Process and system for manufacturing a roller blind

Abstract

A process and system for manufacturing roller blinds is provided which includes structure for performing plural steps including a first step of helically winding slat fabric about a drum, thereby forming a slat product. A second step includes moving the slat product from the drum to a platform. A third step includes winding the slat product about a roller tube to form a roller blind. A fourth step includes moving the blind from the platform to a heat treating device.

1 . A method of manufacturing a blind including a roller and a covering material, the covering material being formed by overlapped layers of fabric, the method comprising:
 helically winding fabric about a drum to form the covering material formed by the overlapped layers of fabric, the covering material including one or more cells;   attaching the roller to a top end of the covering material;   winding the covering material about the roller; and   heat treating the blind to set a wound shape into each layer of the overlapped layers of fabric.   
     
     
         2 . The method of  claim 1 , wherein the one or more cells includes a first cell and a second cell, a first adjacent layer of the overlapped layers of fabric forms a rear surface of the first cell and a front surface of the second cell. 
     
     
         3 . The method of  claim 1 , wherein the one or more cells includes a first cell and a second cell, each of the first and second cells includes a front surface and a rear surface, the rear surface of each of the first and second cells is formed from a first layer of the overlapped layers of the covering material, the front surface of each of the first and second cells is formed by a later laid second layer of the overlapped layers of the covering material, the later laid second layer being laid on top of the first layer. 
     
     
         4 . The method of  claim 1 , further comprising:
 attaching a second layer of the overlapped layers of the covering material to a previously laid first layer of the overlapped layers of the covering material, the second layer forming a front surface of a cell.   
     
     
         5 . The method of  claim 1 , wherein helically winding fabric about a drum to form the covering material includes forming attachment lines spaced along an axis of the drum to define the one or more cells between adjacent attachment lines. 
     
     
         6 . The method of  claim 5 , wherein forming the attachment lines comprises adhering adjacent layers of the overlapped layers of the covering material together via adhesive lines. 
     
     
         7 . The method of  claim 6 , further comprising applying the adhesive lines to the fabric prior to helically winding the fabric about the drum. 
     
     
         8 . The method of  claim 1 , wherein helically winding fabric about the drum comprises:
 attaching an end of the fabric to the drum;   rotating the drum about the axis of the drum; and   moving the fabric along a length of the drum via a fabric distributing structure as the fabric is being wound around the drum.   
     
     
         9 . The method of  claim 1 , further comprising moving the covering material to a platform, wherein moving the covering material to the platform comprises:
 restricting rotation of the drum; and   cutting the covering material along an axial opening in the drum.   
     
     
         10 . The method of  claim 9 , further comprising:
 gripping an edge of the covering material formed by cutting the covering material; and   moving the edge of the covering material lateral to the axis of the drum to unwind the covering material from the drum and position the covering material onto the platform.   
     
     
         11 . The method of  claim 10 , wherein gripping the edge of the covering material comprises gripping the edge via a movable magnet. 
     
     
         12 . The method of  claim 1 , further comprising trimming the covering material at opposing ends thereof to form the top end and a bottom end of the covering material. 
     
     
         13 . The method of  claim 1 , further comprising encapsulating the blind to keep the overlapped layers of fabric tightly wound about the roller. 
     
     
         14 . The method of  claim 1 , wherein the wound shape comprises a spiral curvature profile. 
     
     
         15 . A method of manufacturing a blind including a roller and a covering material, the covering material being formed by overlapped layers of fabric, the method comprising:
 helically winding fabric about a drum to form the covering material formed by the overlapped layers of fabric;   attaching the roller to a top end of the covering material;   winding the covering material about the roller; and   heat treating the blind to set a wound shape into each layer of the overlapped layers of fabric;   wherein a first adjacent layer of the overlapped layers of fabric forms a front surface of a first cell and a rear surface of an adjacent second cell.   
     
     
         16 . The method of  claim 15 , wherein helically winding fabric about a drum to form the covering material includes forming attachment lines spaced along an axis of the drum to define a cell between adjacent attachment lines. 
     
     
         17 . The method of  claim 16 , further comprises adhering adjacent layers of the overlapped layers of fabric together via adhesive lines. 
     
     
         18 . A method of manufacturing a blind including a roller and a covering material, the covering material being formed by overlapped layers of fabric, the method comprising:
 helically winding fabric about a drum to form the covering material formed by the overlapped layers of fabric, the covering material including one or more cells therebetween;   attaching the roller to a top end of the covering material;   winding the covering material about the roller; and   heat treating the blind to set a wound shape into each layer of the overlapped layers of fabric;   wherein the wound shape includes a concave curvature.   
     
     
         19 . The method of  claim 18 , wherein a first adjacent layer of the overlapped layers of fabric forms a front surface of a first cell and a rear surface of an adjacent second cell. 
     
     
         20 . The method of  claim 18 , helically winding fabric about a drum to form the covering material includes forming attachment lines spaced along an axis of the drum to define the one or more cells between adjacent attachment lines. 
     
     
         21 . The method of  claim 18 , wherein the concave curvature is facing a layer of the overlapped layers of fabric over which the fabric is laid. 
     
     
         22 . The method of  claim 18 , wherein the concave curvature corresponds to a curvature of the roller.