WO1990013728A1 - Textile fabric horizontal blinds and slats - Google Patents

Textile fabric horizontal blinds and slats Download PDF

Info

Publication number
WO1990013728A1
WO1990013728A1 PCT/US1989/001975 US8901975W WO9013728A1 WO 1990013728 A1 WO1990013728 A1 WO 1990013728A1 US 8901975 W US8901975 W US 8901975W WO 9013728 A1 WO9013728 A1 WO 9013728A1
Authority
WO
WIPO (PCT)
Prior art keywords
textile
slats
slat
venetian
curved portion
Prior art date
Application number
PCT/US1989/001975
Other languages
French (fr)
Inventor
Zdenek Dostal
Original Assignee
Polylok Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Polylok Corporation filed Critical Polylok Corporation
Publication of WO1990013728A1 publication Critical patent/WO1990013728A1/en

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B9/00Screening or protective devices for wall or similar openings, with or without operating or securing mechanisms; Closures of similar construction
    • E06B9/24Screens or other constructions affording protection against light, especially against sunshine; Similar screens for privacy or appearance; Slat blinds
    • E06B9/26Lamellar or like blinds, e.g. venetian blinds
    • E06B9/38Other details
    • E06B9/386Details of lamellae

Definitions

  • This first portion addresses the textile fabric horizontal blind slat according to the present invention, including a novel "family" of S-shaped or reverse curve cross-sectional slat profiles and blinds made up therof having light-trapping characteristics, and the second portion (Part II) of which includes the remainder.
  • the present invention relates generally to Venetian or window-type blinds, and more particularly to a novel concept and system of blinds and textile slats used therein.
  • Another object of this invention is to provide such a slat, which includes a fibrous means for holding a
  • Yet a further object is to provide such a slat which is able to perform without sagging according to its intended function in an environment in which temperatures may reach 150 degrees F., relative humidity may reach 90 percent, and
  • Still another object of the present invention is to provide such a slat which, upon being deformed from an
  • unstressed shape to a degree that would exceed yield points of permanent deformation of a conventional metal Venetian blind slat of similar unstressed shape, will retain sufficient resilience to enable an uninfluenced return to said unstressed shape without any permanent deformation.
  • Yet a further object of the present invention is to provide such a slat which includes means for enabling reshaping by hand to an original unstressed shape after deformation.
  • Another object of this invention is to provide a blind including such textile slats which provide privacy through a degree of light penetration which, in turn, may be controlled and varied from light filtering translucency to room darkening and blackout.
  • Still another object of this invention is to provide such a blind, wherein each and all such slats are sufficiently rigid that they successfully resist sagging which, obviously, would destroy and render worthless both the aesthetics and functioning of the blind.
  • Yet still another object is to provide such slats which have the additional feature of being able to be drilled or die cut without losing their shape during the cutting operation, and permitting achievement of precise cut sizes and shapes, without fraying at the cut edges.
  • a further object is to provide such slats which include in their makeup one of the following bonding materials, namely: resins such as latex, polyurethane, urethane, epoxy, acrylic, melamine formaldahyde, polymer emulsions, copolymer emulsions, and hydrocarbons, and fusible chemicals.
  • resins such as latex, polyurethane, urethane, epoxy, acrylic, melamine formaldahyde, polymer emulsions, copolymer emulsions, and hydrocarbons, and fusible chemicals.
  • Yet a further object of this invention is to provide such slats which may be molded into their desired profile or shape, through the use of thermoplastic, binding or thermal bonding fiber co in their makeup.
  • Another object is to provide such slats which are fusible and which include in their makeup a predetermined percentage of fusible fibers capable of holding a new shape when fused.
  • Still a further object of the present invention is to provide such slats which include a novel "family" of cross- sectional profiles of generally sinusoidal or S-shape,
  • Yet a further object is to provide horizontal or venetian-type blinds made up of or consisting of such S-shaped slats.
  • Another object is to provide such a horizontal or venetian-type blind which exhibits light-trapping
  • Still a further object is to provide such slats and blinds, wherein optional notches formed in either one edge or both forward and rearward edges of the slats accommodate blind control cords, such that more complete light-trapping closure of adjacent slats is facilitated, which enable the blind assemblies to exhibit a more uniform or consistent appearance characterized by the absence of horizontal "bars" of relatively undiffused light common in conventional Venetian-type blinds..
  • a textile slat capable of use in a horizontal Venetian-type blind comprises an elongated member formed with relatively oppositely facing surfaces and having a cross-sectional profile or shape other than truly flat, this member including fibrous means for holding a resin, a resin held by the fibrous means, and surface means forming one of said surfaces for providing the appearance and feel of a textile.
  • the surface means may comprise an embossed or pinsoni ⁇ treated surface or may comprise the surface of an actual, true textile.
  • a "family" of such slats of sinusoidal cross-sectional profiles is provided to make up horizontal or venetian-type blinds which exhibit light-trapping and other superior characteristics.
  • Each slat includes one curved portion and at least one
  • Adjacent slats within such blinds overlap in cooperative relationships to provide novel structures, which enable the blind assemblies to exhibit a more uniform or consistent appearance characterized by the absence of horizontal "bars" of relatively undiffused light common in conventional Venetian-type blinds..
  • Fig. 1A is a fragmentary left perspective view of a Venetian-type blind which includes novel textile slats
  • Fig. 2A is a fragmentary right perspective view of a slat according to the present invention.
  • Fig. 3A is a cross-sectional profile view taken along line 3A-3A of Fig. 2A;
  • Fig. 4A is a cross-sectional profile view of an alternate slat according to another embodiment of this
  • Fig. 5A is an enlarged cross-sectional view of a portion of a five-layered, balanced slat according to the present invention.
  • Fig. 6A is an enlarged cross-sectional view of a portion of another layered slat according to the present invention.
  • Fig. 7A is a block-type flow diagram illustrating necessary and optional steps utilized in forming slats
  • Fig. 8A is an enlarged, fragmentary cross-sectional view through webbing being needle-punched in the formation of a slat according to this invention
  • Fig. 9A is a top plan view of the upper surface of a textile slat according to this invention.
  • Fig. 1B is a right perspective view of a horizontal or venetian-type blind which includes textile slats of novel cross-sectional profiles according to the present invention
  • Fig. 2B is an enlarged sectional view taken along the line 2-2 of Fig. IB;
  • Fig. 3B is a graphic representational view of a slat profile which is representative of the "family" of slats of novel sinusoidal cross-sectional profiles according to this invention
  • Fig. 4B is a graphic representational view of a slat profile which, while not a preferred embodiment, is presented to illustrate the an extreme example of the intended scope of the present invention.
  • Fig. 5B is an enlarged partial fragmentary perspective view illustrating optional notches formed in the slats according to this invention.
  • Fig. 1A is a familiar view of a Venetian or horizontal blind 10A which is presented in the drawings with slats 12A according to the present invention. While, obviously, this invention is not responsible for creation of the basic Venetian blind, it nonetheless is responsible for creating an entirely new
  • Venetian blind which incorporates the new slats as components thereof, and which exhibits features never before enjoyed with a conventional Venetian blind.
  • the blind 10A includes a header 14A which is secured to a frame or wall (not shown) and from which the slats 12A are suspended by means of supporting webs 16A secured at their extremities to vertically extending tapes 17A to form a ladderlike structure at no less than two locations.
  • the distance "D" between these tapes defines an unsupported span along which none of the slats 12A according to this invention sags.
  • slats 12A extend to free, unsupported ends in cantilever fashion a distance "C", along which none of the slats 12A of this invention sags.
  • Slats 12A are tilted forwardly or rearwardly by means of tilting cords 18A, and are raised and lowered by means of an elevating cord 20A.
  • Slats 12A are shaped or profiled, with a cross- sectional shape which is both aesthetically pleasing and structurally having a beam moment of inertia capable of
  • any of a variety of curved, angled straight legs or combined profiles are contemplated by the invention.
  • an arcuate shaped slat 12A is shown in Figs. 2A and 3A, while Fig. 4A illustrates a slat with a double-camber profile, to demonstrate the flexibility afforded by the present invention.
  • the radii "R" associated with curved vanes may be varied, as may the height "H” of the crown of any particular slat shape.
  • curves without true radii are examples of curves without true radii.
  • Slats 12A may be formed of a single fibrous layer, or may be of a multi-layered construction.
  • Fig. 5A illustrates a slat construction wherein a balanced, multi-layered slat
  • construction includes upper and lower fibrous layers 22A and 24B, between which spun bond layers 26A and 28A are situated and, within which, an optional film layer 30A is at the center.
  • An optional outer layer 31A of decorative yarns is shown in Fig. 5A adjacent fiber layer 22A, and serves as additional means for controlling the aesthetic overall appearance of the slat 12A.
  • stitching 33A which penetrates all layers.
  • Fig. 6A illustrates a slat construction wherein a fibrous or fiber web 32A is attached to an optional film layer 34A, while an optional spun bond layer 36A is secured to this combination at a side of the slat opposite that of the fiber web. Stitching 33A holds this combination together, as in the case of the combination of Fig. 5A.
  • Fig. 7A the sequence of forming a slat according to the present invention is illustrated, with some but
  • Fig. 8A is presented to illustrate the bidirectional piercing of web 40A without any associated layers.
  • transverse extensions of fibers 50A and their needle-caused protrusions actually serve as fiber "rivets" or holding means which tangle or frictionally engage and hold together the layers emerging from loom 46A.
  • the extent and quantity of the protruding fibers 50A, and the density of needle penetration provide control of the "feel" of the resulting product, as well as means for
  • the holes 54A formed by needles 48A may be left open or filled, to control the amount of unobstructed light which will be able to penetrate the finished product - the slat according to the present invention.
  • the stroke of the needles 46A will govern the cover, appearance and feel of the finished slat.
  • stitching zone 56A where any of a variety of stitching patterns is added to the felt.
  • a fine tricot for example, will yield a decorative pattern, as will a malimo or arachne or other suitable stitch-through pattern.
  • the stitched felt 52A thereafter leaves the stitching zone 56A and enters a molding/resinating zone 58A from which a rigid textile slat having resilience emerges.
  • a resin is added to the stitched felt. This resin may include
  • the present invention contemplates either use of a resin, as aforesaid, or the use of one or more fusible fibers in predetermined percentages in the makeup of the textile slat, such that without a resin present, the profile is achieved by fusing the fiber makeup in its desired functional form.
  • appearance of the finished slat may be varied by the addition, for example, of decorative yarns which are stitched to the fibrous web, or through pinsonic-type alterations in the surfaces of the slat which will yield a textile appearance.
  • the slats of the present invention are capable of being die cut or drilled with no loss of shape, and no
  • Such cuts may be desirable for cords or chains, and there will be no fraying or loss of cut shapes - thereby enabling clean, precision sizing and shaping of the cut holes or openings. Similarly, there will be no loss of slat resiliency as a result of such cutting, the shape or outline of the cut being maintained after the cutting operation.
  • the rigid textile slat of this invention which does not sag and which gives the feel and aesthetics of textile (or fabric) is accomplished because the slat is in fact a textile. True fabric appearance and feel of this invention is not attainable in the case of laminations of the prior art.
  • Fig. IB is a perspective view of a horizontal or venetian-type blind 10B, viewed from the right, and made up of or including a plurality of horizontally extending slats 12B according to the present invention.
  • My invention contemplates both the novel slats 12B described herein, per se, as well as the blind
  • Blind 10B includes a header 14B which is to be secured to a frame or wall (not shown) and from which the slats 12B are suspended by means of forward and rearward supporting cords 16B and 18B, respectively, at a pair of spaced-apart locations. Supporting cords 16B and 18B, which extend
  • horizontal members 19B form a ladder-like structure which assists the user in raising, lowering, and opening and closing blind 10B.
  • the distance between supporting cords 16B defines an unsupported span along which none of slats 12B sags,
  • slats 12B extend unsupported in cantilever fashion a predetermined distance along which, again, none of slats 12B sag. Elevating control cords 2OB are fragmentarily illustrated in Fig. IB, as are slat tilting control cords 22B.
  • Slats 12B extend substantially horizontally and preferably, but not necessarily, include a substantially uniform cross-sectional profile of novel configuration which is not only aesthetically pleasing, but also structurally of a beam moment of inertia capable of supporting a relatively rigid slat without sagging.
  • slats 12B are contemplated as being the same as described for slats 12A, and what is set forth above in connection with slats 12A is incorporated herein by reference as if fully set forth again.
  • Blind 10B further includes at least two central control cords 24B which extend through slots 27B formed through predetermined locations in slats 12B, best seen in Fig. 2B.
  • Blind 10B illustrated in full line (as opposed to broken line) sectional view in Fig. 2B is shown in "closed” or light- trapping configuration.
  • Broken or phantom lines in Fig. 2B illustrate the relative disposition of slats 12B when the blind 10B is in a more open condition.
  • Fig. 3B a preferred or best mode of the slat profile according to my invention is illustrated in a graphical representation. While this preferred or best mode is presented here, it should be understood that my invention contemplates variations and a scope which should not be limited to the examples presented here.
  • a reference sinusoidal waveform is illustrated in phantom or broken lines and assigned reference character 26B extending along an abscissa or horizontally shown reference axis 28B, which is not necessarily to be construed as or limited to the axis of a true sine wave, for reasons that will be apparent from this specification.
  • Sinusoidal waveform 26B is a thirty (30) degree sine wave, with arcuate portions of substantially equal radii R1 and R2 extending above and below axis 28B. These radii are joined by a line extending through and intersecting axis 28B at what will be referred to herein as a tangent point 30B.
  • the profile of a slat 12B is shown in Fig. 3B
  • a rearward slat edge 32B is shown coinciding with the point of greatest amplitude or distance of sine waveform 26B from its axis 28B, while the forward edge 34B of slat 12B preferably, but not necessarily, coincides with a point along sine wave 26B which is not at its point of greatest amplitude which, as shown in Fig. 3B, is offset a distance D3 from axis 28B as the slat is shown oriented. And yet, the offset
  • distances D1 and D2 between axis 28B and these rearward and forward slat edges 32B and 34B, respectively, are preferably equal in magnitude.
  • Distance L1 in the same view is preferably shorter than distance L2.
  • slat 12B is not truly symmetrical, although, again, I do not wish to be limited to the example shown in Fig. 3B.
  • the overall width of slats 12B which have been tested is approximately two inches, although other widths are contemplated by this
  • radii R1 and R2 may be varied such that they are unequal. This invention contemplates coverage of truly symmetrical slat profiles as well.
  • Fig. 2B attempts to illustrate the slat configuration just described for Fig. 3B, and further attempts to illustrate the relative disposition between central blind control cord 24B and the slats 12B through which it extends.
  • this view it is also seen that there is an overlap between the concave surface of rearward slat curved portions 36B and that of forward depending slat curved portions 38B, which form what I will sometimes herein refer to as horizontally extending, light-trapping "pockets" or areas defined by these two opposing concave surfaces. In a best or preferred mode, there is approximately one eighth inch overlap.
  • slats 12B are formed with notches 40B in either one or both of slat edges 32B and 34B at locations coinciding with the placement of support cords 16B and 18B, such that these support cords actually extend through these notches (see Fig. 5B). This will permit a closer proximity and even a possible contacting of one or more of the slat edges 32B and 34B, giving the blind 10B a greater degree of closure, and providing other pleasing
  • reference line 52B between edges 32B and 34B at least one substantially closed area is defined on each side of reference line 52B, whether the slat is formed with curved, straight, or combined portions. Such areas are designated A1 and A2 in Fig. 4B.
  • the present invention relates generally to window blinds and more particularly to the construction of such blinds with profiled slats fabricated of textile materials where the shape acts to better seal the spaces between the slats when completely closed and which are capable of effectively
  • slats may be stiffened by additional layers of plastic or metal but this is not the most desirable solution as thinner slats are preferred by the industry.
  • the present invention offers a solution to this problem whereby under the same stress conditions and factors, the moldable textile slat has the ability to spring back to its original form whereas the metal slat will remain bent or dented. See Fig. 3.
  • the textile molded blind will retain its concave shape and structure in circumstances where a metal or plastic blind would become permanently damaged.
  • Another object of the present invention is to provide a horizontal blind system which can be energy-conserving by reflecting and partly absorbing the solar heat rays.
  • the present blind system provides moldable materials constructed from one or multiple layers of textile formations which are manufactured either form 100% synthetic fibers (which have the best moldability value) or a combination of any man- made fibers blended with natural fibers. This point of moldability is achieved by the portion of chemical substances incorporated into the textile structure.
  • This structure may comprise low-melting synthetic fibers, films of low or medium- melting points or resins which are thermo-plast at lower or medium-melting temperatures, preferably a few degrees lower than the melting point of the major textile material used as a carrier for the construction.
  • compositions of slats and slat components the present invention provides.
  • U.S. Patent 4,333,509 granted to William H. Conn on June 8, 1982 discloses a wooden Venetian blind slat fabricated of sections wherein the end of a slat section is cut transversely and provided with a notch to form with a corresponding notch in the other slat section.
  • the sections are joined by a pair of pins of differing length extending from one section being inserted into the holes in the second section at points where the lift strings and tilt ladders are positioned.
  • the stated purpose of this construction is to facilitate the replacement of a broken horizontal slat, to strengthen the slat at its weakest point and economy in manufacturing.
  • U.S. Patent 4,276,954 granted to Paul L. Romano on July 7, 1981 discloses an adjustable light and air admitting barrier that absorbs and blocks the transmission of sound comprised of a plurality of elongated, self-supporting vertical blades
  • the slats are fabricated from an
  • spirally wound paper tube of circular cross section made by conventional techniques with adhesive between the paper layers.
  • the slat comprises end servations or transverse lines of weakness inscribed, cut or otherwise formed by any convenient technique at regularly spaced intervals.
  • the flattened paper tube window shade slat is subject to separation by tearing or breaking in order to conveniently shorten the slat to a desired length.
  • U.S. Patent 3,645,317 to Charles H. Malone on Feb. 29, 1972 discloses a horizontal Venetian blind comprising a horizontal plastic slat and a flexible tape formed of sound deadening and heat insulating material covering one side surface of the slat coated with an adhesive on one surface for attachment to the slat.
  • the tape is fabricated with longitudinal slits and intersecting slits and intersecting holes at the end edges adapted to receive the ropes of a venetial blind to facilitate its attachment to the slat.
  • the object of the invention is to enable a Venetian blind provided with the coating tape to become fully closed so as to keep out any light, sound, heat or cold.
  • U.S. Patent 3,031,013 to Alfred W. Russell on April 24, 1962 discloses a self-supporting structural member formed by bonding two or more sheets of plastic material into a unit having a central longitudinally extending cavity.
  • a reinforcing rod is positioned therein which serves a pivotal supporting member on each end of the unit providing a structure of strength and rigidity where resistance to twisting is necessary so that the unit may be used as a slat or louver.
  • the structural member may be fabricated entirely of plastic material or a thermo- setting resin may be used in conjunction with layers of fiber such as glass or synthetic fiber and then cured without applied pressure.
  • U.S. Patent 2,620,868 granted to Harry S. Rosenbaum on Dec. 9, 1952 discloses a tape holder for securing the upper ends of the tape ladders to the tilting mechanism for tilting the slats of a Venetian blind.
  • the said tape holder is fabricated from a strip of sheet metal bent transversely at the central portion into a U-shaped cross section having an opening at the bottom extending substantially the entire length of the holder, the other end having an extension with an opening adapted to receive the tilting shaft.
  • the two legs of the U snap over the titling shaft to permit concomitant rotation of the holder with the shaft while an adjacent pointed projection serves to retain the holder on the shaft.
  • U.S. Patent 2,567,256 to Andrew J. Toti and Peter Princevalle on Sept. 11, 1951 discloses a horizontal venetial blind slat of thin wood, plastic or metal with undulating uniform sinuous curves on opposite margins substantially in phase which are complemental to one another and extend crosswise the width of the slat.
  • the bodies of the slats are wide enough and arranged to shut off the spaces between the slat undulations when the slats are tilted to overlapped positions so as to completely shut out incoming light.
  • the horizontal slats present a drapery-like effect when in a closed position maximized when the slats are considerably wider than regular slats as
  • U.S. Patent 2,503,074 to John Seagaard and Thomas Triolo on April 4, 1950 discloses a clip for Venetian blind slats and a slat having a transversely elongated cord opening and slat extending from said opening to an adjacent edge of the clip.
  • the clip comprises a spring normally extending across the slat to close the same having the ability to be flexed toward one side of the clip to open the slat upon movement of the slat causing the cord to press against the spring.
  • the forward and rear edges of the clip grip the edges of the slat and therefore permit removal of the slat from the Venetian blind assembly for repair or replacement.
  • U.S. Patent No. 2,498,909 to Stephen D. Bradley patented on Feb. 28, 1950 discloses an end cap for horizontal plastic or metal Venetian blind slats fabricated from a resilient plastic material.
  • the cap has a U-shaped body with rounded end
  • U.S. Patent 2,413,464 granted to Alexis Nihon on Dec. 31, 1946 discloses a translucent glass Venetian blind slat having a flat horizontal body and a bead at one edge and the means of
  • a metal clip is attached at each end thereof having a lug as an extension of the back edge which is apertured to allow the draw-cord through or a modified clip may be attached to the bulb edge of the slat behind the tape and used in conjunction with a pulley
  • the clip facilitates the removal of individual slats for replacement purposes and permits said slats to be inclined in closed head-to-body position.
  • U.S. Patent No. 2,326,454 to Scipio S. Gentile patented on Aug. 10, 1943 discloses a slat for venetial blinds fabricated of paper or thin fiber comprising a flat base member and an arched upper member.
  • the margins of the base are folded over the margins of the upper member and secured by crimping, riveting, gluing or other means, thus stretching the lower member and maintaining the lower surface of the slat in a plane at all times.
  • the width or transverse section of the upper portion of the slat is greater than that of the lower portion, creating the arched effect when the two edges are secured together and providing the slat with sufficient strength, and stiffness to be self-supporting by maintaining a straight edge without any reinforcement.
  • U.S. Patent 2,315,640 to Lulan S. Morse and Clarence W. Morse on April 6, 1943 discloses a curved metal Venetian blind slat having a pre-formed laterally convex crown, rounded corners, straight edges and an elongated aperture at each end for suspension cords.
  • the slat is fabricated of cold rolled high carbon steel of single thickness possessing sufficient
  • U.S. Patent 2,263,540 granted to Samuel J. Johnson on Nov. 18, 1941 discloses a slat for Venetian blinds fabricated of either heavy paper, a cardboard, cloth or composition materials reinforced and strengthened in such a way that warping and sagging are avoided in the transverse direction.
  • the slat is formed from a single sheet of flat material folded to provide a top, side and bottom walls and an end wall with a flap adapted to be folded inwardly and secured by adhesive to the inner surface of the top wall.
  • the invention provides a slat of light, inexpensive material that is durable, easy to clean and manufacture, yet is sufficiently strong and rigid.
  • U.S. Patent 2,209,355 to Herbert J. Schmitz patented on July 30, 1940 discloses a metal Venetian blind slat formed of a thin flexible material shaped with a gentle concave curvature transversely across its width. Relatively narrow edge flanges are bent angularly and backwardly with respect to the main curvature but inclined at wide angle with respect to one
  • U.S. Patent 2,146,816 to George A. Grassby patented Feb. 14, 1939 discloses a slat for a Venetian blind fabricated of sheet metal and having a flat S-shaped transverse cross section with the edges recurved on relatively short radii to form concave- convex reflecting surfaces.
  • the slats are arranged so that the convex upwardly directed curve is adjacent to the outside of the window and the curved edges are arranged so that the concave-convex surface adjacent the outside has its concave side directed upwardly and its convex side downwardly.
  • This construction serves to keep a very large percentage of light and heat out of a building by diffusing and reflecting incoming light rays.
  • U.S. Patent 2,121,217 granted to Charleton Ellis on June 21, 1938 discloses a Venetian blind slat composed of a laminated plastic or paper material comprising a resin or binder of the thermosetting type with a paper filler.
  • the slat is reinforced in the form of thickened edges by folding the material over on itself along the entire edge toward the center line of the slat and press the composition to cause the thickened edges to merge with the slat structure creating a tapered effect.
  • thickened edges prevent sagging and warping and significantly reduce the accumulation of dust on the slat.
  • U.S. Patent 932,127 granted to Azel C. Hough on Aug. 24, 1909 discloses a horizontal slat for porch-shades and Venetian blinds molded and pressed into shape out of layers of any suitable material such as wood or vegetable matter while in the form of pulp.
  • Three reinforcing members preferably made of wire are embedded lengthwise in the pi stic mass to impart thereto the necessary strength and rigidity.
  • the slat may be equipped at one or both edges with fastening attachments in the form of loops having their shanks embedded in the slat to be employed as a means of suspension for the blind.
  • the object of the invention is to provide a strong, durable uniform slat adapted to be utilized as a weft unit in shades as an
  • U.S. Patent 173,224 to Damon Y. Kilgore patented on Feb. 8, 1876 discloses an adjustable slat for window blinds and the means of raising, lowering and operating the same by cords and pulleys.
  • the slats are lapped at their inner ends by means of two bands while the center portion contains the two opposite ends which may be pulled out.
  • the position of the slats is controlled and regulated by the same cords by which the blind is suspended and by simultaneous pulling of these cords the slats may be elevated to any desired height.
  • a blind constructed from 100% synthetic fiber, resin finished and molded at 400oF will perform equally in all aspects as a blind constructed of synthetic fibers combined with thermoplast resins functioning as a vehicle for moldability at lower temperatures and molded at 300*F.
  • thermoplast resins in a percentage or portion which is able to reach the supporting factor of the construction.
  • Fig. 1 is a section view of the molding process wherein (A) represents the material as it enters the molding system and (B) represents the material during the molding process of a 3" or 3 1/2" profiled slat.
  • Fig. 3 is a representation of a comparison of 11b. of pressure applied to a molded textile slat and a profiled aluminum slat.
  • Fig. 4 is a partial view of the material during the molding process of a 2" profiled slat.
  • Fig. 5 is a partial view of the material during the molding process of a 1" profiled slat.
  • Fig. 6 is a representation of the material and the slitting, molding and cutting systems as arranged during the molding process.
  • Fig. 7 is a cross-sectional side elevational view of the novel profiled cloth slat embodying the invention.
  • Fig. 8 is a cross-sectional side elevational view of the profiled cloth slat comprising novel features of the invention.
  • Fig. 9 is a partial schematic and partial realistic plan view of an alternative preferred embodiment of the present invention in which the system of the invention comprising the method, apparatus and product are illustrated.
  • Fig. 10 is a side elevational view of the system of Fig. 9.
  • Fig. 11 is a sectional view taken along line 11-11 of Fig. 9, illustrating one of several embodiments of blind slats according to the present invention.
  • Fig. 12 is a sectional view taken along line 12-12 of Fig. 9.
  • Fig. 13 is a partial fragmentary elevational view taken along line 13-13 of Fig. 9.
  • novel blind slats capable of existing in a variety of materials, shapes and forms including, without limitation, a single layer of material or a combination of layers thereof; (2) novel methods of making each and all of the aforesaid blind slats; and (3) novel apparatus for
  • Fig. 6 illustrates the system preferred in fabricating the profiled cloth slats and blind systems of the present invention.
  • the finished material 2 enters the system 11 as a 47" wide roll, for example and is score cut 7 into strips of the desired width 8.
  • the score cutting function is controlled by means of air pressure 10 applied to the cutting system 9 to which the cutting blades 7 are attached.
  • the cutting system is not fixed and the position of the blades can be varied in order to obtain slats of different widths as desired.
  • the flatstrips of finished material are fed into molding tubes 1 which are so mounted that hot air 4 in a desired temperature range is applied by means of tube 12 and individually supplied to each molding tube 1 by connection 3.
  • molding process itself occurs inside molding tube 1 and is best illustrated in Fig. 1 wherein in part A the flat strips of material 2 enter the molding tube 1 and while
  • the hot air 4 is applied to the cloth strip by connection 3, as shown in part B.
  • the cloth strips acquire the concave curvature at this point in the molding process as the resins contained in the material are softened sufficiently by the hot air flow 4 for the cloth strips to assume the shape of the molding tube.
  • the exposure time of the material in the molding tube 1 is a minimum of 3 seconds and the preferred tube length is 36 inches allowing for a molding speed of 20 yds. per minute.
  • the thickness of the material 1 is before molding is 0.060 inches and remains stable throughout the molding process, thus assuring a constant thickness of the blind slats.
  • the profiled cloth strip 15 is cooled by a cold air flow 13 immediately upon leaving the molding tubes 1 while moving along metal throug 14, thereby insuring that the cloth slats retain their profiled shape.
  • the profiled cloth strip is cut to desired length.
  • the diameter of the molding tube 1 can be constant at greater than 3 1/2 inches diameter for blind slat widths of 3 1/2 inches to 2
  • the molding tube diameter may be small for slat widths of less than one inch. As seen in Fig. 5, a 1/2 inch wide slat requires that the preferred molding tube 1 diameter be no larger than one inch.
  • Figs. 7 and 8 Some novel features of the invention are illustrated in Figs. 7 and 8, wherein the profiled cloth slat 2 in Fig. 7 comprises a top layer 17 of bonded nov-woven 100% polyester material, a center layer 18 of needlepunched non-woven 100% polyester and another top layer 17.
  • Fig. 8 illustrates a profiled cloth slat comprising a top layer 19 of metalized 100% polyester, a supporting layer 21 of heat bonded non-woven 100% polyester and another top layer 19. Both slats in Fig. 7 and 8, respectively are stitched polyester filament with an acrylic binder saturation of 20%.
  • a system 50 of this invention is shown to include a feed spool 52 journalled upon shaft 54, from which a substantially continuous layer of stock 56 precut to a desired width is fed.
  • the specific makeup of stock 56 is predetermined and widely variable, depending upon the desired characteristics of the finished product, including aethetics, strength, hand, insulating ability, to name only a few by way of example.
  • Stock 56 progresses to and through a cutting or slitting assembly 58 consisting of a plurality of spaced-apart rotary knives 60, each of which comprises a cutting edge capable of continuously cleanly piercing the entire thickness of stock 56 which, at slitting assembly 58, passes over backing roller 62 at the time of cutting or slitting.
  • This invention contemplates a mere cutting of stock 56 by means of knives 60, with no waste material removed, as well as providing for a variety of cutting shapes not described in detail in the present specification.
  • the stock 56 comprises a
  • Fig. 11 in an enlarged sectional view illustrates an upper polyester felt layer 68 adjacent a mylar layer 70 to which an exaggerated view of the mylar's nonwoven reinforcement 72 is prebonded, and against which bottom or lower polyester felt layer 74 is bonded.
  • reinforcement layer 72 is provided to give body to as well as to discourage undesirable tearing of mylar 70 during handling prior to bonding within stock 56.
  • polyester felt layers 68 and 74 each further provide an
  • invention contemplates stock 56 consisting solely of a single layer of such polyester felt.
  • the mylar provides a thermal or heat transfer barrier which, for example, where it is desired to cool the interior of a room such as by air
  • the mylar serves to prevent heat transfer from the warmer ambient or outer environment to the cooler inner air.
  • the same mylar serves to prevent heat transfer from the room to the surroundings.
  • the layer of mylar 70 may be metallized with a deposition of a reflecting medium upon at least one side thereof.
  • Fig. 11 The overall thickness of the strip section shown in Fig. 11 may , by way of example, only, be 0.5 millimeters or any other desired or predetermined thickness.
  • Fig. 12 is an attempt to illustrate an ability of the system of the present invention to create and form alternative cross-sectional shapes such as the "wrapped" embodiment 76, wherein lower layer 74 is wider and extends about the side edges of the remaining layers of the strip 64.
  • each form roller assembly 80 includes an upper roller 82 formed with an outer working convex surface 84 and being journalled upon an idler shaft 86, and a lower roller 88 formed with an outer working concave surface 90 matingly proximate surface 84 of its adjoining roller, and journalled upon a drive shaft 92 carried within a bearing 94 intermediate the rollers and a distant sprocket wheel 96 which, in turn, is driven via motor 98 by a drive chain 100.
  • the gripping friction on strips 64 between rollers 82 and 88 serves to "pull" the stock 56 from its roll or spool.
  • forming/cooling chamber 102 of system 50 is there a drive chain associated with form roller assemblies, however the invention contemplates placement of same in either or both locations.
  • Fig. 13 illustrates same within the
  • the relatively softened and formable strips 64 pass between rollers 82 and 88, and assume the profile or shape of the working surfaces
  • the amount of travel within each chamber, and the working temperatures within each chamber are selectable and controllable to provide a quality product of repeatedly
  • strips 64 After leaving heating/forming chamber 78, strips 64 enter forming/cooling chamber 102 and pass between form roller assemblies comparable to assemblies 80 (and therefore assigned the identical reference characters).
  • These formed strips 64 now leave forming/cooling chamber 102 and progress to a slicing station or assembly 108 at which a blade 110 reciprocably moves up and downwardly through the path of each strip 64 at a controlled speed and timing, thereby forming cut length slats 112 capable of use in connection with window blinds.
  • These slats 112 may at the same slicing station be die cut with other functional openings useful with mechanisms of one or more blind manufacturers, before being accumulated in stacked configuration within a temporary or movable or permanent holding bin 114.
  • pre-heat chamber 66 may be entirely eliminated without
  • rollers with convex/concave or other profile surfaces may only be provided within the rollers with convex/concave or other profile surfaces
  • the preferred heating chamber temperatures at which forming is desired, while being in the range of 360o to 420o may be at other controllable temperatures that will yield favorable results.

Abstract

The present invention provides a system which includes a shaped or profiled elongated textile slat (12A) for use in venetian blinds and which includes a composite textile product achieved by needle punching and stitching using one or more of a variety of textile technologies, resinating and thereafter molding the same into an elongated textile slat (12A) having a profile which is other than truly flat or planar. In an embodiment the elongated textile slat (12A) is a multi-layered slat construction including upper and lower fibrous layers (22A), (24A) between which spun bond layers (26A), (28A) are situated and, within which, an optional outer layer (31A) of decorative yarns is disposed adjacent fiber layer (22A), and serves as enhancing the overall aesthetic appearance of the slat (12A). The combination of layers just described is held together by stitching (33A), which penetrates all layers. The profiles of slats (12B) are generally sinusoidal and adjacent slats (12B) cooperate to create a light trap therebetween.

Description

TEXTILE FABRIC HORIZONTAL BLINDS & SLATS
The present application is a continuation-in-part application of copending application Serial No. 187,323 filed on May 10, 1988 entitled TEXTILE FABRIC HORIZONTAL BLIND SLAT which, in turn, is a continuation-in-part application of copending application Serial No. 144,212 filed January 15, 1988 entitled PROFILED VERTICAL/HORIZONTAL BLIND which, in turn, is a continuation of application Serial No. 081,495 filed August 4, 1987 which, in turn, is a continuation of application Serial No. 014,558 filed February 13, 1987 which, in turn, is a continuation of application Serial No. 907,558 filed September 15, 1986 which, in turn, is a continuation of application
Serial No. 851,831 filed April 14, 1986 which, in turn, is a continuation of application Serial No. 789,858 filed October 21, 1985 which, in turn, is a continuation of application
Serial No. 724,694 filed April 18, 1985 which, in turn, is a continuation of application Serial No. 665,904 filed October 29, 1984 which, in turn, is a continuation of application
Serial No. 585,642 filed March 9, 1984 which, in turn, is a continuation-in-part of application Serial No. 434,461 filed October 15, 1982. The assignee of each and all of the
foregoing applications, together with the present application which claims the October 15, 1982 filing date as to common subject matter, is Polylok Corporation.
NOTE; To assist the reader, the present
specification has been divided into two primary portions, the first portion of which consists of two subsections directed, respectively, to Figs. 1A through 9A and Figs. 1B through 5B. This first portion addresses the textile fabric horizontal blind slat according to the present invention, including a novel "family" of S-shaped or reverse curve cross-sectional slat profiles and blinds made up therof having light-trapping characteristics, and the second portion (Part II) of which includes the remainder.
The present invention relates generally to Venetian or window-type blinds, and more particularly to a novel concept and system of blinds and textile slats used therein.
To my knowledge, there has never existed a shaped or profiled rigid, resilient textile slat capable of use in horizontal Venetian-type blinds, other than lamination
attachments of fabric to aluminum or polyvinyl chloride (PVC) by means of glue or inserts, for example.
Apart from the added cost, added handling in fabrication, additional materials, additional equipment and other undesirable requirements associated with the type of prior art characterized by such laminations, the prior art products themselves are simply unable to exhibit or achieve the novel and desirable characteristics of the present invention, including, without limitation, the ability to permit controlled penetration of light which will yield privacy as well as illumination. A need has existed until the present time for a horizontal type window or Venetian blind having slats which exhibit true textile appearance and feel, while being able to operate in a window environment in which temperatures may reach 150 degrees F., in which the relative humidity may reach 90 percent, and in which exposure to direct sunlight is expected.
It is an object of the present invention to provide a profiled or shaped textile slat capable of use in a Venetian- type horizontal blind, wherein the slat exhibits the appearance and feel of a textile. It is another object of the present invention to provide such a slat, which includes at least one textile element.
Another object of this invention is to provide such a slat, which includes a fibrous means for holding a
predetermined quantity of a resin.
Yet a further object is to provide such a slat which is able to perform without sagging according to its intended function in an environment in which temperatures may reach 150 degrees F., relative humidity may reach 90 percent, and
exposure to direct sunlight is expected.
Still another object of the present invention is to provide such a slat which, upon being deformed from an
unstressed shape to a degree that would exceed yield points of permanent deformation of a conventional metal Venetian blind slat of similar unstressed shape, will retain sufficient resilience to enable an uninfluenced return to said unstressed shape without any permanent deformation.
Yet a further object of the present invention is to provide such a slat which includes means for enabling reshaping by hand to an original unstressed shape after deformation.
Another object of this invention is to provide a blind including such textile slats which provide privacy through a degree of light penetration which, in turn, may be controlled and varied from light filtering translucency to room darkening and blackout.
Still another object of this invention is to provide such a blind, wherein each and all such slats are sufficiently rigid that they successfully resist sagging which, obviously, would destroy and render worthless both the aesthetics and functioning of the blind.
Yet still another object is to provide such slats which have the additional feature of being able to be drilled or die cut without losing their shape during the cutting operation, and permitting achievement of precise cut sizes and shapes, without fraying at the cut edges.
A further object is to provide such slats which include in their makeup one of the following bonding materials, namely: resins such as latex, polyurethane, urethane, epoxy, acrylic, melamine formaldahyde, polymer emulsions, copolymer emulsions, and hydrocarbons, and fusible chemicals.
Yet a further object of this invention is to provide such slats which may be molded into their desired profile or shape, through the use of thermoplastic, binding or thermal bonding fiber co in their makeup.
Another object is to provide such slats which are fusible and which include in their makeup a predetermined percentage of fusible fibers capable of holding a new shape when fused.
Still a further object of the present invention is to provide such slats which include a novel "family" of cross- sectional profiles of generally sinusoidal or S-shape,
sometimes herein referred to as a reverse curve shape.
Yet a further object is to provide horizontal or venetian-type blinds made up of or consisting of such S-shaped slats.
Another object is to provide such a horizontal or venetian-type blind which exhibits light-trapping
characteristics by means of cooperation between adjacent S- shaped slats.
Still a further object is to provide such slats and blinds, wherein optional notches formed in either one edge or both forward and rearward edges of the slats accommodate blind control cords, such that more complete light-trapping closure of adjacent slats is facilitated, which enable the blind assemblies to exhibit a more uniform or consistent appearance characterized by the absence of horizontal "bars" of relatively undiffused light common in conventional Venetian-type blinds.. In one embodiment of the present invention which is representative of a relatively simple form, a textile slat capable of use in a horizontal Venetian-type blind comprises an elongated member formed with relatively oppositely facing surfaces and having a cross-sectional profile or shape other than truly flat, this member including fibrous means for holding a resin, a resin held by the fibrous means, and surface means forming one of said surfaces for providing the appearance and feel of a textile. The surface means may comprise an embossed or pinsoniσ treated surface or may comprise the surface of an actual, true textile.
In another embodiment of the present invention, a "family" of such slats of sinusoidal cross-sectional profiles is provided to make up horizontal or venetian-type blinds which exhibit light-trapping and other superior characteristics.
Each slat includes one curved portion and at least one
additional reverse curve portion. Adjacent slats within such blinds overlap in cooperative relationships to provide novel structures, which enable the blind assemblies to exhibit a more uniform or consistent appearance characterized by the absence of horizontal "bars" of relatively undiffused light common in conventional Venetian-type blinds..
Other forms and arrangements of the present invention will become clearer from a detailed reading of this
specification, taken together with the accompanying drawings, in which:
Fig. 1A is a fragmentary left perspective view of a Venetian-type blind which includes novel textile slats
according to the present invention;
Fig. 2A is a fragmentary right perspective view of a slat according to the present invention;
Fig. 3A is a cross-sectional profile view taken along line 3A-3A of Fig. 2A; Fig. 4A is a cross-sectional profile view of an alternate slat according to another embodiment of this
invention;
Fig. 5A is an enlarged cross-sectional view of a portion of a five-layered, balanced slat according to the present invention;
Fig. 6A is an enlarged cross-sectional view of a portion of another layered slat according to the present invention;
Fig. 7A is a block-type flow diagram illustrating necessary and optional steps utilized in forming slats
according to the present invention;
Fig. 8A is an enlarged, fragmentary cross-sectional view through webbing being needle-punched in the formation of a slat according to this invention;
Fig. 9A is a top plan view of the upper surface of a textile slat according to this invention;
Fig. 1B is a right perspective view of a horizontal or venetian-type blind which includes textile slats of novel cross-sectional profiles according to the present invention;
Fig. 2B is an enlarged sectional view taken along the line 2-2 of Fig. IB;
Fig. 3B is a graphic representational view of a slat profile which is representative of the "family" of slats of novel sinusoidal cross-sectional profiles according to this invention;
Fig. 4B is a graphic representational view of a slat profile which, while not a preferred embodiment, is presented to illustrate the an extreme example of the intended scope of the present invention; and
Fig. 5B is an enlarged partial fragmentary perspective view illustrating optional notches formed in the slats according to this invention. Referring now in more detail to the drawings. Fig. 1A is a familiar view of a Venetian or horizontal blind 10A which is presented in the drawings with slats 12A according to the present invention. While, obviously, this invention is not responsible for creation of the basic Venetian blind, it nonetheless is responsible for creating an entirely new
component thereof - a new textile slat - and, thus, a new
Venetian blind which incorporates the new slats as components thereof, and which exhibits features never before enjoyed with a conventional Venetian blind.
The blind 10A includes a header 14A which is secured to a frame or wall (not shown) and from which the slats 12A are suspended by means of supporting webs 16A secured at their extremities to vertically extending tapes 17A to form a ladderlike structure at no less than two locations. The distance "D" between these tapes defines an unsupported span along which none of the slats 12A according to this invention sags. On either side of tapes 16A, slats 12A extend to free, unsupported ends in cantilever fashion a distance "C", along which none of the slats 12A of this invention sags. Slats 12A are tilted forwardly or rearwardly by means of tilting cords 18A, and are raised and lowered by means of an elevating cord 20A.
Slats 12A are shaped or profiled, with a cross- sectional shape which is both aesthetically pleasing and structurally having a beam moment of inertia capable of
supporting a relatively rigid slat without sagging. Thus, any of a variety of curved, angled straight legs or combined profiles are contemplated by the invention. For illustration purposes only, an arcuate shaped slat 12A is shown in Figs. 2A and 3A, while Fig. 4A illustrates a slat with a double-camber profile, to demonstrate the flexibility afforded by the present invention. The radii "R" associated with curved vanes may be varied, as may the height "H" of the crown of any particular slat shape. Similarly, curves without true radii are
contemplated, as are compound curves. Slats 12A may be formed of a single fibrous layer, or may be of a multi-layered construction. Fig. 5A illustrates a slat construction wherein a balanced, multi-layered slat
construction includes upper and lower fibrous layers 22A and 24B, between which spun bond layers 26A and 28A are situated and, within which, an optional film layer 30A is at the center. An optional outer layer 31A of decorative yarns is shown in Fig. 5A adjacent fiber layer 22A, and serves as additional means for controlling the aesthetic overall appearance of the slat 12A. The combination of layers just described is held together by means of stitching 33A, which penetrates all layers.
Fig. 6A illustrates a slat construction wherein a fibrous or fiber web 32A is attached to an optional film layer 34A, while an optional spun bond layer 36A is secured to this combination at a side of the slat opposite that of the fiber web. Stitching 33A holds this combination together, as in the case of the combination of Fig. 5A.
In Fig. 7A the sequence of forming a slat according to the present invention is illustrated, with some but
certainly not all optional components and their interrelationship are shown. A fibrous web 40A of any preselected weight and thickness, such as 2-6 ounces per square yard, is fed either alone or with optional layers of other webs and/or of film 42A and/or spun bond 44A to a needle loom 46A, where a plurality of needles 48A of preselected length and diameter are arranged in a preselected needle density. Needles 48A are caused with a variable stroke to penetrate the entire thickness of the web 40A and its associated layers from either one or both sides. Fig. 8A is presented to illustrate the bidirectional piercing of web 40A without any associated layers.
The piercing of web 40A by needles 48A results in a carrying or urging of otherwise random fibers 50A to and extending from the surface 52A through which the needle 48A emerges, with a resulting creation of a "tuft" or minute "mushroom" of fibers 50A which, collectively, cause a felt 52A to exit the needle loom 46A. In the cases where a plurality of layers is fed to and through the loom 46A, these minute
transverse extensions of fibers 50A and their needle-caused protrusions actually serve as fiber "rivets" or holding means which tangle or frictionally engage and hold together the layers emerging from loom 46A.
The extent and quantity of the protruding fibers 50A, and the density of needle penetration provide control of the "feel" of the resulting product, as well as means for
controlling the amount of resin held by the product, as will be explained further below. Furthermore, the holes 54A formed by needles 48A may be left open or filled, to control the amount of unobstructed light which will be able to penetrate the finished product - the slat according to the present invention. The stroke of the needles 46A will govern the cover, appearance and feel of the finished slat.
After leaving loom 46A, the felt 52A enters a
stitching zone 56A where any of a variety of stitching patterns is added to the felt. A fine tricot, for example, will yield a decorative pattern, as will a malimo or arachne or other suitable stitch-through pattern.
The stitched felt 52A thereafter leaves the stitching zone 56A and enters a molding/resinating zone 58A from which a rigid textile slat having resilience emerges. In the case of the resinated embodiment of the present invention, a resin is added to the stitched felt. This resin may include
polyurethane, latex, urethane, epoxy, acrylic, melamine
formaldehyde, polymer emulsions, copolymer emulsions, a or a hydracarbon. The present invention contemplates either use of a resin, as aforesaid, or the use of one or more fusible fibers in predetermined percentages in the makeup of the textile slat, such that without a resin present, the profile is achieved by fusing the fiber makeup in its desired functional form. Thus, NOT TAKEN INTO CONSIDERATION
FOR THE PURPOSES OF INTERNATIONAL PROCESSING
90 percent. There will be no loss of shape or profile, nor sagging. No undesirable twisting or turning will occur, even in direct sunlight. Spans of up to 16 inches and cantilevers of up to 8 inches will not prevent straight, non-sagging functioning and proper appearance of the slats and the
assembled blind. This is so with a variety of slat widths such as, by way of example only, 1/2 to 6 inch widths. The
appearance of the finished slat may be varied by the addition, for example, of decorative yarns which are stitched to the fibrous web, or through pinsonic-type alterations in the surfaces of the slat which will yield a textile appearance.
The slats of the present invention are capable of being die cut or drilled with no loss of shape, and no
permanent distortion. Such cuts may be desirable for cords or chains, and there will be no fraying or loss of cut shapes - thereby enabling clean, precision sizing and shaping of the cut holes or openings. Similarly, there will be no loss of slat resiliency as a result of such cutting, the shape or outline of the cut being maintained after the cutting operation.
It is important here to emphasize that with the slat of the present invention there is both a resiliency which permits self-restoring of shape and profile after relatively limited deformation, as well as a capability of the slat to be reformed to its original shape and profile, by hand and
wetting, after relatively drastic deformations (such as by twisting the slat into a knot, to give an example of the
"drastic" deformation).
The rigid textile slat of this invention, which does not sag and which gives the feel and aesthetics of textile (or fabric) is accomplished because the slat is in fact a textile. True fabric appearance and feel of this invention is not attainable in the case of laminations of the prior art.
Privacy through a controlled degree of light penetration, plus controllable translucency, is achieved. It is also important here to further emphasize that while examples of combinations of the fibrous web with film, such as polyester film - uncoated or coated such as with metal, spun bond layers, etc. are presented merely as examples of combinations achievable with the present invention.
Referring now to Figs. IB through 4B, inclusive, Fig. IB is a perspective view of a horizontal or venetian-type blind 10B, viewed from the right, and made up of or including a plurality of horizontally extending slats 12B according to the present invention. My invention contemplates both the novel slats 12B described herein, per se, as well as the blind
assemblies 10B including same.
Blind 10B includes a header 14B which is to be secured to a frame or wall (not shown) and from which the slats 12B are suspended by means of forward and rearward supporting cords 16B and 18B, respectively, at a pair of spaced-apart locations. Supporting cords 16B and 18B, which extend
vertically, together with interconnecting "rung"-type
horizontal members 19B, form a ladder-like structure which assists the user in raising, lowering, and opening and closing blind 10B. The distance between supporting cords 16B defines an unsupported span along which none of slats 12B sags,
according to this invention. On either side of supporting cords 16B and 18B, slats 12B extend unsupported in cantilever fashion a predetermined distance along which, again, none of slats 12B sag. Elevating control cords 2OB are fragmentarily illustrated in Fig. IB, as are slat tilting control cords 22B.
Slats 12B extend substantially horizontally and preferably, but not necessarily, include a substantially uniform cross-sectional profile of novel configuration which is not only aesthetically pleasing, but also structurally of a beam moment of inertia capable of supporting a relatively rigid slat without sagging. The flexibility of the present
invention, insofar as possible slat profiles is concerned, is illustrated above by way of example of the double-camber or S- shaped slat 12A illustrated in Fig. 4A. However in this subsection of the present specification, additional information concerning preferred designs is set forth.
It should be emphasized here that the material and structural makeup of slats 12B is contemplated as being the same as described for slats 12A, and what is set forth above in connection with slats 12A is incorporated herein by reference as if fully set forth again.
Blind 10B further includes at least two central control cords 24B which extend through slots 27B formed through predetermined locations in slats 12B, best seen in Fig. 2B.
Blind 10B illustrated in full line (as opposed to broken line) sectional view in Fig. 2B is shown in "closed" or light- trapping configuration. Broken or phantom lines in Fig. 2B illustrate the relative disposition of slats 12B when the blind 10B is in a more open condition.
The reader is directed to Fig. 3B at this point, wherein a preferred or best mode of the slat profile according to my invention is illustrated in a graphical representation. While this preferred or best mode is presented here, it should be understood that my invention contemplates variations and a scope which should not be limited to the examples presented here.
In Fig. 3B, a reference sinusoidal waveform is illustrated in phantom or broken lines and assigned reference character 26B extending along an abscissa or horizontally shown reference axis 28B, which is not necessarily to be construed as or limited to the axis of a true sine wave, for reasons that will be apparent from this specification. Sinusoidal waveform 26B is a thirty (30) degree sine wave, with arcuate portions of substantially equal radii R1 and R2 extending above and below axis 28B. These radii are joined by a line extending through and intersecting axis 28B at what will be referred to herein as a tangent point 30B. The profile of a slat 12B is shown in Fig. 3B
superimposed upon sine wave 26B in darker line, but without illustrating its thickness so that this view is more clear. As illustrated, a rearward slat edge 32B is shown coinciding with the point of greatest amplitude or distance of sine waveform 26B from its axis 28B, while the forward edge 34B of slat 12B preferably, but not necessarily, coincides with a point along sine wave 26B which is not at its point of greatest amplitude which, as shown in Fig. 3B, is offset a distance D3 from axis 28B as the slat is shown oriented. And yet, the offset
distances D1 and D2 between axis 28B and these rearward and forward slat edges 32B and 34B, respectively, are preferably equal in magnitude. Distance L1 in the same view is preferably shorter than distance L2.
It will now be appreciated that the best mode of slat 12B is not truly symmetrical, although, again, I do not wish to be limited to the example shown in Fig. 3B. The overall width of slats 12B which have been tested is approximately two inches, although other widths are contemplated by this
invention. Similarly, radii R1 and R2 may be varied such that they are unequal. This invention contemplates coverage of truly symmetrical slat profiles as well.
Fig. 2B attempts to illustrate the slat configuration just described for Fig. 3B, and further attempts to illustrate the relative disposition between central blind control cord 24B and the slats 12B through which it extends. In this view, it is also seen that there is an overlap between the concave surface of rearward slat curved portions 36B and that of forward depending slat curved portions 38B, which form what I will sometimes herein refer to as horizontally extending, light-trapping "pockets" or areas defined by these two opposing concave surfaces. In a best or preferred mode, there is approximately one eighth inch overlap.
In the embodiment of this invention illustrated in Fig. 2B, the permitted proximity of adjacent rearward and forward slat edges 32B and 34B is limited by the diameter or thickness of the braided central cord 24B. However, this invention contemplates an optional embodiment wherein slats 12B are formed with notches 40B in either one or both of slat edges 32B and 34B at locations coinciding with the placement of support cords 16B and 18B, such that these support cords actually extend through these notches (see Fig. 5B). This will permit a closer proximity and even a possible contacting of one or more of the slat edges 32B and 34B, giving the blind 10B a greater degree of closure, and providing other pleasing
aesthetic choices to the user of blind assemblies 10B.
By referring to a "family" of S-shaped or reverse curved slats, what is meant is that variations in curvature, specific shapes, and widths are contemplated as coming within the scope of this invention. I do not wish to be limited to S- shaped or sinusoidal shaped slats and, for this reason, have presented in Fig. 4B an extreme example of blind slats 50B which include only relatively straight portions 52B, 54B and 56B in profile. My invention further contemplates, without limitation, combinations of curved and straight portions. In this regard it can be seen that by drawing an imaginary
reference line 52B between edges 32B and 34B, at least one substantially closed area is defined on each side of reference line 52B, whether the slat is formed with curved, straight, or combined portions. Such areas are designated A1 and A2 in Fig. 4B.
Other forms and embodiments of the invention will suggest themselves to those skilled in this art and are
contemplated by me.
PART II
The present invention relates generally to window blinds and more particularly to the construction of such blinds with profiled slats fabricated of textile materials where the shape acts to better seal the spaces between the slats when completely closed and which are capable of effectively
resisting sagging or warping.
A major problem encountered with the use of metal or plastic in the fabrication of horizontal blinds is the tendency of these materials to become damaged when bent beyond their point of resiliency. The slats may be stiffened by additional layers of plastic or metal but this is not the most desirable solution as thinner slats are preferred by the industry.
The present invention offers a solution to this problem whereby under the same stress conditions and factors, the moldable textile slat has the ability to spring back to its original form whereas the metal slat will remain bent or dented. See Fig. 3. The textile molded blind will retain its concave shape and structure in circumstances where a metal or plastic blind would become permanently damaged.
Accordingly, it is an object of the present invention to provide a horizontal blind fabricated of textile materials with a profiled concave slat which is heat molded, self- supporting and rigid enough to resist sagging or warping.
Another object of the present invention is to provide a horizontal blind system which can be energy-conserving by reflecting and partly absorbing the solar heat rays.
The present blind system provides moldable materials constructed from one or multiple layers of textile formations which are manufactured either form 100% synthetic fibers (which have the best moldability value) or a combination of any man- made fibers blended with natural fibers. This point of moldability is achieved by the portion of chemical substances incorporated into the textile structure. This structure may comprise low-melting synthetic fibers, films of low or medium- melting points or resins which are thermo-plast at lower or medium-melting temperatures, preferably a few degrees lower than the melting point of the major textile material used as a carrier for the construction. Another important feature of the present invention which must be emphasized here is the ability of the present invention to provide slats having a very wide aesthetically pleasing range of colors, compositions, feels, textures and textile characteristics, to name a few, which will enable parties to color and fabric-coordinate rooms incorporating the blinds or other window or other structures in which slats according to the present invention are incorporated. There is no limit to the imagination for the variety of uses and
compositions of slats and slat components the present invention provides.
It is the combination of the foregoing features - structural and appearance - that give the present invention particular appeal as a substitute for the traditional aluminum and other rigid material slats.
Referring now in detail to certain prior patent art which, while not particularly relevant to the present invention as is here and will in continuing applications be claimed, the following brief abstracts of certain interesting and unrelated features disclosed therein are set forth in separate paragraphs in which each paragraph describes a particular patent.
U.S. Patent 4,333,509 granted to William H. Conn on June 8, 1982 discloses a wooden Venetian blind slat fabricated of sections wherein the end of a slat section is cut transversely and provided with a notch to form with a corresponding notch in the other slat section. The sections are joined by a pair of pins of differing length extending from one section being inserted into the holes in the second section at points where the lift strings and tilt ladders are positioned. The stated purpose of this construction is to facilitate the replacement of a broken horizontal slat, to strengthen the slat at its weakest point and economy in manufacturing.
U.S. Patent 4,276,954 granted to Paul L. Romano on July 7, 1981 discloses an adjustable light and air admitting barrier that absorbs and blocks the transmission of sound comprised of a plurality of elongated, self-supporting vertical blades
pivotally mounted and longitudinally parallel in a mutually spaced apart relation. The slats are fabricated from an
aluminum or plastic material to form a core containing a
relatively thin web extending across the full width of the core and a plurality of longitudinally extending, outwardly opening cavities on opposing sides of the core. Within the cavities is placed a sound-absorbing insulation materials such as rock wool or insulating foam or fiberglass; the said core is wrapped laterally with cover material such as burlap or a foambacked or absorptive cloth.
U.S. Patent 4,139,043 to John Donfrio patented on Feb. 13, 1979 discloses a window shade slat consisting of a flattened
spirally wound paper tube of circular cross section made by conventional techniques with adhesive between the paper layers. The slat comprises end servations or transverse lines of weakness inscribed, cut or otherwise formed by any convenient technique at regularly spaced intervals. With this
construction the flattened paper tube window shade slat is subject to separation by tearing or breaking in order to conveniently shorten the slat to a desired length.
U.S. Patent 3,645,317 to Charles H. Malone on Feb. 29, 1972 discloses a horizontal Venetian blind comprising a horizontal plastic slat and a flexible tape formed of sound deadening and heat insulating material covering one side surface of the slat coated with an adhesive on one surface for attachment to the slat. The tape is fabricated with longitudinal slits and intersecting slits and intersecting holes at the end edges adapted to receive the ropes of a venetial blind to facilitate its attachment to the slat. The object of the invention is to enable a Venetian blind provided with the coating tape to become fully closed so as to keep out any light, sound, heat or cold.
U.S. Patent 3,031,013 to Alfred W. Russell on April 24, 1962 discloses a self-supporting structural member formed by bonding two or more sheets of plastic material into a unit having a central longitudinally extending cavity. A reinforcing rod is positioned therein which serves a pivotal supporting member on each end of the unit providing a structure of strength and rigidity where resistance to twisting is necessary so that the unit may be used as a slat or louver. The structural member may be fabricated entirely of plastic material or a thermo- setting resin may be used in conjunction with layers of fiber such as glass or synthetic fiber and then cured without applied pressure.
U.S. Patent 2,620,868 granted to Harry S. Rosenbaum on Dec. 9, 1952 discloses a tape holder for securing the upper ends of the tape ladders to the tilting mechanism for tilting the slats of a Venetian blind. The said tape holder is fabricated from a strip of sheet metal bent transversely at the central portion into a U-shaped cross section having an opening at the bottom extending substantially the entire length of the holder, the other end having an extension with an opening adapted to receive the tilting shaft. The two legs of the U snap over the titling shaft to permit concomitant rotation of the holder with the shaft while an adjacent pointed projection serves to retain the holder on the shaft.
U.S. Patent 2,567,256 to Andrew J. Toti and Peter Princevalle on Sept. 11, 1951 discloses a horizontal venetial blind slat of thin wood, plastic or metal with undulating uniform sinuous curves on opposite margins substantially in phase which are complemental to one another and extend crosswise the width of the slat. The bodies of the slats are wide enough and arranged to shut off the spaces between the slat undulations when the slats are tilted to overlapped positions so as to completely shut out incoming light. The horizontal slats present a drapery-like effect when in a closed position maximized when the slats are considerably wider than regular slats as
heretofore manufactured. U.S. Patent 2,503,074 to John Seagaard and Thomas Triolo on April 4, 1950 discloses a clip for Venetian blind slats and a slat having a transversely elongated cord opening and slat extending from said opening to an adjacent edge of the clip.
The clip comprises a spring normally extending across the slat to close the same having the ability to be flexed toward one side of the clip to open the slat upon movement of the slat causing the cord to press against the spring. The forward and rear edges of the clip grip the edges of the slat and therefore permit removal of the slat from the Venetian blind assembly for repair or replacement.
U.S. Patent No. 2,498,909 to Stephen D. Bradley patented on Feb. 28, 1950 discloses an end cap for horizontal plastic or metal Venetian blind slats fabricated from a resilient plastic material. The cap has a U-shaped body with rounded end
positions at each end of the leg portions and an internal groove along the inside edges of the legs and the body. The side and end edges of the slat are fitted in the groove wherein the flanges on the cap will overlie a certain portion of the side edge of the slat preventing the slats from rattling when moved.
U.S. Patent 2,413,464 granted to Alexis Nihon on Dec. 31, 1946 discloses a translucent glass Venetian blind slat having a flat horizontal body and a bead at one edge and the means of
raising, supporting and tilting said slats. A metal clip is attached at each end thereof having a lug as an extension of the back edge which is apertured to allow the draw-cord through or a modified clip may be attached to the bulb edge of the slat behind the tape and used in conjunction with a pulley
arrangement. The clip facilitates the removal of individual slats for replacement purposes and permits said slats to be inclined in closed head-to-body position.
U.S. Patent No. 2,326,454 to Scipio S. Gentile patented on Aug. 10, 1943 discloses a slat for venetial blinds fabricated of paper or thin fiber comprising a flat base member and an arched upper member. The margins of the base are folded over the margins of the upper member and secured by crimping, riveting, gluing or other means, thus stretching the lower member and maintaining the lower surface of the slat in a plane at all times. The width or transverse section of the upper portion of the slat is greater than that of the lower portion, creating the arched effect when the two edges are secured together and providing the slat with sufficient strength, and stiffness to be self-supporting by maintaining a straight edge without any reinforcement.
U.S. Patent 2,315,640 to Lulan S. Morse and Clarence W. Morse on April 6, 1943 discloses a curved metal Venetian blind slat having a pre-formed laterally convex crown, rounded corners, straight edges and an elongated aperture at each end for suspension cords. The slat is fabricated of cold rolled high carbon steel of single thickness possessing sufficient
resilience to be coiled upon itself and upon release to resume its original performed curvature. The resilience and
flexibility of the slat effectively resists ordinary bending or other distortion; moreover when painted with a gloss paint a maximum of light will be reflected by the crown without glare. U.S. Patent 2,263,540 granted to Samuel J. Johnson on Nov. 18, 1941 discloses a slat for Venetian blinds fabricated of either heavy paper, a cardboard, cloth or composition materials reinforced and strengthened in such a way that warping and sagging are avoided in the transverse direction. The slat is formed from a single sheet of flat material folded to provide a top, side and bottom walls and an end wall with a flap adapted to be folded inwardly and secured by adhesive to the inner surface of the top wall. The invention provides a slat of light, inexpensive material that is durable, easy to clean and manufacture, yet is sufficiently strong and rigid.
U.S. Patent 2,209,355 to Herbert J. Schmitz patented on July 30, 1940 discloses a metal Venetian blind slat formed of a thin flexible material shaped with a gentle concave curvature transversely across its width. Relatively narrow edge flanges are bent angularly and backwardly with respect to the main curvature but inclined at wide angle with respect to one
another. These flanges are very narrow but provide the slat with needed rigidity while allowing the slats to rest evenly against one another when closed. The shape of the slat
diffuses the light when closed but allows the maximum amount of light through when the blind is open.
U.S. Patent 2,146,816 to George A. Grassby patented Feb. 14, 1939 discloses a slat for a Venetian blind fabricated of sheet metal and having a flat S-shaped transverse cross section with the edges recurved on relatively short radii to form concave- convex reflecting surfaces. The slats are arranged so that the convex upwardly directed curve is adjacent to the outside of the window and the curved edges are arranged so that the concave-convex surface adjacent the outside has its concave side directed upwardly and its convex side downwardly. This construction serves to keep a very large percentage of light and heat out of a building by diffusing and reflecting incoming light rays.
U.S. Patent 2,121,217 granted to Charleton Ellis on June 21, 1938 discloses a Venetian blind slat composed of a laminated plastic or paper material comprising a resin or binder of the thermosetting type with a paper filler. The slat is reinforced in the form of thickened edges by folding the material over on itself along the entire edge toward the center line of the slat and press the composition to cause the thickened edges to merge with the slat structure creating a tapered effect. The
thickened edges prevent sagging and warping and significantly reduce the accumulation of dust on the slat.
U.S. Patent 932,127 granted to Azel C. Hough on Aug. 24, 1909 discloses a horizontal slat for porch-shades and Venetian blinds molded and pressed into shape out of layers of any suitable material such as wood or vegetable matter while in the form of pulp. Three reinforcing members preferably made of wire are embedded lengthwise in the pi stic mass to impart thereto the necessary strength and rigidity. The slat may be equipped at one or both edges with fastening attachments in the form of loops having their shanks embedded in the slat to be employed as a means of suspension for the blind. The object of the invention is to provide a strong, durable uniform slat adapted to be utilized as a weft unit in shades as an
inexpensive substitute for the wooden slat.
U.S. Patent 173,224 to Damon Y. Kilgore patented on Feb. 8, 1876 discloses an adjustable slat for window blinds and the means of raising, lowering and operating the same by cords and pulleys. The slats are lapped at their inner ends by means of two bands while the center portion contains the two opposite ends which may be pulled out. By this method of lapping the slats the blind may be extended or contracted to fit any window. The position of the slats is controlled and regulated by the same cords by which the blind is suspended and by simultaneous pulling of these cords the slats may be elevated to any desired height.
Unlike the prior art, in the present invention, it is possible to achieve equal results with varying combinations and percentages of materials and chemicals. For example, a blind constructed from 100% synthetic fiber, resin finished and molded at 400ºF will perform equally in all aspects as a blind constructed of synthetic fibers combined with thermoplast resins functioning as a vehicle for moldability at lower temperatures and molded at 300*F.
Other combinations of materials according to the present invention which will provide an equally satisfactory blind may be fabricated of natural fibers combined with
selected thermoplast resins in a percentage or portion which is able to reach the supporting factor of the construction.
Synthetic fibers or a variety of blends with natural fibers or 100% natural fibers without any thermo-plast resins in an adequate proportion to fiber weight and the same moldability and performance will be achieved as with synthetic fibers.
These and other novel features of the invention will be more clearly understood from the following description of specific embodiments of the invention taken in conjunction with the accompanying drawings in which:
Fig. 1 is a section view of the molding process wherein (A) represents the material as it enters the molding system and (B) represents the material during the molding process of a 3" or 3 1/2" profiled slat.
Fig. 3 is a representation of a comparison of 11b. of pressure applied to a molded textile slat and a profiled aluminum slat.
Fig. 4 is a partial view of the material during the molding process of a 2" profiled slat.
Fig. 5 is a partial view of the material during the molding process of a 1" profiled slat.
Fig. 6 is a representation of the material and the slitting, molding and cutting systems as arranged during the molding process.
Fig. 7 is a cross-sectional side elevational view of the novel profiled cloth slat embodying the invention.
Fig. 8 is a cross-sectional side elevational view of the profiled cloth slat comprising novel features of the invention.
Fig. 9 is a partial schematic and partial realistic plan view of an alternative preferred embodiment of the present invention in which the system of the invention comprising the method, apparatus and product are illustrated.
Fig. 10 is a side elevational view of the system of Fig. 9.
Fig. 11 is a sectional view taken along line 11-11 of Fig. 9, illustrating one of several embodiments of blind slats according to the present invention. Fig. 12 is a sectional view taken along line 12-12 of Fig. 9.
Fig. 13 is a partial fragmentary elevational view taken along line 13-13 of Fig. 9.
Before referring in detail to the various view of the drawings it is desired to emphasize here that the present invention additionally contemplates protection of each and all of the following, namely: (1) novel blind slats capable of existing in a variety of materials, shapes and forms including, without limitation, a single layer of material or a combination of layers thereof; (2) novel methods of making each and all of the aforesaid blind slats; and (3) novel apparatus for
employing such methods.
While specific examples or embodiments of the
invention are herein described in varying degrees of detail, it must be kept in mind that applicant in no way wishes to be limited to these specific examples presented.
Referring in more detail to the drawings, Fig. 6 illustrates the system preferred in fabricating the profiled cloth slats and blind systems of the present invention. The finished material 2 enters the system 11 as a 47" wide roll, for example and is score cut 7 into strips of the desired width 8. The score cutting function is controlled by means of air pressure 10 applied to the cutting system 9 to which the cutting blades 7 are attached. The cutting system is not fixed and the position of the blades can be varied in order to obtain slats of different widths as desired. The flatstrips of finished material are fed into molding tubes 1 which are so mounted that hot air 4 in a desired temperature range is applied by means of tube 12 and individually supplied to each molding tube 1 by connection 3.
The molding process itself occurs inside molding tube 1 and is best illustrated in Fig. 1 wherein in part A the flat strips of material 2 enter the molding tube 1 and while
continually moving through the molding tube 1 the hot air 4 is applied to the cloth strip by connection 3, as shown in part B. The cloth strips acquire the concave curvature at this point in the molding process as the resins contained in the material are softened sufficiently by the hot air flow 4 for the cloth strips to assume the shape of the molding tube. The exposure time of the material in the molding tube 1 is a minimum of 3 seconds and the preferred tube length is 36 inches allowing for a molding speed of 20 yds. per minute. The thickness of the material 1 is before molding is 0.060 inches and remains stable throughout the molding process, thus assuring a constant thickness of the blind slats.
The profiled cloth strip 15 is cooled by a cold air flow 13 immediately upon leaving the molding tubes 1 while moving along metal throug 14, thereby insuring that the cloth slats retain their profiled shape. The profiled cloth strip is cut to desired length.
As best illustrated by Figs. 4 and 5, the diameter of the molding tube 1 can be constant at greater than 3 1/2 inches diameter for blind slat widths of 3 1/2 inches to 2
inches. The molding tube diameter may be small for slat widths of less than one inch. As seen in Fig. 5, a 1/2 inch wide slat requires that the preferred molding tube 1 diameter be no larger than one inch.
Some novel features of the invention are illustrated in Figs. 7 and 8, wherein the profiled cloth slat 2 in Fig. 7 comprises a top layer 17 of bonded nov-woven 100% polyester material, a center layer 18 of needlepunched non-woven 100% polyester and another top layer 17. Fig. 8 illustrates a profiled cloth slat comprising a top layer 19 of metalized 100% polyester, a supporting layer 21 of heat bonded non-woven 100% polyester and another top layer 19. Both slats in Fig. 7 and 8, respectively are stitched polyester filament with an acrylic binder saturation of 20%.
Referring now to Figs. 9-13, these additional drawings are presented only to further illustrate in varying degrees how the goals and objects of the present invention may be realized and employed. In Fig. 9 a system 50 of this invention is shown to include a feed spool 52 journalled upon shaft 54, from which a substantially continuous layer of stock 56 precut to a desired width is fed. The specific makeup of stock 56 is predetermined and widely variable, depending upon the desired characteristics of the finished product, including aethetics, strength, hand, insulating ability, to name only a few by way of example.
Stock 56 progresses to and through a cutting or slitting assembly 58 consisting of a plurality of spaced-apart rotary knives 60, each of which comprises a cutting edge capable of continuously cleanly piercing the entire thickness of stock 56 which, at slitting assembly 58, passes over backing roller 62 at the time of cutting or slitting. This invention contemplates a mere cutting of stock 56 by means of knives 60, with no waste material removed, as well as providing for a variety of cutting shapes not described in detail in the present specification.
The slitted stock, now existing in the form of relatively continuous strips 64 next advance from slitting assembly 58 to a heating or pre-heating chamber 66, wherein an elevated temperature is maintained in order to soften or reduce the rigidity of the material making up strips 64. In one embodiment of this invention, the stock 56 comprises a
polyester felt or nonwoven material layer on either side of or sandwiching an internal reinforced mylar layer therebetween. Fig. 11 in an enlarged sectional view illustrates an upper polyester felt layer 68 adjacent a mylar layer 70 to which an exaggerated view of the mylar's nonwoven reinforcement 72 is prebonded, and against which bottom or lower polyester felt layer 74 is bonded. At the risk of repetition, one or more of these layers may be eliminated without departing from the scope of the invention. For example, reinforcement layer 72 is provided to give body to as well as to discourage undesirable tearing of mylar 70 during handling prior to bonding within stock 56.
Quite apart from its aesthetic qualities, the polyester felt layers 68 and 74 each further provide an
absorbent layer to which a liquid resin, such as an acrylic, has previously been applied and allowed to preset. This
invention contemplates stock 56 consisting solely of a single layer of such polyester felt.
In the embodiment of Fig. 11, the mylar provides a thermal or heat transfer barrier which, for example, where it is desired to cool the interior of a room such as by air
conditioning during summer months, the mylar serves to prevent heat transfer from the warmer ambient or outer environment to the cooler inner air. By the same token, in cooler climates where it is desired to keep warmer air within a room from escaping, the same mylar serves to prevent heat transfer from the room to the surroundings. A more detailed description of the mylar's radiant reflecting characteristics, quite apart from heat convection and conduction considerations, will not be provided here to avoid the risk of burdening this
specification. It is contemplated that the layer of mylar 70 may be metallized with a deposition of a reflecting medium upon at least one side thereof.
The overall thickness of the strip section shown in Fig. 11 may , by way of example, only, be 0.5 millimeters or any other desired or predetermined thickness. Fig. 12 is an attempt to illustrate an ability of the system of the present invention to create and form alternative cross-sectional shapes such as the "wrapped" embodiment 76, wherein lower layer 74 is wider and extends about the side edges of the remaining layers of the strip 64.
After travelling through pre-heating chamber 66 and therein facilitating a "relaxing" of the strips and their respective resin components, strips 64 enter a heating/forming chamber 78 wherein a plurality of form roller assemblies 80 are disposed in the paths of each of these strips 64. Each form roller assembly 80 includes an upper roller 82 formed with an outer working convex surface 84 and being journalled upon an idler shaft 86, and a lower roller 88 formed with an outer working concave surface 90 matingly proximate surface 84 of its adjoining roller, and journalled upon a drive shaft 92 carried within a bearing 94 intermediate the rollers and a distant sprocket wheel 96 which, in turn, is driven via motor 98 by a drive chain 100. The gripping friction on strips 64 between rollers 82 and 88 serves to "pull" the stock 56 from its roll or spool.
It is important here to emphasize that in a preferred embodiment of the present invention, only within the
forming/cooling chamber 102 of system 50 is there a drive chain associated with form roller assemblies, however the invention contemplates placement of same in either or both locations.
Accordingly, Fig. 13 illustrates same within the
forming/cooling chamber 102 so as to minimize the number of such "pulling" assemblies.
Within heating/forming chamber 78, the relatively softened and formable strips 64 pass between rollers 82 and 88, and assume the profile or shape of the working surfaces
thereof. The amount of travel within each chamber, and the working temperatures within each chamber are selectable and controllable to provide a quality product of repeatedly
definable properties. After leaving heating/forming chamber 78, strips 64 enter forming/cooling chamber 102 and pass between form roller assemblies comparable to assemblies 80 (and therefore assigned the identical reference characters).
However, whereas in the heating/forming chamber 78 hot air is introduced through ports into the confines thereof, a cold medium or refrigerated air is introduced via inlet ports 104 by means of conduits 106 to cool and stabilize the formed strips. This stabilization occurs as a result of the temperature of the resin being dripped below its "setting" threshold temperature, thereby enabling a reliable and relatively permanent holding of each strip shape.
These formed strips 64 now leave forming/cooling chamber 102 and progress to a slicing station or assembly 108 at which a blade 110 reciprocably moves up and downwardly through the path of each strip 64 at a controlled speed and timing, thereby forming cut length slats 112 capable of use in connection with window blinds. These slats 112 may at the same slicing station be die cut with other functional openings useful with mechanisms of one or more blind manufacturers, before being accumulated in stacked configuration within a temporary or movable or permanent holding bin 114.
It is contemplated that with the present invention pre-heat chamber 66 may be entirely eliminated without
affecting to scope of the invention. Similarly, it is
contemplated that the rollers with convex/concave or other profile surfaces may only be provided within the
forming/cooling chamber, if desired. The preferred heating chamber temperatures at which forming is desired, while being in the range of 360º to 420º may be at other controllable temperatures that will yield favorable results.
The following examples and specifications are
presented as examples and, as in the case of all other values and specifications throughout this disclosure, are not meant to limit or in any other way restrict or prejudice the present invention and its intended scope.
Figure imgf000033_0001
Figure imgf000034_0001
Figure imgf000035_0001
Figure imgf000036_0001
Figure imgf000037_0001
Figure imgf000038_0001

Claims

WHAT IS CLAIMED IS:
1. A textile slat capable of use in a horizontal Venetian-type blind, or the like, comprising, in combination:
an elongated member formed with two relatively oppositely facing surfaces and having a cross-sectional profile other than truly flat, said member including
fibrous means for holding a resin, a resin held by said fibrous means, and
surface means forming one of said surfaces for providing the appearance and feel of a textile.
2. A textile slat capable of use in a horizontal venetian-type blind, or the like, comprising, in combination:
an elongated member formed with two relatively oppositely facing surfaces and having a cross-sectional profile other than truly flat, said member when supported at two points such as those of a substantially extending blind "ladder" being sufficiently rigid so as not to sag from a substantially horizontal configuration, and said member including
means capable of functioning in an environment which includes exposure to sunlight, relative humidities reaching 90 percent, and temperatures reaching 150 degrees F. without losing said non-sagging rigidity properties.
3. A Venetian-type blind, comprising, in
combination:
a plurality of substantially horizontally
extending textile slats,
means for supporting said slats a predetermined elevations,
means for supporting said slats at predetermined elevations,
means for elevating said slats, and
means for tilting said slats. said slats each comprising an elongated member formed with two relatively oppositely facing surfaces and having a cross-sectional profile other than truly flat, said member when supported at two points such as those of a substantially
extending blind "ladder" being sufficiently rigid so as not to sag from a substantially horizontal configuration, and said member including
means capable of functioning in an environment which includes exposure to sunlight, relative humidities reaching 90 percent, and temperatures reaching 150 degrees F. without losing said non-sagging rigidity properties.
4. A Venetian-type blind, comprising, in
combination:
a plurality of substantially horizontally extending textile slats,
means for supporting said slats at predetermined elevations,
means for elevating said slats, and
means for tilting said slats,
said slats such comprising an elongated member formed with two relatively oppositely facing surfaces and having a cross-sectional profile other than truly flat, said member including
fibrous means for holding a resin,
a resin held by said fibrous means, and
surface means forming one of said surfaces for providing the appearance and feel of a textile.
5. A textile slat capable of use in a horizontal Venetian-type blind, or the like, comprising, in combination:
an elongated member formed with two relatively oppositely facing surfaces and having a cross-sectional profile other than truly flat, said member including
fibrous means for holding a resin, a resin held by said fibrous means, and
surface means forming one of said surfaces for providing the appearance and feel of a textile,
the cross-sectional profile of said elongated member including a first curved portion and a second curved portion, wherein the direction of curvature of said second curved portion is substantially opposite that of the first curved portion.
6. A textile slat according to claim 5, wherein said cross-sectional profile is other than truly symmetrical.
7. A textile slat according to claim 5, wherein said cross-sectional profile is symmetrical about an axis of
symmetry.
8. A textile slat according to claim 5, wherein said cross-sectional profile is substantially S-shaped.
9. A textile slat according to claim 5, wherein said first and second curved portions meet at a tangent point.
10. A textile slat according to claim 5, wherein the locus of points along said first curved portion define a curve of a first radius.
11. A textile slat according to claim 10, wherein the locus of point along said second curved portion define a curve of a second radius.
12. A textile slat according to claim 11, wherein said first and second radii are substantially equal to one another.
13. A textile slat according to claim 5, wherein said elongated member is formed with relatively forward and rearward elongated edges, said elongated member being further formed with at least one notch which communicates with at least one of said edges, said notch being of a depth and width
capable of accommodating at least a portion of a venetian-type blind control element.
14. A textile slat according to claim 13, wherein said elongated member is formed with a plurality of such
notches.
15. A textile slat according to claim 5, for use as one of a plurality of substantially vertically disposed and aligned like textile slats, wherein said first curved portion is capable of cooperating with a second curved portion of an adjacent such textile slat to provide a variable light trap area whose boundaries are adjustable by the user for variably defining a predetermined number of angles at which light will be able to freely pass from a front side of such a venetian- type blind to its opposite rearward side.
16. A textile slat according to claim 15, wherein said first and second curved portions of adjacent textile slats define an elongated horizontally extending pocket which serves as a light trap.
17. A textile slat capable of use in a horizontal venetian-type blind, or the like, comprising, in combination:
an elongated member formed with two relatively oppositely facing surfaces and having a cross-sectional profile other than truly flat, said member when supported at two like elevation points such as those of a pair of substantially vertically extending blind "ladders" being sufficiently rigid so as not to sag from a substantially horizontal configuration. and said member including means capable of functioning in an environment which includes exposure to sunlight, relative humidities reaching 90 percent, and temperatures reaching 150 degrees F. without losing said non-sagging rigidity properties, the cross-sectional profile of said elongated member including a first curved portion and a second curved portion, wherein the direction of curvature of said second curved portion is substantially opposite that of the first curved portion.
18. A textile slat according to claim 17, wherein said cross-sectional profile is other than truly symmetrical.
19. A textile slat according to claim 17, wherein said cross-sectional profile is symmetrical about an axis of symmetry.
20. A textile slat according to claim 17, wherein said cross-sectional profile is substantially S-shaped.
21. A textile slat according to claim 17, wherein said first and second curved portions meet at a tangent point.
22. A textile slat according to claim 17, wherein the locus of points along said first curved portion define a curve of a first radius.
23. A textile slat according to claim 22, wherein the locus of point along said second curved portion define a curve of a second radius.
24. A textile slat according to claim 23, wherein said first and second radii are substantially equal to one another.
25. A textile slat according to claim 17, wherein said elongated member is formed with relatively forward and rearward elongated edges, said elongated member being further formed with at least one notch which communicates with at least one of said edges, said notch being of a depth and width
capable of accommodating at least a portion of a venetian-type blind control element.
26. A textile slat according to claim 25, wherein said elongated member is formed with a plurality of such
notches.
27. A textile slat according to claim 17 for use as one of a plurality of substantially vertically disposed and aligned like textile slats, wherein said first curved portion is capable of cooperating with a second curved portion of an adjacent such textile slat to provide a variable light trap area whose boundaries are adjustable by the user for variably defining a predetermined number of angles at which light will be able to freely pass from a front side of such a venetian- type blind to its opposite rearward side.
28. A textile slat capable of use in a horizontal venetian-type blind, or the like, comprising, in combination:
an elongated member formed with two relatively oppositely facing surfaces and having a cross-sectional profile other than truly flat, said member when supported at two like elevation points such as those of a pair of substantially vertically extending blind "ladders" being sufficiently rigid so as not to sag from a substantially horizontal configuration, and said member including means capable of functioning in an environment which includes exposure to sunlight, relative humidities reaching 90 percent, and temperatures reaching 150 degrees F. without losing said non-sagging rigidity properties. the cross-sectional profile of said elongated member being such that if one interconnects the extreme edge ends thereof with a substantially straight reference line, at least one substantially closed area on each side of said reference line is at least partially defined by said reference line and each of said oppositely facing surfaces.
29. A Venetian-type blind, comprising, in combination:
a plurality of substantially horizontally extending textile slats,
means for supporting said slats at predetermined elevations,
means for elevating said slats, and
means for tilting said slats,
said slats such comprising an elongated member formed with two relatively oppositely facing surfaces and having a cross-sectional profile other than truly flat, said member including
fibrous means for holding a resin,
a resin held by said fibrous means, and
surface means forming one of said surfaces for providing the appearance and feel of a textile,
the cross-sectional profile of said elongated member including a first curved portion and a second curved portion, wherein the direction of curvature of said second curved portion is substantially opposite that of the first curved portion.
30. A Venetian-type blind according to claim 29, wherein said cross-sectional profile is other than truly symmetrical.
31. A Venetian-type blind according to claim 29, wherein said cross-sectional profile is symmetrical about an axis of symmetry.
32. A Venetian-type blind according to claim 29, wherein said cross-sectional profile is substantially S-shaped.
33. A Venetian-type blind according to claim 29, wherein said first and second curved portions meet at a tangent point.
34. A Venetian-type blind according to claim 29, wherein the locus of points along said first curved portion define a curve of a first radius.
35. A Venetian-type blind according to claim 34, wherein the locus of point along said second curved portion define a curve of a second radius.
36. A Venetian-type blind according to claim 35, wherein said first and second radii are substantially equal to one another.
37. A Venetian-type blind according to claim 29, wherein said elongated member is formed with relatively forward and rearward elongated edges, said elongated member being further formed with at least one notch which communicates with at least one of said edges, said notch being of a depth and width capable of accommodating at least a portion of a
venetian-type blind control element.
38. A Venetian-type blind according to claim 33, wherein said elongated member is formed with a plurality of such notches.
39. A Venetian-type blind according to claim 29, for use as one of a plurality of substantially vertically disposed and aligned like textile slats, wherein said first curved portion is capable of cooperating with a second curved portion of an adjacent such textile slat to provide a variable light trap area whose boundaries are adjustable by the user for variably defining a predetermined number of angles at which light will be able to freely pass from a front side of such a venetian-type blind to its opposite rearward side.
PCT/US1989/001975 1989-05-05 1989-05-09 Textile fabric horizontal blinds and slats WO1990013728A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US34696189A 1989-05-05 1989-05-05
US346,961 1989-05-05

Publications (1)

Publication Number Publication Date
WO1990013728A1 true WO1990013728A1 (en) 1990-11-15

Family

ID=23361753

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1989/001975 WO1990013728A1 (en) 1989-05-05 1989-05-09 Textile fabric horizontal blinds and slats

Country Status (2)

Country Link
AU (1) AU3571689A (en)
WO (1) WO1990013728A1 (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2303661A (en) * 1995-07-26 1997-02-26 John Garth Reynolds S-shaped slat for a vertical blind
US5657806A (en) * 1996-04-19 1997-08-19 Hung; Tai-Lang Venetian blind and a slat therefor
EP1717403A2 (en) * 2005-04-28 2006-11-02 Griesser Holding AG Slat for an outside Venetian blind
DE102008037358A1 (en) 2008-08-12 2010-02-25 Roma Rolladensysteme Gmbh shading device
US11186070B2 (en) 2017-02-06 2021-11-30 Hunter Douglas Inc. Room darkening material and architectural covering made from same

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2156163A (en) * 1935-09-19 1939-04-25 Nat Standard Co Venetian blind
US2254705A (en) * 1940-11-18 1941-09-02 Clarence W Morse Venetian blind
US2620869A (en) * 1950-05-03 1952-12-09 Friedman Jay Leon Venetian blind slat construction
US3032099A (en) * 1959-08-03 1962-05-01 Donald J Croxen Full closing venetian blind
US3645317A (en) * 1969-11-26 1972-02-29 Charles H Malone & Co Inc Venetian blind
DE2644354A1 (en) * 1976-10-01 1978-08-17 Schlitzer Leinen Ind Stiller U Strip of fabric for venetian blinds - has longitudinal as well as lateral threads twisted in alternating directions
US4309472A (en) * 1979-05-30 1982-01-05 Hoechst Aktiengesellschaft Slats serving as protection against light
DE3038480A1 (en) * 1980-10-11 1982-05-27 Schlitzer Leinen - Industrie Driessen GmbH & Co KG, 6407 Schlitz Fabric window blind strips - are used as sun blinds, and incorporate metal threads
US4519435A (en) * 1984-08-01 1985-05-28 Kenneth Stier Slats for vertical venetian blinds
US4773958A (en) * 1984-08-01 1988-09-27 Goodman Barry I Method for making blind slats and components thereof
US4802521A (en) * 1985-02-26 1989-02-07 Kuron Corporation Overhead blind

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2156163A (en) * 1935-09-19 1939-04-25 Nat Standard Co Venetian blind
US2254705A (en) * 1940-11-18 1941-09-02 Clarence W Morse Venetian blind
US2620869A (en) * 1950-05-03 1952-12-09 Friedman Jay Leon Venetian blind slat construction
US3032099A (en) * 1959-08-03 1962-05-01 Donald J Croxen Full closing venetian blind
US3645317A (en) * 1969-11-26 1972-02-29 Charles H Malone & Co Inc Venetian blind
DE2644354A1 (en) * 1976-10-01 1978-08-17 Schlitzer Leinen Ind Stiller U Strip of fabric for venetian blinds - has longitudinal as well as lateral threads twisted in alternating directions
US4309472A (en) * 1979-05-30 1982-01-05 Hoechst Aktiengesellschaft Slats serving as protection against light
DE3038480A1 (en) * 1980-10-11 1982-05-27 Schlitzer Leinen - Industrie Driessen GmbH & Co KG, 6407 Schlitz Fabric window blind strips - are used as sun blinds, and incorporate metal threads
US4519435A (en) * 1984-08-01 1985-05-28 Kenneth Stier Slats for vertical venetian blinds
US4773958A (en) * 1984-08-01 1988-09-27 Goodman Barry I Method for making blind slats and components thereof
US4802521A (en) * 1985-02-26 1989-02-07 Kuron Corporation Overhead blind

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2303661A (en) * 1995-07-26 1997-02-26 John Garth Reynolds S-shaped slat for a vertical blind
US5657806A (en) * 1996-04-19 1997-08-19 Hung; Tai-Lang Venetian blind and a slat therefor
EP1717403A2 (en) * 2005-04-28 2006-11-02 Griesser Holding AG Slat for an outside Venetian blind
EP1717403A3 (en) * 2005-04-28 2008-01-23 Griesser Holding AG Slat for an outside Venetian blind
DE102008037358A1 (en) 2008-08-12 2010-02-25 Roma Rolladensysteme Gmbh shading device
US11186070B2 (en) 2017-02-06 2021-11-30 Hunter Douglas Inc. Room darkening material and architectural covering made from same

Also Published As

Publication number Publication date
AU3571689A (en) 1990-11-29

Similar Documents

Publication Publication Date Title
US5490553A (en) Fabric window covering with rigidified vanes
CA2253780C (en) Light control window covering
US6068039A (en) Material for venetian type blinds
US4884615A (en) Sound absorbent slats for window blinds
US5845690A (en) Fabric light control window covering with rigid vanes and support cords
US4884612A (en) Pleated blind with articulative slat extensions
CA2174915C (en) Fabric for an architectural covering and method and apparatus of manufacturing same
US4928369A (en) Method of making a pleated blind with articulative slat extensions
US6354353B1 (en) Door and window coverings employing longitudinally rigid vanes
US8277591B2 (en) Tubular slat for coverings for architectural openings
US5141042A (en) Web covered vertical blind slat assemblies
US6598650B1 (en) Hollow, rigid vanes for door and window coverings
US5358024A (en) Web covered vertical blind slat assemblies
US5620035A (en) Material utilizing flexible strands
US6440247B2 (en) Light control window covering and method of making same
AU662030B2 (en) Covering assembly for architectural openings
WO1990013728A1 (en) Textile fabric horizontal blinds and slats
WO1990005233A1 (en) Textile fabric vertical blind vane
US20060249261A1 (en) Removable vane cover fastened to a conventional vertical blind system
CA2004447A1 (en) Sound absorbent slats for window blinds
JP2000008744A (en) Slat for blind
MXPA98010146A (en) Cover for window to control the step of the
MXPA97000304A (en) Improved sheet for an architectural cover and method for its manufacture

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): AU BR DE DE JP

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): AT BE CH DE FR GB IT NL SE

REG Reference to national code

Ref country code: DE

Ref legal event code: 8642