WO2021148480A1

WO2021148480A1 - Motorised roller blind actuation device

Info

Publication number: WO2021148480A1
Application number: PCT/EP2021/051220
Authority: WO
Inventors: Adam Michael ALLISON; Jonathan Stephen Luke MCEWAN
Original assignee: E-Smart Home Systems Limited
Priority date: 2020-01-20
Filing date: 2021-01-20
Publication date: 2021-07-29
Also published as: GB2592899A; GB202000813D0

Abstract

A motorised roller blind actuation device (100). The roller blind actuation device (100) comprises attachment means (180) for attachment of the device to a roller blind comprising a roller tube having first and second open ends. The roller tube supports a blind material, and the attachment means (180) are insertable into the first open end of the roller tube. The device (100) also comprises a powered motor (140) arranged to rotate the attachment means (180), wherein the powered motor (140) is arranged so that, when the attachment means (180) are inserted into the roller tube, the powered motor (140) is external to the roller tube. A roller blind comprising the motorised roller blind actuation device is also provided.

Description

Motorised Roller Blind Actuation Device

[0001] This invention is a motorised roller blind actuation device and separately a roller blind having a motorised roller blind actuation device. [0002] Roller blinds are commonly fitted about window frames and are used to control light intrusion through a window. A roller blind comprises a blind fabric wound about a roller tube. Generally, the roller tube is supported between a pair of end brackets that are mounted upon, or adjacent to, the window frame. The fabric is deployed and retracted by rotation of the roller tube. Rotation of the tube may be actuated in a number of different ways and will typically include a drive mechanism which may comprise a looped chord or rotatable wand attached to one end of the roller tube. Pulling either side of the looped chord or rotating the wand causes the roller tube to rotate and the blind fabric to be deployed or retracted accordingly. [0003] Whereas the blinds described above are manually actuated, some roller blind are provided with a motorised drive mechanism. In some prior art systems, a motor is attached to the looped chord of a blind and rotation of the motor rotates the blind tube with the looped chord to deploy or retract the blind. However, these motorised blinds, and blinds having looped chords in general, present a strangulation hazard. Furthermore, with the motorised looped chord blinds there is significant stress placed on the chord which greatly reduces its working life.

[0004] Alternatively, motorised roller blinds are provided with an internal cylindrical motor provided inside the roller tube. Rotation of the internal motor causes rotation of the roller tube to retract and deploy the blind. However, such motors are larger than the standard diameter of a roller tube. Therefore, these motors can only be provided in specially-adapted blind systems and cannot be incorporated into a user’s pre-existing blind system. Therefore, there is a considerable cost to a user of having to replace all of their blinds should they wish to switch to a motorised blind system. The present invention addresses the disadvantages of the prior art systems. [0005] Therefore, according to the present invention there is provided a motorised roller blind actuation device comprising attachment means for attachment of the device to a roller blind, the roller blind comprising a roller tube having first and second open ends, the roller tube supporting a blind material, the attachment means being insertable into the first open end of the roller tube; a powered brushless motor arranged to rotate the attachment means; a housing in which the powered brushless motor is disposed; wherein the attachment means extend from the housing so that, when the attachment means are inserted into the roller tube, the powered motor is external to the roller tube.

[0006] A motorised roller blind actuation device according to this invention can therefore be retrofitted to existing roller blinds, as well as being provided as part of a system also including a roller blind.

[0007] The device comprises a housing in which the brushless powered motor is disposed, wherein the attachment means extend from the housing. The housing could be any appropriate shape to house the motor and be made from any suitable material such as metal or a plastics material. Preferably, the housing will be dimensioned such that the device can, in use, be attached to one open end of the roller tube and then be attached to the wall or a window frame in place of one of the end brackets that would normally be attached to the roller tube. Prior art end brackets/caps tend to be relatively narrow, and so at least the part of the device that connects to the end of the roller tube is preferably of a similar width to a prior art end cap. Preferably, the part of the device that connects to the end of the roller tube and is disposed between the end of the roller and the wall is 10- 15mm wide.

[0008] So that the housing can be attached to a surface, the device may further comprise a bracket, attachable to a surface such as a window frame, recess or wall, the housing being releasably attached to the bracket. The bracket can be attachable to a surface by any means such as being provided with adhesive strips or be provided with screw holes in order to firmly attach the bracket to the surface. The housing is preferably removable from the bracket, firstly to aid installation of the blind but also to permit easy removal for servicing of the housing. [0009] To permit releasable attachment of the housing to the bracket, the housing preferably comprises a slot for receiving the bracket. The bracket preferably comprises a cantilever having an engagement part, the cantilever being insertable into the slot for engagement with the housing. The cantilever may be U-shaped and extend away from a side edge of the bracket, and loop back above an upper surface of the bracket. The engagement part may comprise a resilient raised lip for releasable insertion into the slot provided in the housing, and the slot may further comprise an aperture to receive the raised lip.

[0010] Preferably, the housing further comprises a release mechanism for releasing the cantilever portion from the housing, so as to release the housing from the bracket when desired. Alternative releasable attachment means for attaching the housing to the bracket can be provided such as a press fit or bolted fit. The release mechanism may comprise a shaft, a spring and an end cap arranged so that the end cap is external of the housing and the shaft extends into the housing, wherein the spring biases the release assembly in a raised position. When the housing is engaged with the bracket and the cantilever is inserted into the slot, and the raised lip is engaged with the aperture, the base of the shaft may be provided above the raised lip.

[0011] The attachment means may comprise a spigot extending from the housing. The spigot is then insertable into the first open end of the roller tube. The attachment means may further comprise a plug insertable into the first open end of the roller tube, the plug being dimensioned to form a pressure fit within the surface of the roller tube. The plug in use can be attached to the spigot extending from the housing. The plug may be cylindrical and comprise a plurality of radial attachment members extending from the outer surface of the plug, the radial attachment members being of different lengths and having frangible sections. The plus is therefore insertable into roller tubes of different diameters. Some of the frangible radial attachment members may be longer than the radius of the roller tube. Therefore, when the plug is inserted into the open end of the roller tube, any frangible members that are longer than and extend beyond the radius of the roller tube will snap off and those radial members that are the same radius as the roller tube will form a pressure fit with the inside of the roller tube. Alternatively, a kit may be provided with a plurality of different sized plugs to fit into a range of different sized tube diameters.

[0012] The device may further comprise a second attachment means, attachable to a second open end of the roller tube and may further comprise a second bracket attachable to a surface, the second attachment means being supportable and rotatable within the second bracket. The second bracket may be provided with the present device or could be a bracket previously attached to the roller tube if the present device is being retrofitted.

[0013] The powered motor is a brushless motor. Brushed motors are potentially disadvantageous in that they are larger than brushless motors, and have a shorter active life.

[0014] Power to the motor may be provided by any suitable means, and the device may include at least one of batteries, solar panels and attachment to mains power, or a combination thereof.

[0015] The motor may be connected to the attachment means via a drive train so that rotation of the motor drives rotation of the attachment means. The drive train may be in the form of gears, so that the speed of rotation of the roller blind tube relative to the speed of rotation of the motor can be controlled. Alternative drive trains such as a belt and pulley may be provided instead of gears. A belt and pulley may be advantageous in that it may dampen motor noise in use. Alternatively, the drive train may comprise spur gears. The spur gear drive train may comprise a self-locking mechanism. Spur gears are advantageous in being able to convert a high level of revolutions of the motor to a high level of torque capable of deploying blinds comprising the heaviest fabric at an appropriate speed and with good control.

[0016] It is preferred that the motor drive train does not backdrive under the weight of the blind. It is therefore preferred that the drive train comprises a self locking mechanism to prevent backdriving. A preferred drive train comprises a self-locking mechanism comprising a worm gear at the first gear stage. This ensures that the heaviest blind can be supported in all scenarios, without the use of a sizeable and costly electromagnetic brake. [0017] The device may further comprise control means, the control means being arranged to actuate the motor in a clockwise or counter clockwise direction. The control means may be wirelessly controllable. Wireless control could be via infrared whereby the device comprises an infrared sensor and is controllable via an infrared transmitter. The device may alternatively be linked to a mesh network and can be controlled by an interconnected device such as a mobile telephone, and/or via a hub. Alternative control means can operate through the following communication protocols: Bluetooth®, Z Wave, Wi-Fi, 6 LoWPAN, ZigBee, Thread and IEE 802.15.42016, or other known protocols.

[0018] According to a second aspect of the present invention, there is provided a roller blind comprising a roller tube and blind fabric, and further comprising a motorised roller blind actuation device as previously described. [0019] So that it may be better understood, embodiments of the present invention will be described in detail by way of example only with reference to the following drawings:

Figure 1 shows a prior art roller blind system;

Figure 2 shows an exploded view of the motorised roller blind actuation device;

Figures 3 a-f show various views of a fully assembled motorised roller blind actuation device;

Figures 4 a-c shows housing of a motorised roller blind actuation device from a side, top and end perspective, respectively;

Figures 5 a and b show a top and side view of a first lid part of the motorised roller blind actuation device respectively;

Figures 6 a and b show a top and side view of a second lid part of the motorised roller blind actuation device respectively;

Figures 7 a and b show a top and side view of an inner plate;

Figures 8 a-f shows a brushless motor and base;

Figures 9 a-f show the components of a gear assembly;

Figures 10 a-d show further components of the gear assembly as shown in Figures 9 a-f; Figures 11 a-d show various views of end caps for attachment to a roller blind tube;

Figure 12 a-c show various views of a bracket;

Figure 13 shows part of a release mechanism; and

Figure 14 shows an exploded view of a second bracket.

[0020] With reference first to Figure 1 there is shown a roller blind system generally indicated 10 that is comprised of a pair of end plugs generally indicated 12, 14 which support a roller tube generally indicated 16. A blind fabric generally indicated 18 is wound around the roller tube 16. The roller tube 16 is hollow to receive the end plugs 12, 14. One end plug 12 is an idle end fitting, and is mounted to a bracket 26, which is attachable to a surface such as a wall or window frame. The end cap 12 can freely rotate about the bracket 18. The other end plug 14 is attached to a clutch mechanism 22 which includes pull chord 24 (or may alternatively comprise a wand or motor) to drive the rotation of the roller tube 16 in one direction or the other in order to wind or unwind the blind fabric 18 about the surface of the roller tube 16. The roller blind actuation device according to the present invention may be provided in the place of the end plug 14 and clutch mechanism 22.

[0021] Turning now to Figure 2, there is shown a motorised roller blind actuation device generally indicated 100. The device 100 comprises a housing generally indicated 110, a bracket generally indicated 120, a motor generally indicated 140, a release mechanism generally indicated 150, a control chip generally indicated 160, a drive train generally indicated 170, and attachment means generally indicated 180.

[0022] T urning now to Figure 2, Figures 3a-f and Figures 4a-c, there is shown the motorised roller blind actuation device 100 fully assembled, and also various views of the housing 110. There is shown a housing comprising a body section generally indicated 200 comprising generally L-shaped side walls 210, front wall 220, rear wall 230 and base 240. The side walls 210 comprise a wide section 242 and a narrow section 244. Rear wall 230 further comprises a slot 246 which is parallel with the plane of the base 240. [0023] As further shown in Figures 5a-b there is provided a first lid part generally indicated 250 having a generally L-shaped side profile (as shown in Figure 5b) and further comprising an aperture for receiving a release mechanism 150 (discussed later). First lid part 250, as shown in Figure 3, is attached to the upper and side edges of the wide section 242 of the side walls 210. Figure 5a-b also show an aperture 270 through which the release mechanism 150 extends when the device 100 is assembled.

[0024] As further shown in Figures 6a-b, there is shown a second lid section generally indicated 260 having an aperture 280 through which the attachment means 180 extends when assembled and a further aperture 290 for receiving the shaft of a gear member (as described below). The underside of the second lid section 260 is provided with four clips 295 at the outer edge thereof to attach the second lid section 260 to the side walls 210 of the housing 200.

[0025] Figure 7, shows an inner plate generally indicated 300 which is attachable to the upper surface of the base 240 of the body 200. The inner plate comprises a generally planar body portion 310, comprising a number of apertures 320, 330, 340, 860, 870 provided for attachment to the motor 140 and drive train 170 (described in more detail below).

[0026] As shown in Figures 2 and 8a-f there is shown a brushless motor generally indicated 400 which is retained in a bracket generally indicated 410. The bracket 410 comprises screw holes 420 for securing the bracket 410 to the inner plate 300 and to the base 240 of the body section 200. The brushless motor 400 further includes a spigot 430 which extends into a first gear cog 440 situated beneath the motor 400 within the bracket 410. Although not shown here, the motor is provided power by at least one of batteries, solar panels, and mains power.

[0027] As shown in Figures 2, 9a-f and 10a-d there is shown a gear assembly generally indicated 500, which comprises part of the drive train 170, which gear assembly 500 comprises three gear cogs generally indicated 510, 520 and 530 respectively. The gear cogs 520 and 530 are rotatably secured to the housing 110 via shafts 540 and 550 respectively. Gear cog 510 is rotatably mounted to the housing via bracket 560 which comprises a generally U-shaped body section 570. The U-shaped body section 570 comprises feet 580 for attachment of the bracket 560 to the inner plate 300 and 240 the base of the housing 110 and an aperture 590. Mounted to gear cog 510 is a spigot generally indicated 600 having a generally cylindrical body 610 which has opposed flattened surfaces 620 at the distal end thereof. The spigot 600 extends through the aperture 590 of the bracket 560 when the device 100 is assembled and is secured via cap 640. The spigot 600 further extends out of the housing 110 through aperture 280 in the lid 260 (as shown In Figure 6a) when assembled and forms part of the attachment means 180. In use, rotation of the motor 400 causes rotation of the gears 510 to 530 and 440 to rotate the spigot 600.

[0028] Although not shown hear, the gear assembly 500 will be encased in a separated housing so as to soundproof the device 100 during use.

[0029] It is preferred that the motor drive train does not backdrive under the weight of the blind. Although not shown here, the drive train comprises a self locking mechanism to prevent backdriving. In an alternative embodiment, not shown here, there is provided a self-locking mechanism comprising a worm gear at the first gear stage and a worm drive.

[0030] The inner plate 300, as shown best in Figure 7a, comprises a series of apertures for attachment of the gear assembly 500. Aperture 320 is positioned to receive spigot 430 of the motor 400 once it has been inserted through gear cog 440 to secure gear cog 440 in place. Apertures 330 and 340 are provided in the inner plate 300 to receive shafts 550 and 540 to secure in place gear cogs 530 and 520 respectively. Aperture 350 is provided to receive spigot 600 of gear cog 510. The inner plate 300 further comprises inner attachment member 360 which comprises an aperture 370 as part of a securing mechanism, which is described later.

[0031] The attachment means 180 as shown in Figures 11a to 11 d further comprises end caps generally indicated 700 which comprise a cylindrical flange member 710, cylindrical insertion member 720 and radially extending attachment members 730. The end caps 700 are hollow and comprises a channel 740 extending therethrough. The end caps are to be inserted into the hollow end of a roller blind tube. The cylindrical insertion member 720 is dimensioned so as to fit inside the end of the roller tube, and the cylindrical flange member 710 is dimensioned so as to abut the end of the roller tube and prevent complete insertion of the end cap 700 into the roller tube. The radially extending attachment members 730 as best shown in Figure 11 d are of varying lengths and comprise frangible portions, as identified by phantom lines 750. When the end caps 700 are inserted into a roller blind tube having a particular radius any radially extending attachment members 730 that extend beyond the radius of the tube will break off, thus ensuring a snug fit of the radially extending attachment members 730 with the inner surface of the tube. The exposed corners of the radially extending attachment members 730 are bevelled to assist with insertion in a roller tube.

[0032] As shown in Figures 11a and 11 b the end caps are further provided with securing means comprising a cylindrical gasket 760 made from a resilient material such as rubber dimensioned so as to fit within the channel 740 of the end caps 700. There is also provided pin members 770, 780 which when inserted into the gaskets 760 cause expansion of the end caps 700 and further secures the end cap 700 in the roller tube. The gasket 760 further has the effect of dampening any vibrations caused by actuation of the motorised roller blind device. Pin member 770 has a extending head portion 775 for retainment in an end bracket as described later. The pin member 780 shown in Figure 11 b comprises a slot 785 in an end thereof for attachment to the narrowed end 620 of the spigot 600 so as to secure the end cap 700 to the body 200 of the device. [0033] As shown in Figures 2 and 12 a-c there is provided a bracket generally indicated 120 for supporting the housing 110 on a surface. The bracket 120 comprises a substantially planar body portion 800 comprising apertures 810 for enabling screwed attachment of the bracket 120 to a surface. Alternatively, the bracket 120 may be provided with adhesive means. The bracket 120 is further provided with extending pegs 820 which extend into the base of the housing 110 when connected. The bracket 120 further comprises a generally U-shaped cantilever 830 including a resilient raised lip 840 for releasable insertion into the slot 246 provided in the back wall 230 of the housing 110 as best shown in Figures 3e and 3f. To connect the housing 110 to the bracket a user slides the housing 110 on to the bracket 120 such that the cantilever 830 enters into the slot 246. Raised lip 840 then engages with the aperture 370 in the inner plate 300. Pegs 820 are then inserted into reciprocal apertures in the base of the housing 110.

[0034] Figures 2 and 13 shows the release assembly generally indicated 150 which comprises a shaft 900, a spring 910, a circlip 930 and end cap 940. The release mechanism 150 is arranged so that end cap 940 is external of the aperture 270 in the lid 250 and the shaft 900 extends into the housing 110 when assembled. The circlip 930 is secured to the housing 110 and the spring 910 biases the release assembly so that the end cap 940 is raised. When assembled so that the housing 110 is attached to the bracket 120 and the cantilever 830 is inserted into the slot 246 and the raised lip 840 is engaged with the aperture 370 of the inner plate 300, the base of the shaft 900 is provided above the raised lip 840. To release the housing 110 from the bracket 120, the end cap 940 is depressed which pushes the shaft 900 into the housing 130 causing the end of the shaft 900 to press the raised lip 840 of the cantilever 830 away from the aperture 370 in the inner plate 300 thus permitting slidable removal of the housing 110 from the bracket 120. After removal, the biased spring 910 raises the shaft 900 within the housing 110. The surface of the end cap 940 distal to the shaft 900 does not raise beyond the level of the lid 250 when raised.

[0035] Figure 14 shows a second bracket, generally indicated 1000 for attachment of the second end of the roller tube to a surface such as a wall or window frame. The bracket 1000 comprises a first member 1010 for attachment to a wall or window frame. The first member 1010 comprises a planar surface 1020 having a series of apertures 1030 for screwed attachment of the first member 1010 to the surface. The first member 1010 further comprises a looped member 1040 which defines an aperture 1050. The looped member extends perpendicularly from a side edge the planar surface 1020 to form a right angle. The second bracket 1000 further comprises a hooked member 1060 for retaining the second end cap 700 attached to the second end of the roller blind tube in use. Flooked member 1060 comprises an aperture 1070 for attachment of the hooked member 1060 to the first member 1010. A screw 1090 may be extended through a washer 1100 and through the aperture 1050 in the first member 1010 and into the aperture 1070 of the hooked member 1060 to connect the two members 1010, 1060. Hooked member includes profiled regions 1080 adjacent aperture 1070 in order to provide a friction grip between the first member 1010 and the hooked member 1060 and prevent relative movement when connected. [0036] Hooked member 1060 further comprises an arm 1110 to define an opening 1120. Retaining member 1130 is attached to an aperture 1140 towards the end of the arm 1110 via a pin 1150, so that the retaining member 1130 is rotationally attached to the hooked member 1060. In use, the head 775 of pin member 770 is inserted into opening 1120 and is releasably secured in place by rotating retaining member 130 to close opening 1120.

[0037] The device also includes control means provided on control chip 160, as shown in Figure 2. The housing 110, as best shown in Figures 4a and 4c, further comprises slot members 1200 into which chip 160 can be inserted. The chip 160 includes processing means for controlling the device 100. The control chip 160 comprises a sensor to receive information from a device such as an infrared sensor to receive infrared signals from an infrared remote control, or may be part of a mesh network to receive information from a control hub or mobile telephone app. The control chip 160 receives information to actuate the blind by rotating the motor in a clockwise or counter clockwise direction, which in turn rotates the blind tube in a clockwise or counter clockwise direction and thus raise or lower the blind. The control chip 160 further comprises a processing resource linked to a database to record the extent to which the blind has been rotated or extracted so that when fully extended or retracted the chip ceases the rotation of the blind. Whilst the user is able to control the extent to which the blind is raised or lowered the chip may detect if there is significant load on the blind, for example, if there is something pulling on the blind or if it is caught. In such cases the control chip will cause the motor to pause. In one example, if the blind is pulled down or snagged the blind motor will stop operation and attempt to correct itself three times before issuing an error message to a user’s interface device.

[0038] In certain embodiments, the blind is controlled via THREAD compatible MCU PCB (160) and is linked to an entire system, which could include control devices, hubs, other blinds etc, via a THREAD network. The MCU chip (160) receives control signals from a user’s interface device for real time operation and may have the function to store pre-set values on a timed interval. In other words, the blind could be programmed to open and close at set times of the day. Additionally, from using a connected sensor network located in a solar charger (if present) there is the function to monitor light and solar gain (temperature) to self-adjust.

Claims

1. A motorised roller blind actuation device comprising: attachment means for attachment of the device to a roller blind, the roller blind comprising a roller tube having first and second open ends, the roller tube supporting a blind material, the attachment means being insertable into the first open end of the roller tube; a powered brushless motor arranged to rotate the attachment means; a housing in which the powered brushless motor is disposed; wherein the attachment means extend from the housing so that, when the attachment means are inserted into the roller tube, the powered motor is external to the roller tube.

2. A device as claimed in claim 1 , wherein the device further comprises a bracket, attachable to a surface, the housing being releasably attachable to the bracket, wherein the housing comprises a slot for receiving the bracket, and wherein the bracket comprises a cantilever having an engagement part, the cantilever being insertable into the slot for engagement with the housing.

3. A device as claimed in claim 2, wherein the cantilever is U-shaped and extends away from a side edge of the bracket, and loops back above an upper surface of the bracket.

4. A device as claimed in claim 2 or claim 3, wherein the engagement part comprises a resilient raised lip for releasable insertion into the slot provided in the housing, and wherein the slot further comprises an aperture to receive the raised lip.

5. A device as claimed in any of claims 2 to 4, wherein the housing further comprises a release mechanism for releasing the cantilever from the housing, so as to release the housing from the bracket.

6. A device as claimed in claim 5, wherein the release mechanism comprises a shaft, a spring and an end cap arranged so that the end cap is external of the housing and the shaft extends into the housing and wherein the spring biases the release assembly in a raised position, wherein when the housing is engaged with the bracket and the cantilever is inserted into the slot, and the raised lip is engaged with the aperture, the base of the shaft is provided above the raised lip.

7. A device as claimed in any of the preceding claims, wherein the attachment means comprise a spigot extending from the housing and wherein the attachment means further comprises a plug insertable into the first open end of the roller tube, the plug being dimensioned to form a pressure fit with an inner surface of the roller tube.

8. A device as claimed in claim 7, wherein the plug is cylindrical, and comprises a plurality of radial attachment members extending from the outer surface of the plug, the radial attachment members being of different lengths and being frangible.

9. A device as claimed in any of the preceding claims, further comprising a second attachment means attachable to the second open end of the roller tube, and further comprising a second bracket attachable to a surface, the second attachment means being supportable and rotatable within the second bracket.

10. A device as claimed in any of the preceding claims, wherein the motor rotates the attachment means via a drive train.

11. A device as claimed in claim 10, wherein the drive train comprises spurred gears.

12. A device as claimed in claim 10 or 11 , wherein the drive train is enclosed in a further housing within the housing of the device.

13. A device as claimed in any of the preceding claims, further comprising control means, the control means being arranged to actuate the motor in a clockwise or counter-clockwise direction.

14. A device as claimed in claim 13, wherein the control means are wirelessly controllable.

15. A device as claimed in claim 14, wherein the device is linked to a mesh network.

16. A roller blind comprising a roller tube and blind fabric, and further comprising a motorised roller blind actuation device as claimed in any preceding claim.