamber 130. A front lip 138 extends inwardly from the top of front flange 134 and a 30 rear lip 140 extends inwardly from the top of rear flange 136. This sill rail 14 is attached to the honeycomb panel 16 in a manner similar to the attachment of the head rail 12 to the honeycomb panel 16. Specifically, the bottom IO • '22 8 0 2 4 tubular cell section 190 is flattened and inserted through the opening between lips 13$, 140 into the chamber 130 and sill rail 14. A second stiffener member 196 is inserted longitudinally into the bottom tubular cell 190 to prevent 5 extraction thereof from the sill rail 14. It should be noted that this feature of this invention is significant in that it accommodates adjustment of the length of the honeycomb panel 16 quite readily and easily by relatively unskilled installers. 10 Such adjustment can be accomplished by varying or changing the number of tubular cells stuffed into either the sill rail or the head rail. For example, referring to Figure 5, if the actual window size dictates that the honeycomb panel 16 be approximately an inch shorter for proper fit 15 and aesthetics, the second to the bottom tubular cell 192 could also be folded and inserted into the chamber 130 inside sill rail 14. In that case, the stiffener member 196 would be inserted longitudinally through the second to bottom tubular cell 192. It has been found that in normal 20 sized installations with relatively small sized head rails and sill rails for a pleasing appearance in windows, over a foot of adjustment can be provided for the installer in this manner. In other words, the honeycomb panel 16 can be fabricated in standard incremental sizes, while indivi-25 dual users and installers have sufficient flexibility in the field or at home to adjust the actual effective length of the honeycomb panel 16 or to a foot more or less. Such adjustment can be accomplished without cutting or modification to the panel by merely stuffing more or fewer of 30 the top or bottom tubular cells into the head rail or sill rail. 22 8 0 2 4 The sill rail 14 also has a longitudinal channel 152 and a longitudinal rib 150 similar to those described in the head rail 12 for component mounting purposes to be described below. It also includes two upright protrusions 5 144, 146 on the interior surface of the web 132 to form an interior channel 142 along the length of the sill rail 14 for purposes described below. Exterior slots 154, 156 in the web 132 are provided for mounting weather stripping 30 therein. The effective length of the honeycomb panel 16 10 should be adjusted as described above so that the weather stripping 30 on the bottom of sill rail 14 contacts and U seals against infiltration at the window sill 73 shown in Figure 2. As shown in Figure 3, left and right end caps 110, 15 120, respectively, are provided to close the ends of the head rail 12. The left end cap 110 has a closure plate 112 with a rib 113 extending inwardly from its rear edge and reinforced by a web 119. A'pair of spaced apart ribs 114, 115 extend inwardly from the front edge of closure 20 plate 112 to form a longitudinal channel 116 therebetween. A reinforcing web 117 supports the channel 116. This rib 118 is sized and shaped to mate with the interior channel 102 in head rail 12, and the channel 116 is shaped and sized to engage the longitudinal rib 100 in the interior 25 of head rail 12. Therefore, when the end cap 110 is inserted into the left end of head rail 12, the mating rib 118 and channel 116 engage the channel 102 and rib 100 in the head rail 12 to firmly secure the end cap 110 in place. 30 Likewise, the right end cap 120 has a rib 128 reinforced by a web 129 on the rear side and a pair of -12 22 8 0 2 4 ribs 124, 125 defining a channel 126 reinforced by a web 127 on the front. This rib 128 and channel 126 are also sized and shaped to engage the channel 102 and rib 100 inside head rail 12 to firmly hold the end cap 120 in 5 place. Likewise, end caps 160, 170 are provided for enclosing the ends of sill rail 14 in a similar manner. For example, left end cap 160 has a closure plate 162, rib 168, and channel 166 adapted to engage channel 152 and rib 10 150 inside the sill rail 14. The right end cap 170 has a closure plate 172, a rib 178, and a channel 176 also adapted to engage the rib 150 and channel 152 in sill rail 14 to enclose the right end of sill rail 14. The lift mechanism is preferably described in 15 reference to Figures 3 and 5. It is comprised of a lift cord 60 adapted for the user to grasp by hand and pull the sill rail 14 upwardly or allow the sill rail 14 to move downwardly. The pull cord 60 is comprised of two separate cords, a left cord 62, and a right cord 64. These cords 20 extend from the exterior of head rail 12 through a hole 61 in the front flange 84 to the interior chamber 80 of head rail 12. From that point, the left cord 62 extends to a position near the left side of honeycomb panel 16, where it then extends downwardly through the middle of honeycomb 25 panel 16 and into the sill rail 14. In the sill rail 14, the left cord 62 extends through the stiffener member 196 and through a large flat washer 206 positioned under stiffener member 196 and the bottom tubular cell 190. A knot or bead 207 is placed at the lower end of left cord 30 62 to anchor it under the washer 206. The washer 206 is nroferably large enough to bear against the lips 138, 140 i 22 8 0 2 4 of sill rail 14 to firmly anchor the cord 62 in the sill rail 14. Likewise, the right cord 64 extends downwardly through the stiffener member 186 in the head rail 12, 5 through the right side of honeycomb panel 16 downwardly into the sill rail 14. In sill rail 14, the right cord 64 extends downwardly through the stiffener member 196 and bottom tubular cell 190 and through a large diameter washer 208 and terminates at an anchor knot or bead 209. 10 Left and right guide plates 200, 202, respectively, are positioned in the head rail 12 to maintain proper alignment of the left and right cords 62, 64 with the holes in the honeycomb panel 16. For example, left guide plate 200 has a hole 201 therethrough positioned directly 15 over hole 181 through the top tubular cell 180 and stiffener member 186. Likewise, the right guide plate 202 has a hole 203 therethrough positioned directly over hole 183 in top tubular cell 180 and stiffener member 186. These guide plates 200, 202 are retained in proper 20 alignment in the head rail 12 by screws 204, 205, respectively. A grommet or eyelet 63 is positioned around the cord 60 in the hole 61 in front flange 84 to reduce wear on the cord 60. A unitary bottom section 65 of the cord is provided 25 with a handle 69. The bottom cord portion 65 is attached to the left and right cords 62, 64 by a joiner ball 66. The joiner ball 66 is comprised of an upper half 67 and lower half 68 that are adapted to be screwed together with knots of the respective ends of the cord sections enclosed 30 therein. A tie down 78 is fastened to the frame F or window jamb 72 adjacent the side track 20 for tying the 22 8 0 2 4 pull cord 60 when it is desired to retain the sill rail 14 in a raised position with the honeycomb panel 16 collapsed between the sill rail 14 and head rail 12. The preferred embodiment edge seals, according to the 5 present invention, are best described in reference to Figures 1, 2, 3, 4, and 6. Left and right side tracks 18, 20, respectively, are provided to extend along opposite sides of the honeycomb panel 16. The left and right edge seal elements 22, 32, respectively, are positioned inside r right 10 the respective left and side tracks 18, 20 and adjacent the open ends of the cells of the honeycomb panel 16. For example, the right side track 20, which is adapted to be j fastened to the right window jamb 72, is comprised of an elongated extruded channel member having a web 52, front 15 flange 54, and rear flange 56. A front lip 55 extends inwardly from the distal end of front flange 54, and a similar lip 57 extends inwardly from the distal end of rear flange 56. Exterior slots 58, 59 are provided to retain weather stripping 30 therein for sealing against 20 the window jamb 72. Referring primarily now to Figure 6, and secondarily to Figures 1 and 3, the right seal element 32 is positioned in the interior 50 of side track 20. It is comprised of a web 34 positioned against the open end of 25 intermediate hoheycomb cells 210 to close and seal the end thereof. A front leg portion 36 extends from a fold at the front edge of the web 34 and at an acute angle thereto into contact with the web 52 of side track 20. Likewise, a rear leg 38 extends from the fold at the rear edge of 30 web 34 into contact with the web 52 of side track 20. The edge seal element 32 is preferably fabricated of a fairly rigid, resilient thin film material with its 22 8 0 2 4 natural cross-sectional shape similar to that shown in Figure 3 with a curved web portion 34 and divergent leg members 36, 38. In this manner, when the honeycomb panel 16 is assembled with the side track 20 and edge seal 5 element 32, the edge seal element 32 will assume the shape shown in Figure 6 with its web 34 flat against the open end of the cell 210. The legs 36 , 38 then tend to bias the web 34 inwardly toward the cell^210 to maintain constant contact and effective closure against the open end ^ ceils 210. Further, this contact is maintained in a sliding manner between the web 34 and the honeycomb panel 16 as the honeycomb panel 16 slides upwardly and downwardly within the track 20. Further, when the honeycomb panel 16 is pulled upwardly, as shown in Figure 2, the 15 lips 55, 57 retain the edge seal element 32 in position in the side track 20 until the honeycomb panel 16 is dropped downwardly again in sliding contact with the web 34. In this manner, a constant and effective sliding closure and seal is maintained between the web 34 and the cells 210 of 20 honeycomb panel 16 regardless of the position in which honeycomb panel 16 is placed over the window W. For further description, it is noted that in Figure .6, the glue line or attachment between the cell 210 and the next adjacent cell above 210 is indicated at 212. 25 Also, the right cord 64 is shown extending through a hole 214 in cell 210 in a typical manner. Likewise, the left side track 18 is adapted for attachment to the left window jamb 71 and is comprised of a web 42, front flange 44, and rear flange 46. A front 30 lip 45 extends inwardly from front flange 44, and a rear lip 47 extends inwardly from rear flange 46 for retaining l(p the edge seal element 22 within the interior 40 of side track 18. The edge seal element 22 is comprised of a web 24 for closing and sealing the open left ends of the cells in honeycomb panel 16, and front and rear leg portions 26, 28 for biasing 5 the rib 24 against the honeycomb panel 16. The side tracks 18, 20 not only serve to retain the edge seal elements 22, 32 in proper position, but they also retain the edges of the honeycomb panel 16 in proper alignment and serve as a guide track for the sill rail 14 in which the sill rail 14 can slide up and 10 down as the panel 16 is raised and lowered. In a variation, the left and right cords 62,64 extend respectively through left and right side tracks 18,20 respectively, instead of through the honeycomb panel 16. This alternate cord arrangement is preferred when the honeycomb cell 15 material 16 is fabricated of a somewhat transparent material that would expose cords running through the center of the honeycomb panel 16 as described in the preferred embodiment and shown in fig. 3. The cords 62,64 would be more concealed in the side tracks 18,20 then if they were running through honeycomb panel 20 16 in such transparent materials. It should be noted, however, in that^honeycomb panel installations that do not utilize the side tracks 18,20 and edge seals 22,32, the embodiment described in fig. 3 with the cord running through the honeycomb panel 16 would be required. 25 30 17 NEW ZEALAND PATENT OFFICE 2 7 APR 1990 22 8 0 5 Some installations are not conducive to the preferred vertical drop embodiment 10 described above. For example, in some installations, as shown in Figure 7 , it is desirable to have the honeycomb panel 16 attached to the 10 sill 12 with the moveable end on top so that the panel can be moved upwardly and downwardly from the sill. Also, as shown in Figure 8 , it is sometimes desirable to mount the honeycomb panel 16 for horizontal movement over a window W. Further, some windows are positioned at a non-vertical 15 slant, as shown in Figure 9 . The preferred alternate parallel bar system 310, illustrated in Figure 10, is appropriate for many non-conventional uses, such as those illustrated in Figures 7,8, and 9. As shown in FigurelO , this parallel bar 20 embodiment is quite similar to the preferred vertical drop system 10 described above. It has a head rail 12, attached to a window jamb by mounting brackets 290. The expandable honeycomb panel 16 is attached to the head rail 12 in the same manner as that described for the preferred 25 embodiment 10 described above. Also, a moveable sill rail 14 is attached to the other end of the honeycomb panel 16 as described in the preferred vertical drop embodiment 10, above. Also, the side tracks 18, 20 and edge seal elements 22, 32 are the same as those described in the 30 preferred vertical drop embodiment 10, above. However, rather than utilizing a pull cord 60, as 18 22 8 02'A described above, this parallel bar system embodiment 310 utilizes two independent cords 320, 324 anchored at the top to'head rail 12 and at the bottom to opposite sides of the window sill 73. More specifically, left cord 320 is anchored at the top by a bead or knot 321 to guide plate 200. Guide plate 200 is fastened to the head rail 12 by a screw 204, as described in the preferred vertical drop embodiment 10 above. Left cord 320 extends downwardly I hole 315 in a through the panel 16 and through a second guide plate 3 14 10 and into the interior of sill rail 14. Guide plate 3 14 is held in position by screw 3]^, From guide plate 314, the \ left cord 320 passes through the interior of sill rail 14 and out hole 173 and right end cap 170. Outside end cap 170, the left cord 320 is anchored to the window sill 73 15 by an anchor member 322. 1 by a bead or knot 325 The right cord 324 is anchored at the top to right guide plate 202 which is attached to head rail 12 by screw 205. It extends downwardly through panel 16 and into sill rail 14 through a hole 317 in a lower guide plate 316 20 attached to sill rail 14 by a screw 319. At that point, right cord 324 passes to the left through the interior of sill rail 14 and out hole 163 and left end plate 160. Outside end plate 160, the right cord 324 is anchored to the left side of window sill 73 by anchor member 326. 25 The bottom of web 24 has notch 312 therein to slip over the anchor member 326 without interfering with the functioning of edge seal element 22. A handle 328 is attached to the front flange 134 of sill rail 14 for moving sill rail 14 upwardly and 30 downwardly within the side tracks IS, 20. Because of the arrangement and positioning of the left and right cords 320, 324 with their respective anchors at opposite sides 19 228024 of sill rail 14, sill rail 14 can be moved easily upwardly and downwardly within the guide tracks '18_ 20. However, this arrangement also always maintains the sill rail 14 in parallel relation to the head rail 12, thereby keeping the 5 entire panel system in proper alignment within the tracks 18, 20. Also, this arrangement provides just the friction in the cords to keep the sill rail 14 at any position desired by the user between the window sill 73 and the head rail 12. It can also be appreciated that pulley 10 blocks could be used in place of the guide plates 314, 316 in this embodiment if excessive friction or cord wear is encountered, particularly in large installations. Another alternate preferred embodiment in the form of 15 a continuous loop system 330 can also be used for the non-conventional installations in which the preferred vertical drop system 10, described above, are not appropriate. Such an installation in a skylight is shown in Figure 11 , wherein the continuous loop honeycomb panel system 330, 20 according to the present invention, is mounted in a horizontal overhead position. This alternate preferred embodiment continuous loop system is best described in reference to Figures 11 and 12. in this continuous loop system, a head rail 12 is fastened by brackets 290 to 25 a window frame, as described in the preferred embodiments above. The honeycomb panel 16 is also attached to the head rail 12, as described above. Further, a moveable sill rail 14 is attached to the opposite end of the honeycomb panel 16, again, as described in the preferred 30 embodiments above. This part of the arrangement is 20 > 22 8 0 2 4 virtually the same as the vertical drop embodiment 10, described above and illustrated in Figure 3. In this continuous loop system embodiment 330, however, a secondary sill rail 332 is permanently attached 5 to the sill or frame of the window adjacent the main sill rail 14. A reverse operating cord 335, comprised of a left cord 336 and a right cord 338, extends through a hole 348 into the interior of secondary sill rail 332. The left cord 336 passes out the left end through hole 345 in 10 end plate 344 and upwardly to the left end of main sill rail 14. It passes through hole 163 and end plate 160 into the interior of main sill rail 14 and is; anchored or terminated therein at a tension spring 216. Likewise, the right cord 338 passes out the right end of secondary sill 15 rail 332 through a hole 347 and end plate 346. It then passes upwardly and into the right end of the main sill rail 14 through hole 173 in right end plate 170. Inside sill rail 14, the right cord 3 3 8 also anchors or terminates at the tension spring 216. The outer end of 20 reverse operating cord 335 is joined by a joiner ball comprised of an upper section 67 and a lower section 68 together with the forward operating cord 60. In operation, when cord 60 is pulled out, it will pull main sill rail 14 upwardly in the conventional 25 manner. As main sill rail 14 moves upwardly, it will pull reverse operating cord 335 into the secondary sill rail 332. Then, when it is desired to move the main sill rail 14 downwardly, the reverse operating cord 335 can be pulled out of secondary sill rail 332. This outward pull 30 on reverse operating cord 335 will move main sill rail 14 downwardly, thus pulling operating cord 60 into the head rail 12. The tension spring 216 maintains the cords in ' 21 22 8 0 2 4 proper tension and alignment so that no loose ends or unparallel action occurs. When the honeycomb panel installation 330 is positioned out of reach, such as in an overhead skylight 5 shown in Figure 11 , a pole 340 with a hook 342 on the end thereof can be used to engage the joiner ball to pull the cords back and forth, thereby moving the honeycomb panel 16 one way and then the other. Another alternate embodiment 350 of the present 10 invention, preferred for use in non-vertical curved surface or curved track applications is illustrated in Figures 13-18. Such applications are typical in green house installations, such as that illustrated in Figure 13, wherein the panel is stretched through a non-vertical 15 section around a curve and into a vertical section. In this notched-bearing, edge track embodiment 350, which is designed for optimum tracking through curves, the edges of the honeycomb cells- are notched as shown at 390 in Figure 14 . Each notch 390 provides a bearing surface for that 20 particular tubular cell. Corresponding notches 392, 394 are provided in the head rail 12 and sill rail 14, respectively. As best shown in Figures 15 and 16, the edge, track 360 is comprised of a web 364 extending outwardly from the frame 354 of the green house installa-25 tion G. This edge track 360 extends into the notched bearings 390 in the honeycomb panel 16. When edge tracks 360 are engaged with notched bearing 390 on both sides of the honeycomb panel 16, the sill rail 14 can be pulled along the edge tracks 360, including around curves, and 30 the honeycomb panel 16 will follow meticulously and smoothly. 22 22 8 0 2 4 A drive system for this kind of installation is also illustrated in Figure 13 and Figures 15-18. A drive shaft 378 is positioned horizontally along the bottom of the green house panels. A crank 374 and corresponding gear 5 drive 376 are used to turn the shaft 378. As illustrated in Figures 15, 16, and 17, the edge track 360 is comprised of a flange 362 attached to the green house frame 354. A web 364 extends upwardly from the flange 362 into engagement with the notched edge bearings 390 of the 10 honeycomb panel 16. The distal end of the web 364 is returned in a lip a partial distance toward the flange 362/ thereby creating a space or channel between the lip 366 and web 364. A continuous cord passing around a drive pulley 386 mounted on drive shaft 378 passes upwardly 15 through the channel in the edge track 360 to the top of the green house. At the top of the green house, the cord 370 passes around a idler pulley 382 and a pulley block 380 fastened to the upper end of the green house frame 354. A similar installation of drive pulleys and a drive 20 cord is installed on the opposite side of the honeycomb panel 16. As shown in Figure 19, the cord 370 is anchored at one end 371 to the sill rail 14 and at the opposite end 372 to a tension spring 216. Therefore, when the shaft 378 is-turned, the pulley 38 6 drives the cord 370 to pull 25 the sill rail 14 upwardly or downwardly along the edge track 360. The tension spring 216 maintains the cord 370 and the corresponding cord on the opposite side of honeycomb panel 16 in proper tension and alignment for smooth movement upwardly and downwardly over the curved 30 surface. If edge seals are desired for maximizing thermal insulation of the honeycomb panel 16, such edge seals can 23 22 8 02 4 be provided, as shown in Figure 2Q In this illustration, an edge seal element 400 is anchored by a rivet 412 under the edge track 360. It includes a web 402, a front leg 404 and a rear leg 406 extending from the outer edges of 5 the web 402 to respective front and rear face panels 408, 410. The face panels 408, 410 provide a sliding seal for the open ends of the honeycomb cells 210, and the resilient bias legs 404/ 406 bias the face panels 408, 410 against the edges of celJs 21Q. Edge seal element 400 10 can be provided in an optional side track channel 20, if desired, although the side track channel is not necessary when the edge track 360 is used. An alternate embodiment of edge seal 420 is shown in Figure 21. It is similar to the embodiment shown in 15 Figure 20 but it has a web portion 422 anchored under the edge track 360 by a rivet 436 with resilient biased legs 428, 432 attached to face panels 424, 430. As in the embodiment described above in Figure' 20, the resilient legs 428 , 432 tend to bias the face panels 424 , 430 20 against the open ends of the tubular cells 210 of honeycomb panel 16. In this embodiment, however, there is also added a set of secondary legs 426, 434 to bias the outer ends of the face panels 424, 430 against the honeycomb panel cells to maintain a more positive seal at 25 the outer edges thereof. Accordingly, the present invention has been described with some degree of particularity directed to the preferred embodiment of the present invention. It should be appreciated, though, that the present invention is 30 defined by the following claims construed in light of the prior art so that raodifications or changes may be made to ■2 2 8 0 2 4 the preferred embodiment of the present invention without departing from the inventive concepts contained herein. ti </div>

Claims

<div class="application article clearfix printTableText" id="claims"> 228024 WHAT WE CLAIM IS:

1. A method of assembling a honeycomb blind construction, which is capable of expanding and collapsing, the construction comprising a plurality of elongate parallel, hollow, cell structures, the interiors of which are sealed from one another to form a honeycomb panel, the cells themselves being expandable in a direction transverse to their length and width, said method comprising the steps of:

positioning two parallel, elongate members of a first elongate panel support rail and a first cell of the panel of said hollow cell structures at or adjacent one end of said honeycomb panel in parallel relationship, said two parallel members of the rail being spaced apart a distance from each other less than the width of the hollow cell structure;

positioning said first hollow cell structure in a space in the rail behind said parallel members;

inserting a rigid stiffener member that is wider than the gap between said two parallel members longitudinally through said first hollow cell structure within the space in the rail member;

positioning a movable second elongate panel support rail parallel to and spaced from said first support rail; and connecting said second panel support rail with a second hollow cell structure of the honeycomb panel substantially over the full length thereof at or adjacent the other end of said honeycomb panel.

2. A method according to claim 1, wherein the second panel support rail is provided with two spaced apart parallel elongate members and the step of connecting' it with the second hollow cell structure includes similar positioning and inserting steps to those for connecting the first support rail with the first hollow cell structure.

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3. A method according to claim 1 or 2 and including the steps of positioning an elongate edge seal means along each lateral edge of said honeycomb panel, said seal means each including an elongate seal strip which is adapted to close and seal the ends of said expanded cell structures while allowing said honeycomb panel to slide upwardly and downwardly in relation to said seal strips and biasing said seal strips against the lateral edges of said honeycomb panel.

4. The method of claim 3, including the steps of positioning the honeycomb panel within said seal means which comprise a side track in the shape of a channel adjacent each lateral edge of said honeycomb panel with the respective edges of the panel protruding partially into said channel, and positioning said seal strips longitudinally, in said channels and interposed between said honeycomb panel and a web of said channels which side tracks are thereby adapted to engage the honeycomb panel in a manner to permit upward and downward slidable movement of said panel in longitudinal relation to said side tracks while preventing lateral and transverse movement of said panel in relation to said side tracks.

5. A honeycomb blind construction which is capable of being expanded and collapsed, comprising a plurality of elongate parallel hollow cell structures, the interiors of which are sealed from one another, the cells themselves being expandable in a direction transverse to their length and width, a first elongate panel support rail having two parallel elongate members, the two parallel elongate members being spaced apart from each other by a distance less than the width of the hollow cell structures, one of said cell structures at or adjacent one end of said honeycomb panel being positioned in a space in the rail behind said parallel members, rigid stiffener means positioned in said one cell structure and

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being wider than the gnp between said parallel members and preventing said one cell structure from collapsing and moving through the gap, a movable second elongate panel support rail being positioned at the opposite end of said honeycomb panel from said first support rail and being connected with a second hollow cell structure of the honeycomb panel over substantially the full length <?'•

thereof.

6. A blind construction according to claim 5, further including motion producing means connected to said movable panel support rail for moving said movable panel support rail towards and away from said first rail for collapsing and expanding said honeycomb panel.

7. A blind construction according to claim 5 or 6, wherein the movable panel support rail is provided with two spaced apart parallel elongate members and a second stiffener means is positioned in a second of said hollow cell structures at or adjacent the other end of the panel, said second stiffener means being wider than the gap between the two parallel members of said movable panel support rail and preventing said second cell structure from collapsing and moving through the gap between the two parallel members of said movable panel support rail.

8. A blind construction according to claim 6 or 7, wherein said motion producing means include a first flexible cord and a second flexible cord with respective first ends of said first and second cords being spaced apart and anchored to said movable panel support rail and the respective opposite ends of said first and second cords extending through said honeycomb panel in parallel spaced apart relationship to each other and into and through said rail to a position outside said rail.

9. A blind construction according to any one of claims 5 to 8, and including elongate edge seal means along the lateral edges of said honeycomb panel, said swai-means

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each including an elongate seal strip, said seal strips being adapted to close and seal the ends of said cell structures while allowing said honeycomb panel to slide upwardly and downwardly in relation to said seal strips, and bias means urging said seal strips against the lateral edges of said honeycomb panel.

10. A blind construction according to claim 9, said seal means including side tracks engaging and maintaining proper lateral and transverse alignment of said honeycomb panel within the path of the side tracks while allowing longitudinal movement of said honeycomb panel within said side tracks, wherein each side track includes an elongated channel with the lateral edge of said honeycomb panel inserted partially therein, said channel including a pair of lips extending inwardly toward each other from the distal ends of opposite flanges of the channel, and said elongated seal strip therein being positioned in said channel between the lateral edge of said honeycomb panel and the web of said channel, said seal strip being wider than the gap between said lips, wherein said bias means includes a pair of leg portions extending rearwardly from opposite sides of said strip into contact with the web of said channel, said legs and the juncture of said legs to said strip being resilient and deformed beyond a perpendicular relationship.

11. A blind construction according to any one of claims 5 to 10, wherein said motion producing means includes;

a first flexible cord and a second flexible cord with respective first ends of said first and second cords being spaced apart and anchored to said movable panel support rail and the respective opposite ends of said first and second cords extending through said honeycomb panel in parallel spaced apart relation to each other and into and through said rail to a position beyond said honeycomb panel;

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anchor means cooperating with a third cord and said movable panel support rail and positioned on the opposite side of said rail to the honeycomb panel and in fixed spacial relation to said first rail; and a third flexible cord with its first end anchored to said movable support rail, and said cord being engaged slidable with said anchor means and returned to a connection with said opposite ends of said first and second cords.

12. A blind construction according to claim 11 wherein said anchor means is an elongated rigid channel positioned parallel to said movable support rail, and a fourth flexible cord, the respective first ends of said third and fourth cords being anchored to said movable support rail and in spaced apart relation to each other with the respective third and fourth cords extending from opposed ends of said movable rail and extending together through said anchor means to a connection with said opposite ends of said first and second cords.

13 . bl ind construction according to claim 12, further including spring tension means in said movable support rail which anchor said third and fourth cords to each other and to said movable support rail.

14. A blind construction according to claim 6 or claim 7, wherein said motion producing means includes;

a first flexible cord, the first end of which is anchored to said first panel support rail and which cord extends adjacent the left lateral edge of said honeycomb panel to the left side of said movable support rail and then to the right side thereof where it is anchored in fixed spacial relation beyond said movable support rail; and a second flexible cord, the first end of which is anchored to said first rail and which cord extends

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adjacent the right lateral edge of said honeycomb panel to the right side of said movable support rail and then to the left side thereof where it is anchored in fixed spacial relation beyond said movable support rail.

15. A method of assembling an expandable honeycomb blind construction according to claim 1 and substantially as hereinbefore described with reference to and as illustrated in Figures 1 to 12 of the accompanying drawings.

16. An expandable honeycomb blind construction substantially as hereinbefore described with reference to and as illustrated in Figures 1 to 12 of the accompanying drawings.

HUNTER DOUGLAS INTERNATIONAL N.V. By their attorneys

TED

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NEW ZEALAND PATENT OFFICE

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