WO2012149067A2

WO2012149067A2 - Quiet integrated cylindrical motor system for interior and exterior window shadings and projector screens

Info

Publication number: WO2012149067A2
Application number: PCT/US2012/035063
Authority: WO
Inventors: Thomas Peterson
Original assignee: Performance Concepts, Llc
Priority date: 2011-04-25
Filing date: 2012-04-25
Publication date: 2012-11-01
Also published as: WO2012149067A3; WO2012149067A9

Abstract

The quiet integrated cylindrical motor system is designed to provide an ultra-quiet motorization solution for interior and exterior window shadings and projector screens. The motor system rotates an output drive hub that in turn rotates a roller mechanism in a forward or reverse direction. The cylindrically shaped motor system sits within the outer roller mechanism that rotates in a forward or reverse direction, thereby, raising or lowering a reelable shade or screen. The quiet integrated cylindrical motor system is designed to reduce the emission of sound and vibration from the motor and gear assembly, by utilizing a combination of the following: primary and secondary vibration suppression motor mounts, a sound suppression motor sleeve and a vibration reduction driveshaft/actuator.

Description

QUIET INTEGRATED CYLINDRICAL MOTOR SYSTEM

FOR INTERIOR AND EXTERIOR WINDOW SHADINGS AND PROJECTOR SCREENS

[0001] FIELD OF THE INVENTION

[0002] This invention relates generally to motorized window coverings and video projector screens.

[0003] BACKGROUND OF THE INVENTION

[0004] When the motor system is energized, the output drive hub of the motor system will turn an outer roller mechanism or tube in either direction, thus raising or lowering a window shade or projection screen.

[0005] The powered motor system requires an electric motor that is coupled to a gear train (the assembly), and the gear train is in turn coupled to an output drive mechanism which rotates when the motor is energized. The powered motor assembly is generally mounted within a steel housing or tube that is cylindrical in its shape. This assembly is disposed within a hollow roll tube or similar structure to which a window shading system, window treatment, video projection screen or like item may be attached. This external rotatable tube rotates around the motor system assembly, thereby raising and lowering the shading system, window treatment, projector screen or like item.

[0006] Prior art motor assemblies utilize noise or vibration dampening couplings between the motor and the motor mount as well as between the gear train and the output driveshaft. The drawback to this technology is that it makes for a motor system that is lengthy and is often incapable of being utilized for applications that may require a shorter (i.e., smaller) mechanism in order to fit within the confines of the window or application. For example, the narrower a window is, the shorter (narrower) the motor system for the window should be.

[0007] Additional objects and advantages of this invention will be set forth in the description that follows, and in part will be apparent from the description, or may be learned by practice of the invention. [0008] SUMMARY OF THE INVENTION

[0009] This invention relates to a quiet motor system that generates less vibration and operates at a lower decibel level of sound. This is relative to achieving the lowest possible decibel level of sound and vibration that may emanate from a motorized roller mechanism. Described herein is a quiet motor system assembly having a roller tube rotatable about a longitudinal axis for raising or lowering a shade or screen. An AC or DC powered electric motor system is generally disposed within the interior of the roller tube mechanism and has an output drive hub for rotating the roller tube.

[0010] At least one vibration suppression motor mount is interposed between the internal motor and/or gear assembly and the motor system housing. A sound suppression sleeve may be interposed between the motor system housing and the internal motor and/or gear assembly and at least one vibration reduction drive shaft is interposed between the gear assembly and the drive hub that is utilized to rotate the roller mechanism.

[0011] In one advantageous embodiment, the primary vibration suppression motor mount can be comprised of rubber, vinyl or plastic or a combination thereof, and has at least an inner mounting surface that contacts the interior of the motor casing and an outer surface that contacts the interior of the motor assembly housing, and which may also include an outer mounting surface that contacts the exterior of the motor casing, and the interior of the motor assembly housing. This embodiment may also include a motor and gearbox that exist within the same casing. This particular combination reduces the vibration and sound that is transferred from the motor and/or gearbox assemblies to the outer housing.

[0012] The vibration suppression motor mount can be interposed between the motor assembly and the motor system housing and can also include a secondary vibration suppression motor mount that is interposed between the gearbox assembly and the motor system housing. Furthermore, a secondary vibration suppression motor mount can be interposed between the motor casing, which includes the gearbox, and the outer housing. This particular combination reduces the vibration and sound that is transferred from the gearbox to the outer housing.

[0013] According to yet another aspect of the invention, a sound suppression sleeve or coating comprised of vinyl, rubber or plastic encompasses all or part of the exterior surface of the motor assembly and gearbox and is positioned between the primary and secondary motor mounts, thereby reducing the transmission of vibration and sound that emanates from the motor assembly and gearbox assembly into the motor housing. Furthermore, a primary sound suppression sleeve or coating may encompass all or part of the exterior surface of the motor assembly, when separated from the gearbox assembly. In which case, a secondary sound suppression sleeve or coating may encompass the gearbox assembly, when separated from the motor assembly, thereby reducing the transmission of vibration and sound from the gearbox assembly into the motor system housing.

[0014] In yet another aspect, the motor assembly and gearbox are surrounded all or in part by the sound suppression sleeve or coating, thereby reducing the vibration and sound that is emitted from the motor and gearbox into the housing. Both the vibration suppression motor mount(s) and sound suppression motor sleeve(s) are designed such that the exterior surface area that comes in contact with the outer housing is reduced, such as by ribs on the exterior surface, in order to minimize the contact area. This reduces the transfer of both sound and vibration from the inner motor and/or gearbox assemblies to the outer housing. Furthermore, the materials utilized in both the motor and gearbox vibration suppression mounts, as well as the motor and gearbox coating or sleeves, are designed to absorb both vibrations and sound of both the motor and gearbox assemblies.

[0015] In still another aspect, the vibration reduction drive shaft transfers the movement of the output drive to the drive hub. This particular drive shaft can be comprised of plastic, rubber, urethane or metal or any combination thereof. This particular device is rotatable, in that it rotates when the output drive is activated via the internal motor and gearbox. This combination reduces the transfer of vibrations to the drive hub, thereby reducing the transmission of vibration from the gearbox assembly to the drive hub.

[0016] BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate the presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred methods and embodiments given below, serve to explain the principles of the invention:

[0018] FIG. 1 is a view of a prior art internally suspended motor (via couplings) for a motorized or powered window covering system. [0019] FIGS. 2a, 2b and 2c are views a motor system assembly comprising all of the components that make up a preferred embodiment of the quiet integrated motor system including the outer housing. FIG. 2a is a break-out view of the components.

[0020] FIGS. 3a, 3b and 3c are views of a preferred embodiment of the primary vibration suppression motor mount and post.

[0021] FIGS. 4a, 4b and 4c are views of a preferred embodiment of the secondary vibration suppression motor mount and seat.

[0022] FIGS. 5a and 5b are views of a preferred embodiment of the single motor sleeve design and dual motor sleeve design.

[0023] FIGS. 6a, 6b and 6c are views of preferred embodiments of the output drive, actuator, bearing, bearing seat and drive hub.

[0024] FIG. 7 is a view of a second preferred embodiment of the quiet integrated motor system with separate motor and gearbox assemblies.

[0025] FIG. 8 is a perspective view of a preferred embodiment of the quiet integrated motor system which includes the motor assembly outer housing as well as the roller mechanism or tube.

[0026] FIG. 9 is a view of a motor system assembly comprising all of the components that make up another embodiment of the quiet integrated motor system including the outer housing

[0027] FIG. 10 is a view of another embodiment of the output drive assembly

[0028] FIG. 11 is a view of another embodiment of the output drive hub.

[0029] FIG. 12 is a view of another embodiment of the needle bearing assembly.

[0030] FIG. 13 is a view of another embodiment of the output drive shaft assembly.

[0031] FIG. 14 is a view of another embodiment of the output drive actuator in the output drive shaft assembly. [0032] DETAILED DESCRIPTION OF THE INVENTION

[0033] Reference will now be made in more detail to presently preferred methods and embodiments of the invention, as illustrated in the accompanying drawings. While the invention is described more fully with reference to these examples and drawings, the invention in its broader aspects is not limited to the specific details, representative devices, and illustrative examples shown and described. Rather, the description which follows is to be understood as a broad, teaching disclosure directed to persons of ordinary skill in the appropriate arts and not as limiting upon the invention.

[0034] Referring to FIG. 1, there is shown a prior art internally suspended motor system 10 having a motor 11 and gearbox 12 within a casing 15 and suspended within a motor assembly housing or tube 20. The motor 1 1 and gearbox 12 are interposed between two interior couplings as follows: the rotational interior coupling 13a and the non-rotational or stationary interior coupling 13b, both of which reside within the motor and gearbox casing 15. The motor and gearbox casing 15 is interposed between two exterior couplings as follows: the rotatable exterior coupling 14a and the non-rotatable or stationary exterior coupling 14b. The stationary or non-rotatable coupling 14b is affixed to the stationary motor mount 19 and also contains a sound plug 17 between the casing 15 and the stationary exterior mount 14b. The output drive or shaft 18 runs through two sets of bearings 16a and 16b with the exterior rotatable coupling 14a interposed between the two bearings. All of the above components exist within the motor assembly housing or tube 20.

[0035] As shown in FIG. 1, the implementation of multiple couplings adds to the length of the motor system, thereby making it less compact. The elimination of couplings is proposed in the present invention, thereby making for a more compact and less costly technique in achieving a quiet tubular style electronic motor system. It is understood that the motor systems described herein can be operated (via a circuit board or internal processor) through multiple means of control, i.e., wired and wireless (radio frequency) inputs.

[0036] Referring to FIG. 2, there is shown a non-limiting embodiment of the quiet integrated motor system 100, according to the present invention. The quiet integrated motor system includes a primary vibration suppression motor mount 21a and primary mounting post 21b. In this embodiment, the motor 80 and gearbox 82 (motor and gearbox are not shown in FIG. 2) are combined into one assembly 22 with an output drive 23 extending from the gearbox end of the assembly 22. [0037] In this particular embodiment shown in FIG. 2, an optional sound suppression motor sleeve 24 is shown which surrounds the motor and gearbox assembly 22. The sleeve 24 surrounds the motor and gearbox assembly 24, and provides suppression of vibration and noise emanating from the motor and/or gear box. In use, in a preferred embodiment, the sleeve 24 is in communication at one of its ends with the primary motor mounting post 21b, and at its opposite end in communication with the secondary mounting seat 25 a.

[0038] On the opposite end of the motor and gearbox assembly 22 from the primary vibration suppression motor mount 21a and post 21b is a secondary two part vibration suppression motor mount that consists of a secondary motor mount seat 25a and a secondary motor mount 25b. The output drive 23 is connected on one end to the motor and gearbox assembly 22 by inserting a male portion 23a of the output drive 23 into a corresponding female portion of the final gear set of the assembly 22. The other end 23b of the output drive 23 passes through a center hole in secondary motor mount 25b and secondary mounting seat 25a, and is inserted into and engages with a corresponding female portion 26a on a first end of drive shaft/actuator 26. The second end 26b of drive shaft/actuator 26 comprises a male portion which passes through a center hole in bearing 27a and bearing seat 27b, and is inserted into and engages with the female portion 28a of drive hub 28. Thus, the output drive 23 is connected to the vibration reduction drive shaft/actuator 26 that turns when the output drive 23 is activated via the gearbox 82. The vibration reduction drive shaft/actuator 26 rotates silently by the use of a bearing 27a that sits in a bearing seat 27b.

[0039] As also illustrated in FIG. 8, connected to the motor system 100 is the output drive hub 28, which (when the motor system 100 is deployed in a window shade or projection screen system) turns a drive wheel 50 (not shown in FIG. 2) that rotates the outer roller mechanism 49 when the motor system 100 is activated. The drive wheel 50 is attached to or otherwise engages with the outer roller mechanism 49. For example, the drive wheel 50 is attached via screws or a keyed design that matches the inner diameter of all or a portion of the outer roller mechanism 49, which is essentially a rotating tube. The keyed design comprises male and female portions on each of the inner diameter of 49 and the outer diameter of 50; the male and female portions on the respective components engage one another, so that rotation of the drive wheel 50 causes rotation of the outer roller mechanism 49. The outer roller mechanism 49 is a rotating tubular structure to which is attached a fabric shade, projection screen or cords for lifting a Roman-style shade or window covering 51. The outer roller mechanism 49 is turned by drive wheel 50, and the drive wheel 50 is in turn driven by the drive hub 28, which is powered by the motor and gear assembly 22.

[0040] Furthermore, the drive hub 28 shown in FIG. 2 that is external to the motor housing 30 rotates as the motor housing 30 and internal assembly 21-25 (excluding the output drive 23) remain static during operation. The motor head 29 is the portion of the system that receives the electricity and communication via wired or wireless inputs / communication, and signals the motor to turn in either direction or to stop. The motor head

29 typically sits in a bracket (not shown) to support the system 100 from the motor end (i.e., the primary vibration suppression motor mount 21 is NOT connected to the motor head 29, and the motor head 29 sits in a bracket that is attached to a wall or window jam, etc..) An outer roller mechanism 49 rotates around the motor system when the motor/drive is activated. Typically, the non-motor end or idler end (i.e., the motor head 29 in the final product illustrated in FIG. 7) will sit in a bracket and utilize an idler assembly to allow the system to rotate while simultaneously supporting the roller mechanism on the opposite end. The bracket is typically mounted on a wall and/or in a window jam or frame or similar place where one would wish to mount a raisable and lowerable window covering or projection screen.

[0041] Also shown in FIG. 2b is a motor housing 30 which will receive and house the motor system 100. The motor head 29 is rotatably attached to a motor collar 73 (i.e., motor collar 73 rotates while the motor head 29 remains stationary). The motor housing

30 is secured to the motor head 29. The motor head 29 and motor housing 30 remain stationary during operation of the system 100. The collar 73 and outer roller mechanism 49 each are provided with male and female keys or tabs (or similar projections or portions) so that each engages with one another so that they rotate simultaneously. Also illustrated are the following components which are typically but not always found in the final products in which the motor system 100 is used: an electronic limit set assembly 74 which signals the motor to stop and start; an optional limit switch assembly 75 for use when a mechanical limit set is utilized; a capacitor 76; an RF (radio frequency) receiver 78 for receiving wireless signals where applicable; and wires 79 which extend from the motor head 29 to the motor 80 to power the motor system 100. The motor system 100 is inserted into motor housing 30, and is attached to wires 79. Motor housing 30 remains stationary during operation of the "final product" illustrated in FIG. 8. [0042] Referring to FIG. 3, there is shown a multi-dimensional view of an embodiment of the primary vibration suppression motor mount, which is comprised of motor mount 21a and mounting post 21b. In FIG. 3a, there are front perspective views of the motor mount 21a and keyed mounting post 21b which are joined together in order to connect the mount 21a to the motor assembly casing 22. The motor mount 21a comprises a vibration absorption body 21a that surrounds the male portion 72b of 21b when 72b is inserted into the corresponding female portion 72a in mounting post 21a. This is what is meant by a "keyed" mounting post. FIG. 3 shows a preferred embodiment of the shape and dimensions of the female and male portions 72a and 72b. However, other shapes and dimensions may be utilized, so long as they permit parts 21a and 21b to mate closely so as to minimize or substantially prevent 21a and 21b from moving or vibrating independently of one another. This particular motor mount body 21a may for example be composed of a unitary body which absorbs the vibrations that emanate from the motor / gearbox assembly via the mounting post 21b. The motor mount body may be of any material which absorbs vibrations, for example, rubber, plastic or urethane. The outer contact ring 40 of the motor mount is designed to minimize the contact area between the motor mount 21a and outer housing 30. The aforementioned embodiment minimizes the transfer of vibrations from the motor and/or gearbox assembly 22 to the outer housing 30. In a preferred embodiment, as shown in FIG. 3 a, mounting post 21b has a tab 90, a first collar 91 that is preferably narrower than second collar 92. When the system 100 is assembled and deployed in a window shade or projection screen apparatus, the tab 90 assists in keeping the 21b in place.

[0043] FIG. 3b, which is a rear view of the motor mount 21a and mounting post 21b, shows the wire transfer ports 42a/b which extend through which wires from the motor may be passed to connect the motor to the circuit board / processor with a minimal amount of sound transfer through the port 42a/b.

[0044] Referring to FIG. 3c, the outside diameter of the ribbed section 40 of the motor mount is larger than that of the smooth section 41 ; therefore, it is the only portion of the mount 21c that comes in direct contact with the motor housing 30. The optional mounting hole 60 is designed to receive a mounting pin or screw that retains the position of the motor mount 21a and post 21b within the motor housing 30 during operation and under torque.

[0045] Referring to FIG. 4, there is shown a multi-dimensional view of the secondary vibration suppression motor mount 25b and secondary mounting seat 25a. In figure 4a, there is a frontal view of the secondary motor mount 25b which utilizes a mounting seat 25a in order to mount to the motor assembly 22 and/or gear casing (gearbox) 82. Each of 25a and 25b are unitary bodies preferably comprised of materials that absorb vibration, and together form the secondary motor mount assembly 25a/b. The secondary motor mount assembly 25a/b absorbs vibration and protrudes from the secondary mounting seat 25a.

[0046] Secondary motor mounting seat 25a is a unitary body comprised of a first collar 62a, a second collar 62b, and a third collar 62c. The outside diameter of the second collar 62b is larger than the outside diameter of the third collar 62c, and smaller than the outside diameter of the first collar 62a. The inner diameter of the first collar 62a is provided with mounting ribs 45a. Optionally, the mounting seat 25a may be have a third collar (shown in the drawing as collar 62c), and the collar 62c may also be provided with projections or gears 63. In this optional embodiment, when the device of the invention is assembled, the secondary motor mount seat 25a is inserted into the motor/gear assembly 22 at the gearbox end (i.e., at the end near output drive 23), so that projections or gears 63 on 25a mesh with the corresponding complimentary projections or teeth within the inner diameter of at least a portion of the gearbox 23. However, in some instances the projections/teeth 63 will not be needed.

[0047] Secondary motor mounting seat 25 a is preferably provided with a tab

66 which engages a corresponding indentation or recess within the motor and gearbox assembly 22 (or the casing in which the motor and gearbox are disposed), for the purpose of essentially locking the seat 25a and assembly 22 together, to prevent the assembly 22 from rotating as the output drive 23 and drive shaft 26 rotate. In yet another preferred embodiment, the assembly 22 and seat 25a may be further secured to one another using one or more screws or other attachment devices. The inside diameter of collar 62a of mounting seat 25a is provided with mounting ribs 45a, which are designed to engage with corresponding mounting ribs on secondary motor mount 25b, in order to secure 25a and 25b together.

[0048] Secondary motor mount 25b is a unitary body comprised of a first collar 70a, a second collar 70b, and third collar 70c. The outside diameter of the second collar 70b is larger than the outside diameter of the third collar 70c, and smaller than the outside diameter of the first collar 70a. The outer diameter of third collar 70c is provided with mounting ribs 45b. The outer housing 30 rests on and communicates with the exterior diameter of the first collar 70a of motor mount 25b. Secondary motor mount 25b is shown in FIG. 4 to have optional ribs 64 in the inside diameter thereof. The ribs 64 provide structural integrity/strength to 25b.

[0049] This particular motor mount body (i.e., 25a and 25b together) absorbs the vibrations that emanate from the motor / gearbox assembly via the mounting seat. The outer surface diameter of at least a portion of mount 25b contains projections such as ribs 43 to minimize the contact area between the motor mount 25b and outer housing 30. A portion of the outer housing 30 rests around and on the exterior diameter of the first collar 70a of motor mount 25b. The aforementioned embodiment minimizes the transfer of vibrations from the motor and/or gearbox assembly 22 to the outer housing 30.

[0050] Still referring to FIG. 4 in the side view 4c that shows the outside diameter of the ribbed section 70a of the secondary motor mount 25b to be larger than that of the mounting seat 25a; therefore, it is the only portion of the mount 25b that comes in direct contact with the motor housing 30. Referring to FIG. 4 in the rear view 4b, mounting ribs 45a are designed hold the vibration suppression motor mount 25b in the seat 25a via matched mounting ribs 45b that exist within the motor mount 25b.

[0051] Referring to FIG. 5a, there is shown a sound suppression motor sleeve

24 that covers the motor and gear assembly or casing 22. The motor sleeve 24 surrounds, either partially or fully, the motor / gearbox assembly 22. The motor sleeve or coating shall consist of a vinyl, rubber or plastic or any combination thereof, which has the necessary properties to greatly reduce the resonance of sound from the motor and / or gear assembly 22.

The motor sleeve 24 can be a hollow cylindrical shaped unitary structure (composed of a single piece) or may be composed of two or more parts joined together or which simply abut one another without actually being joined when they are placed over and around the motor and gear assembly 22. Alternatively, the motor sleeve could be applied by spraying, dipping and/or molding an appropriate material onto or around the motor and gear assembly 22. In the non-limiting embodiment shown in FIG. 5, the motor sleeve 24 consists of a rubber like material and is provided with projections (e.g., dimples or ribs) on its exterior surface to assist in the absorption of vibrations and sound, as well as to limit the contact area between the motor sleeve 24 and the motor housing 30, thereby, reducing the transfer of vibration to the motor assembly outer housing or tube 30. The motor sleeve 24 may optionally be provided with projections on its interior surface. The projections on the exterior and/or interior surfaces of the motor sleeve 24 are preferably of the same material as the sleeve 24, and still more preferably the projections are formed (such as by molding) at the same time as the sleeve 24 is formed. In a preferred alternative embodiment, the sleeve 24 is provided with a collar 88 formed of the same material as the rest of the sleeve, and the sleeve 24 may optionally contain an aperture 89 therein as illustrated in FIG. 5a. The aperture 89 permits a fastening device, such as a screw, to be placed therethrough, to assist in securing the sleeve 24 to the motor and gear assembly 22 and/or securing the sleeve 24, motor and gear assembly 22 and other parts of the motor system 100 together.

[0052] Referring to FIG. 5b, there is shown an alternative embodiment wherein the motor and gear box are each separate components (a motor assembly 46 and a gearbox assembly 47), rather than a combined motor and gearbox assembly 22 (as is shown in FIG. 2). In this embodiment, there are three vibration absorbing mounts used: a primary motor mount 76a at the far end of the motor assembly 46, a combined motor and gearbox mount 76b disposed between the motor assembly 46 and the gearbox assembly 47, and a third mount 76c at the far end of the gearbox assembly 47. Although three vibration absorbing mounts are shown in FIG. 5b, in alternative embodiments of the invention, only two or even one vibration absorbing mount(s) may be used. Each of the vibration absorbing mounts is provided with a central aperture or hole through which necessary components of the system 100 must pass, for example, the motor and gearbox assembly 22 and the output drive 23. The mounts, particularly mount 76b, can each be comprised of a unitary body (i.e., one piece) or may be composed of more than one piece. For example, in an embodiment of the invention, mount 76c is comprised of a mount and seat similar to that described herein with respect to mount 25b and seat 25 a.

[0053] In yet another embodiment of the invention, each vibration absorbing motor mount may extend so that it covers a portion of the external surface of the motor and gearbox assembly 22, as is shown with respect to motor mount 76a is FIG. 5b, which extends to wrap around a portion of the sides of the assembly 22

[0054] FIG. 5 illustrates a motor sleeve 24 that is comprised of two parts, 32 and 34, with each part covering the motor assembly 80 and gearbox assembly 82, respectively. Although this shows that both 80 and 82 are covered with the motor sleeve 24, in an alternative embodiment, only either the motor assembly 80 or the gear box assembly 82 are covered with the motor sleeve. In yet another alternative embodiment, the sleeve 24 may be comprised of one piece and be used to cover both the motor assembly 80 and the gearbox assembly 82. In still yet another embodiment, the sound suppression sleeve 24 would be replaced with a rubberized or other vibration dampening/absorbing coating that is applied directly to the motor and gearbox assembly 22 or assemblies 80 and 82.

[0055] FIG. 6 illustrates preferred embodiments of the output drive 23, drive shaft/actuator 26, bearing 27a, bearing seat 27b, and drive hub 28.

[0056] Referring to FIG. 7, there is shown another non-limiting embodiment of the quiet integrated motor system whereby the motor 46 and gearbox 47 reside within separate casings. This particular embodiment provides multiple vibration suppression motor mounts 31, 33, 35. The primary vibration suppression motor mount 31 may or may not be configured the same as the primary vibration suppression mount 21a and primary mounting post 21b of the embodiment shown in FIG. 2, but also provides similar vibration reduction capabilities in its design. The secondary vibration suppression motor/gearbox mount 33 is stationed between the motor and gearbox assembly casing(s) and utilizes a different configuration then the vibration suppression mount 21a/b of FIG. 2, but also provides vibration reduction capabilities in its design. The sound suppression motor sleeves 32, 34 are each comprised of a separate portion and are utilized individually, i.e., one for the motor assembly 46 and one for the gearbox assembly 47. In this particular non-limiting embodiment, the motor sleeve(s) or coating 32, 34 may or may not be configured the same as other versions but also provide(s) sound suppression and vibration reduction capabilities. The third or final gearbox assembly vibration suppression mount 35 is shown in this embodiment and may or may not be configured the same as the secondary motor mount 25b and seat 25a, but also provides vibration reduction capabilities in its design.

[0057] Still referring to FIG. 7, the output drive 23 is connected to the vibration reduction drive shaft/actuator 26 that turns when the output drive 23 is activated via the gearbox. The vibration reduction drive shaft/actuator 26 rotates silently by the use of a ball bearing 27a that sits in a bearing seat 27b. In this particular embodiment, the vibration reduction drive shaft/actuator 26 itself provides vibration reduction capabilities. In an embodiment of the invention, the drive shaft/actuator 26 is the only component in the system 100 providing vibration reduction/suppression. In still yet another embodiment of the invention, the drive shaft/actuator 26 and the motor mounts 21a/b and 25a/b are the only components providing vibration reduction/suppression.

[0058] FIG. 8 illustrates the quiet integrated cylindrical motor system 100 of the invention, with portions broken away to show the underlying portions, deployed in a window shade or projection screen structure. The system 100 is shown within the outer motor housing 30, within which resides the motor and gear assembly 22 and other parts shown therein and in other figures to permit the motor and gear assembly 22 to drive the drive hub 28, which is engaged with and causes the drive wheel 50 to rotate. The outer roller mechanism 49 has a larger inner diameter than the motor system housing 30, and engages the drive wheel 50. The drive wheel 50 causes the outer roller mechanism 49 to rotate. The drive wheel 50 preferably is of a larger diameter than the motor housing 30. Rotation of drive wheel 50 causes the outer roller mechanism 49 to rotate about its horizontal axis. A reelable shading window treatment or projection screen 51 is attached to at least one horizontal edge, or cords of a window treatment such as a Roman shade are attached, to the outer roller mechanism 49. When the outer roller mechanism 49 is rotated, the shade or other window treatment or projection screen 51 is wound around the mechanism 49, causing the treatment or screen to be raised or lowered. The motor collar 73 that resides near the motor head 29, which sits in a mounting bracket, also rotates freely allowing the rotatable tube that is the outer roller mechanism 49 to utilize the motor system 48 as a rotating support on the motor end of the mechanism.

Referring to FIG. 9_± there is shown a preferred, non-limiting embodiment of the quiet integrated motor system 200, according to the present invention. Similarly to the system 100 described previously, this embodiment of the quiet integrated motor system 200 includes a mechanical limit switch 201, a primary vibration suppression motor mount 202, primary mounting post 203, motor and gearbox assembly 204, and outer casing 214. In this embodiment, the vibration of the output drive assembly 250 is suppressed through a different combination of components and arrangement of materials. The output drive assembly 250 is also shown in Fig. 10. A output drive inner cap 205 preferably made of ABS plastic or a material with similar properties connects to the output drive 204a of the motor/gear assembly 204. A first end of the output drive actuator 207, preferably made of polyurethane 80 or similar semi-soft material engages with the output drive inner cap 205 and is secured in place through the output drive inner plug 206. This inner plug 206 is preferably made of a soft, highly vibration absorbent material such as rubber or polyurethane 50A. A second, opposite end of the output drive actuator 207 engages with the output drive outer cap 208 preferably made of a strong material such as ABS plastic. A needle bearing assembly 260, whose components are made of steel or similar material, is disposed between the output drive outer cap 208 and the output drive hub 212, preferably made of polyurethane 80. The needle bearing assembly 260, also shown in FIG. 12, includes a needle bearing seat 211 preferably made of polyurethane 80 and a needle bearing 210 and bearing retaining spring 209 made of steel or similarly strong material. The output drive hub 212 preferably made of polyurethane 80 is secured to the output drive outer cap 208 with assembly bolt 213.

[0059] FIG. 1 1 shows several views of the output drive hub 212. These views show a wider inner dimensions to accommodate a larger drive shaft/actuator. Fig. 12 shows detail of the bearing components described above. These components also have a larger diameter to accommodate the larger drive shaft/actuator.

[0060] FIG. 13 shows most of the components that comprise the output drive shaft assembly 250, some partially assembled to indicate the interaction of the soft and hard parts to provide a unique combination of sound absorption and long-lasting strong components. FIG. 14 shows additional details of the output drive actuator 207 that has been assembled in part. The various components of the device according to the invention may be composed of a variety of materials and may include interspersed hard and soft material that interdigitate to form strong, long lasting components and system. The components are manufactured according to well-known processes such as molding and casting, The following are non-limiting examples of these materials. The primary motor mount 21a is comprised of rubber, plastic or urethane 50A or other material that provides vibration absorption properties. The primary motor mounting post 21b is comprised of plastic (preferably ABS plastic) or metal. The motor sleeve/jacket 24 or coating is comprised of vinyl, rubber or fiberglass (or combination thereof) or other material that provides vibration absorption properties. The secondary motor mount seat 25a is composed of plastic or metal. The secondary motor mount 25b is comprised of rubber, plastic or urethane or other material that provides vibration absorption properties. The outer roller mechanism 49 is comprised of aluminum or steel. The drive wheel 50 is comprised of plastic, rubber or urethane or other material that provides vibration absorption properties. The drive shaft /actuator 26 is comprised of rubber, plastic or urethane (or combination thereof) or other material that provides vibration absorption properties. The output drive 23 is comprised of metal, plastic or possibly a high strength ceramic. The output drive hub 28 is comprised of plastic, rubber or urethane or other material that provides vibration absorption properties. The bearing 27a is comprised typically of metal, and the bearing seat typically is plastic or metal. Any existing or new material can be substituted, as long as it has similar characteristics to the materials mentioned above. [0061] Although specific embodiments have been illustrated and described herein, those of ordinary skill in the art will appreciate that any arrangement calculated to achieve same purposes can be substituted for the specific embodiments or exemplary methods shown, such as the substitution of various combinations of character types. This disclosure is intended to cover any and all adaptations or variations of various embodiments of the invention. It is to be understood that the above description has been made in an illustrative fashion, and not a restrictive one. Combinations of the above embodiments, and other embodiments not specifically described herein will be apparent to those of skill in the art upon reviewing the above description. The scope of various embodiments of the invention includes any other applications in which the above methods are used. Therefore, the scope of various embodiments of the invention should be determined with reference to the appended claims, along with the full range of equivalents to which such claims are entitled.

[0062] In the foregoing description, if various features are grouped together in a single embodiment for the purpose of streamlining the disclosure, this method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments of the invention require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus, the following claims, and such other claims as may later be added, are hereby incorporated into the description of the embodiments of the invention, with each claim standing on its own as a separate preferred embodiment.

Claims

What is claimed is:

1. A motor system for rotatably raising and lowering window shades and/or projection screens, comprising the following:

a motor and gear box assembly;

a rotatable output drive connected to the gear box end of the motor and gear box assembly;

a first vibration suppression motor mount and mounting post at the motor end of the motor and gear box assembly;

a vibration suppression sleeve disposed on the motor and gear box assembly;

a secondary vibration suppression motor mount and motor mount seat at the gear box end of the gear box assembly and having a central aperture which receives the output drive; a vibration reduction drive shaft/actuator having a first end and a second end;

a bearing and a bearing seat, each having a central aperture which receives the second end of the drive shaft/actuator; and

an output hub having a first end which receives the second end of the drive shaft/actuator and which rotates as the drive shaft/actuator rotates.

2. The motor system of Claim 1 further including an outer housing wherein at least a portion of the output hub extends beyond the outer housing.

3. The motor system of Claim 1 wherein the vibration suppression sleeve is a hollow cylindrical shaped structure that has at least one rib on its outer surface, the rib contacting an interior surface of the outer housing.

4. The motor system of Claim 1 wherein the vibration suppression sleeve is a hollow cylindrical shaped structure that has a plurality of ribs on its outer surface, the ribs being disposed around the circumference of the vibration suppression sleeve in a staggered arrangement, each rib contacting an interior surface of the outer housing.

5. The motor system of Claim 1 wherein the vibration suppression sleeve is a coating that is applied directly to the motor and gearbox assembly.

6. The motor system of Claim 1 wherein the vibration suppression sleeve engages the first vibration suppression motor mount and the second vibration suppression motor mount.

7. The motor system of Claim 1 wherein the vibration suppression sleeve is made from vinyl, rubber, plastic, or combinations thereof.

8. The motor system of Claim 1 wherein the vibration reduction drive shaft/actuator is made from plastic, rubber, urethane, metal, andcombinations thereof.

9. The motor system of Claim 1 wherein the first end of the vibration reduction drive shaft engages with the output drive.

10. The motor system of Claim 1 wherein the vibration reduction drive shaft includes an inner cap, a drive actuator, and an outer cap, wherein the inner cap and outer cap are made from a hard material and the drive actuator is made from a vibration-absorbing material.

1 1. The motor system of Claim 10 wherein the hard material is plastic and the vibration- absorbing material is rubber or polyurethane.

12. The motor system of Claim 1 wherein the bearing is a ball bearing.

13. The motor system of Claim 1 wherein the bearing is a needle bearing.

14. A motor system for rotatably raising and lowering window shades and/or projection screens, comprising the following:

an outer housing,

a motor and gear box assembly disposed within the outer housing, the motor and gear box assembly having a first and a second end, wherein a rotatable output drive is connected on a first end;

a first vibration suppression motor mount disposed at the second end of the motor and gear box assembly, the first vibration suppression motor mount comprising a vibration absorption body and an outer contact ring wherein only the outer contact ring is in contact with an interior surface of the outer housing;

a vibration suppression sleeve that at least partially surrounds the motor and gear box assembly, the vibration suppression having at least one projection on an exterior surface; a vibration reduction drive shaft/actuator having a first end and a second end wherein the first end engages the output drive; and an output hub having a first end which receives the second end of the drive shaft/actuator and which rotates as the drive shaft/actuator rotates.

15. The motor system of Claim 14 wherein the vibration suppression sleeve has at least one projection on an interior surface.

16. The motor system of Claim 14 wherein the first vibration suppression motor mount further includes a mounting post, wherein the mounting post and the vibration absorption body are connected through a key mechanism.

17. The motor system of Claim 14 further including a second vibration suppression motor mount that is disposed between the motor and gear box assembly and the outer housing.

18. The motor system of Claim 14 wherein the vibration suppression sleeve is a hollow cylindrical unitary structure.

19. The motor system of Claim 14 wherein the vibration suppression sleeve is a hollow cylindrical multi-part structure.

20. The motor system of Claim 14 wherein the output drive hub is made from plastic, rubber, urethane, any other material that provides vibration absorption properties and combinations thereof; and wherein the output drive is made from metal, plastic, high strength ceramic, and combinations thereof.