Apparatus and method for the production of roller blinds

Abstract

Apparatus for use in the manufacture of roller blinds includes means for mounting and rotating one or more roller blind tubes, means for aligning the fabric and means for cutting the fabric to a desired width. Each of these means is arranged in a fix angular arrangement with respect to the other. The mounting means are adjustable to accommodate roller blind tubes of different lengths and the width cutting means are adjustable also. Preferably an adjustable width cutting means and an adjustable mounting means are mounted on a common bracket for adjustment in a single step.

1 . Apparatus for use in the manufacture of a roller blind comprising: 
 (i) drive means for feeding a web of fabric through the apparatus parallel to a first direction;    (vi) alignment means for aligning the web of fabric with respect to the first direction;    (vii) first and second roller blind tube mounting means for mounting a roller blind tube on the apparatus by its respective ends such that the longitudinal axis of the tube lies in a second direction perpendicular to the first direction, wherein at least one of the mounting means is adjustable in the second direction in order to mount roller blind tubes of different lengths;    (viii) roller blind tube drive means for driving one of the mounting means to rotate the roller blind tube about its longitudinal axis;    (ix) width cutting means for cutting the web of fabric to a desired width in accordance with the length of the roller blind tube    wherein the alignment means, mounting means and cutting means are mounted in fixed angular relation with respect to one another.    
     
     
         2 . Apparatus as claimed in  claim 1  wherein the width cutting means comprise at least a first width cutting means which is adjustable in the second direction and is mounted in fixed angular relation to the alignment means and the mounting means.  
     
     
         3 . Apparatus as claimed in  claim 2  wherein the adjustable width cutting means is mounted in fixed relation to the adjustable mounting means, for movement therewith.  
     
     
         4 . Apparatus as claimed in  claim 3  wherein the adjustable mounting means and the adjustable width cutting means are mounted on a common bracket, which bracket is mounted for slideable movement parallel to the second direction.  
     
     
         5 . Apparatus as claimed in  claim 4  including means for locking the common bracket in a desired location after adjustment.  
     
     
         6 . Apparatus for use in the manufacture of roller blinds comprising: 
 (i) drive means for feeding a web of fabric through the apparatus parallel to a first direction;    (vi) alignment means for aligning the web of fabric with respect to the first direction;    (vii) mounting components for mounting n roller blind tubes, where n is an integer greater than 1, such that the longitudinal axis of each roller blind tube lies in a second direction perpendicular to the first direction, said mounting components comprising first mounting means for mounting a proximal end of a first roller blind tube, second mounting means for mounting a distal end of a final roller blind tube and n−1 intermediate mounting means for mounting adjacent respective proximal and distal ends of intermediate roller blind tubes, or, where n=2 for mounting the distal end of the first roller blind tube and the adjacent proximal end of the second roller blind tube, the second and intermediate mounting means being adjustable in the second direction in order to mount roller blind tubes of different lengths;    (viii) roller blind tube drive means for driving one of the mounting means to rotate the roller blind tubes about the longitudinal axis and;    (ix) a plurality of width cutting means for cutting the web of fabric to a desired widths in accordance with the respective lengths of the roller blind tubes    wherein the alignment means, mounting means and cutting means are mounted in fixed angular relation with respect to one another.    
     
     
         7 . Apparatus as claimed in  claim 6  wherein at least n of the width cutting means are adjustable in the second direction and are mounted in fixed angular relation to the alignment means and the mounting means.  
     
     
         8 . Apparatus as claimed in  claim 7  wherein the adjustable width cutting means are mounted in fixed relation to respective adjustable mounting means, for movement therewith.  
     
     
         9 . Apparatus as claimed in  claim 8  wherein each respective adjustable mounting means and adjustable width cutting means is mounted on a common bracket, which brackets are mounted for slideable movement parallel to the second direction.  
     
     
         10 . Apparatus as claimed in  claim 9  including means provided on each common bracket for locking the bracket in a desired location after adjustment.  
     
     
         11 . Apparatus as claimed in any preceding claim wherein the drive means comprise a pair of pinch rollers mounted with their axes of rotation parallel to the second direction and perpendicular to the first direction.  
     
     
         12 . Apparatus as claimed in any preceding claim comprising a planar support surface over which the web of fabric is passed prior to the drive means.  
     
     
         13 . Apparatus as claimed in  claim 12  wherein the alignment means comprises a planar surface disposed at one side of the support surface, said planar surface having a component parallel to the first direction and perpendicular to the second direction, and along which in use, the edge of the fabric makes running contact.  
     
     
         14 . Apparatus as claimed in any of  claim 13  wherein the planar support surface comprises a cutting guide for ensuring accurate cutting of the trailing end of the fabric.  
     
     
         15 . Apparatus as claimed in  claim 14  wherein the cutting guide comprises a linear groove disposed in the planar support surface.  
     
     
         16 . Apparatus as claimed in  claim 14  or  15  further comprising clamping means operable to hold the fabric against the planar surface during cutting of the trailing end of the fabric.  
     
     
         17 . Apparatus as claimed in any preceding claim wherein the roller blind tube drive means includes a slipping clutch operative to maintain a desired tension in the web of fabric.  
     
     
         18 . Apparatus as claimed in any preceding claim further comprising a brake operable to act on the roller blind tube drive means.  
     
     
         19 . Apparatus as claimed in any preceding claim further comprising means of introducing back tension to the web of fabric.  
     
     
         20 . Apparatus as claimed in any preceding claim further comprising electronic control means operative to start and stop the respective drive means.  
     
     
         21 . Apparatus as claimed in  claim 20  wherein the control means is operative to stop the respective drive means at a predetermined point for cutting of the trailing end of the fabric.  
     
     
         22 . Apparatus as claimed in  claim 21  wherein the control means calculates the predetermined point in accordance with an operator input of a desired blind length.  
     
     
         23 . Apparatus as claimed in  claim 20 ,  21  or  22  when dependent on  claim 18  wherein the control means is operative to apply the brake as the trailing end of the fabric approaches the cutting means.  
     
     
         24 . A roller blind tube for use on the apparatus of any preceding claim comprising a hollow metal tube and a cutting guide for guiding cutting of the leading end of the fabric.  
     
     
         25 . A roller blind tube as claimed in  claim 24  wherein the cutting guide comprises a linear groove disposed in the external surface of the roller blind tube, and parallel to the longitudinal axis of the tube.  
     
     
         26 . A roller blind tube as claimed in  claim 24  or  25  including a formation, operative to co-operate with a corresponding formation on the driven roller blind tube mounting means, whereby the roller blind tube is mountable on the apparatus only in a predetermined rotational orientation.  
     
     
         27 . Apparatus as claimed in any of  claims 1  to  23  further comprising a roller blind tube as claimed in  claim 24 ,  25  or  26 .  
     
     
         28 . An assembly for use in the manufacture of a roller blind comprising a roller blind tube as claimed in any of  claims 24  to  26  and a body of fabric wound around the roller blind tube.  
     
     
         29 . An assembly as claimed in  claim 28  wherein the edges of the body of fabric are parallel to the respective ends of the roller blind tube and/or the trailing end of the body of fabric is parallel to the longitudinal axis of the roller blind tube.  
     
     
         30 . A roller blind including a roller blind tube as claimed in  claim 24 ,  25  or  26  or including an assembly as claimed in  claim 28  or  29 .  
     
     
         31 . A method of producing an assembly for use in the manufacture of a roller blind, said assembly comprising a roller blind tube with a body of fabric wound thereupon, the method comprising the steps of: 
 (xiv) providing an apparatus as claimed in  claim 1;     (xv) providing a roller blind tube;    (xvi) mounting a first end of the roller blind tube on the driven roller blind tube mounting means;    (xvii) adjusting the location of the adjustable roller blind tube mounting means and mounting the second end of the roller blind tube on said adjustable roller blind tube mounting means;    (xviii) adjusting the location of the width cutting means at at least one side of the apparatus in accordance with the desired width of the body of fabric.    (xix) aligning a web of fabric with the alignment means;    (xx) driving the respective driving means to drive the web of fabric through the apparatus via the width cutting means until the leading end reaches the roller blind tube;    (xxi) stopping the drive means and mounting the leading end of the web of fabric on the roller blind tube;    (xxii) re-starting the respective drive means and driving a predetermined length of fabric through the apparatus via the width cutting means;    (xxiii) stopping the respective driving means;    (xxiv) cutting the trailing end of the fabric along a line perpendicular to the adjacent means;    (xxv) re-starting the respective driving means; and    (xxvi) optionally, applying a brake to the driving means of the roller blind tube mounting means to slow said means as the trailing end of the web of fabric is cut by the width cutting means.    
     
     
         32 . A method as claimed in  claim 31  wherein the adjustable roller blind tube mounting means and the adjustable width cutting means are mounted in fixed relation to each other whereby steps (iv) and (v) are performed in a single operation.  
     
     
         33 . A method as claimed in  claim 31  or  32  including, after step (viii), the step of (viii)a) cutting the leading edge of the web of fabric so that it is parallel to the longitudinal axis of the roller blind tube.  
     
     
         34 . A method as claimed in  claim 33  wherein the roller blind tube includes a cutting guide in its external surface in the form of a linear groove parallel to the longitudinal axis of the roller blind tube, and said step (viii)a) comprises cutting said leading edge with a knife by guiding the knife blade in said groove.  
     
     
         35 . A method as claimed in any of  claims 31  to  34  further comprising providing a slipping clutch for the roller blind tube driving means and maintaining a desired tension in the web of fabric by means of said slipping clutch.  
     
     
         36 . A method as claimed in any of  claims 31  to  35  further comprising, in step (xi), providing a planar support surface having a cutting guide in the form of a linear groove perpendicular to the alignment means and cutting said trailing end by guiding a cutting knife along said groove.  
     
     
         37 . A method as claimed in any of  claims 31  to  36  further comprising the step of providing clamping means and clamping the web of fabric against a support surface and in step (xi) cutting the trailing end of the web of fabric proximate said clamping means.  
     
     
         38 . A method as claimed in any of  claims 31  to  37  further comprising the step of introducing back tension into the web of fabric.  
     
     
         39 . An apparatus or method substantially as hereinbefore described with reference to any of FIGS.  1  to  15 .