MECHANISM

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001 ] This application claims priority to, and the benefit of, U.S. Provisional Patent Application No. 61 /533,422, filed September 12, 201 1 , the entirety of which is hereby incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention is directed to manually operated window shade assemblies adapted in particular for use in windows of airplanes, that are readily assembled and installed, and which provide convenient and reliable operation. More particularly, the present invention is directed to a manual window shade actuator wherein manipulation of the actuator in a first direction causes release of a brake and allows movement of a window shade in a second direction.

BACKGROUND OF THE INVENTION

[0003] The motorized window shade assembly disclosed in U.S. Patent No. 6,186,21 1 was a major improvement over other mechanisms known at that time and is highly effective in reducing the number of components required, increasing reliability, and meeting the rigid requirements associated with the use aboard aircraft. The shade assembly disclosed in the aforementioned patent includes a pane behind which the shade material, i.e. the shade fabric, is mounted such that direct user contact with the shade material is prevented. As such, the window shade assembly utilizes actuators controlled by electric motors which receive operating power from an aircraft power bus, as is known in the art, to raise and lower the shade fabric. Further improvements of window shade mechanisms are disclosed in U.S. Patent Application Publication No. 201 1/0108208.

[0004] For certain applications, the cost associated with the use of such motor-driven shade assemblies is to be avoided while, simultaneously, utilizing shade assemblies of similar appearance throughout an interior cabin of an aircraft. For example, motorized shade assemblies may be desired in first class and/or business class cabins of an aircraft, whereas non-motorized (i.e., manual) shade assemblies are desired in coach class cabins. Prior art manual aircraft shades typically installed in coach class cabins are configured such that the window shade material is accessible to a passenger and a passenger simply raises or lowers a flange connected to a leading edge of the shade material to raise or lower, respectively, the window shade. The inclusion of such manual shades in coach class cabins of an aircraft, and motorized shade assemblies of the type disclosed in U.S. Patent No. 6,186,21 1 in first or business class cabins of an aircraft, therefore, will not produce a uniform and aesthetically-appealing appearance throughout the aircraft cabin.

[0005] Accordingly, a need exists for a manually-operated shade assembly which is aesthetically similar, from a passenger's perspective, to a motorized shade assembly of the type disclosed in U.S. Patent No. 6,186,21 1 .

SUMMARY OF THE INVENTION

[0006] One object of the present invention is to provide a manually operated window shade assembly for raising and lowering a shade fabric that is mounted behind a pane and, thus, otherwise inaccessible to a passenger.

[0007] Another object of the present invention is to provide a manually operated window shade assembly having a slideable actuator coupled to a brake mechanism which causes disengagement of the brake mechanism when the slideable actuator is manipulated, for raising and lowering of a window shade.

[0008] A further object of the present invention is to provide a manually operated window shade assembly for an airplane having two manually deployed shades which can be selectively controlled by a passenger of the airplane.

[0009] A still further object of the present invention is to provide an actuator mechanism for manually raising and lowering of an airplane window shade by horizontal sliding movement of an actuator assembly for causing vertical raising and lowering of the shade.

[0010] These and other objects are attained in accordance with one aspect of the present invention directed to a manually operated actuator mechanism for operating a window shade for controlling an amount of light admitted through a window of an airplane. The mechanism controls a window shade adapted to be extended from, and retracted to, a member disposed proximate an airplane window or porthole. An actuator assembly is provided and is coupled to an actuator-driven pulley. A cable is looped between the actuator-driven pulley and a second pulley, the second pulley being secured to the housing remotely from the first pulley and, preferably, to an end of the member. A component is coupled to a leading edge of the window shade and is guided by a rail assembly based on motion of the cable in response to manual manipulation of the actuator assembly to extend or retract the window shade across the window. The actuator assembly includes a carrier block which is slidably engaged in a guide track positioned proximate the airplane window, and also includes a brake mechanism which is releasably engaged with the guide track when the actuator assembly is manipulated to allow for slideable movement of the carrier block in the guide track for raising or lowering the shade. Release of the actuator assembly causes redeployment of the brake with the guide track to maintain the shade in its then deployed position.

[001 1 ] In a further embodiment, two actuator assemblies are provided for slidable movement along a common guide track, with each such assembly having an actuator configured as described herein.

[0012] In a further aspect, a window shade assembly, according to the disclosed embodiments, includes one or more shades, each shade being attached at a first end to a shade support and attached at a second end to a moveable elongate member extending between a first frame member and a second frame member. The window shade assembly further includes one or more flexible drive members, each being attached to an end of one of the elongate members and adapted to raise and lower the elongate member to which it is attached. The window shade assembly further includes one or more manual actuator assemblies, one for each shade, adapted to move one of the flexible drive members to move a corresponding shade across the window. Moving one of the manual actuator assemblies in a first direction will drive the corresponding flexible drive member to raise the corresponding elongate member, thereby raising the corresponding shade. Moving the manual actuator assemblies in an opposite, second direction will drive the corresponding flexible drive member to lower the corresponding elongate member, thereby lowering the corresponding shade. The first and second directions are perpendicular to directions of raising and lowering the shades.

[0013] Certain embodiments may include a feature in which moving one of the manual actuator assemblies across an entire horizontal distance of an actuator slot results in a full raising or lowering of one of the shades across an entire vertical height of the window. [0014] Certain embodiments may include a feature in which each of the manual actuator assemblies includes a brake which disengages to allow movement of the manual actuator assembly when an actuator arm extending from the manual actuator assembly is moved away from a biased central position in the first or second direction. The brake engages to stop movement of the manual actuator assembly when the actuator arm is released and returns to the central position.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The above and other objects and advantages of the disclosed subject matter will be apparent upon consideration of the following detailed description, taken in conjunction with accompanying drawings, in which like reference characters refer to like parts throughout, and in which:

[0016] Fig. 1 is a front view of a window shade assembly which includes a manual window shade actuator mechanism in accordance with an embodiment of the invention.

[0017] Fig. 2 is a front view of the window shade assembly of Fig. 1 with the shade fabric removed.

[0018] Fig. 3 is a right-side view of the shade fabric rolls of the window shade assembly taken at line 3-3 of Fig. 1 .

[0019] Fig. 4 is a partial cross-sectional side view taken at line 4-4 of Fig. 1 .

[0020] Fig. 5 is a partial cross-sectional side view taken at line 5-5 of Fig. 1 .

[0021 ] Fig. 6 is an exploded perspective view of a window shade assembly for an aircraft.

[0022] Fig. 7 is a close-up perspective view of the manual window shade actuator mechanism with an actuator arm removed. [0023] Figs. 8a and 8b are top and bottom perspective views, respectively, of two manual actuator assemblies mounted on a common guide track.

[0024] Fig. 8c is a close-up view of a gearing assembly.

[0025] Fig. 9 is an exploded view of a manual actuator assembly absent a carrier block.

[0026] Figs. 10a and 10b are perspective and underside views, respectively of a manual actuator assembly, absent the carrier block, and connected to a timing belt coupler.

[0027] Figs. 10c and 10d show side and cross-sectional views, respectively, of the assembly of Fig. 10a.

[0028] Figs. 1 a-1 b show perspective and underside views, respectively, of a manual actuator assembly with a carrier block positioned in a guide slot in a brake- engaged position.

[0029] Figs. 12a-12b show perspective and underside views, respectively, of the manual actuator assembly with a carrier block positioned in the guide slot in a brake- disengaged position.

[0030] Fig 13 depicts a timing belt mounted to a timing belt coupler.

[0031 ] Figs 14a-14b show right-side plan and bottom perspective views, respectively, of the manual actuator assembly with a carrier block positioned in the guide slot in a brake-engaged position.

[0032] Figs 15a-15b show right-side plan and bottom perspective views, respectively, of the manual actuator assembly with a carrier block positioned in the guide slot in a brake-disengaged position.

[0033] Figs. 16a-16c show various views of the carrier block. DETAILED DESCRIPTION

[0034] With reference to Figs. 1 -3 and 6, a window shade assembly 1 is installed on an airplane panel having a porthole 3 and window shades 5, 7. The shades are movable through operation of a window shade actuator mechanism 200 having two actuator assemblies 202, 202a (one for each shade) for moving the shades across the porthole 3 to control the amount of light entering the porthole. The shades include an opaque shade 5 constructed of an opaque fabric to prevent most, if not all, of the light from entering the porthole, and a pleated shade 7 constructed of a translucent fabric to allow a portion of light through the porthole when the shade 7 is extended over the porthole in its intended manner.

[0035] The pleated shade is made from any known type of pleated material, such as fabric, etc., conventionally used for window shades which can be compressed relatively tightly to a height less than ½ inch, for example, so that it occupies a minimal amount of space proximate the porthole 3 to provide an unimpeded view and to allow light to pass completely unobstructed through the porthole. As shown in Fig. 3, the pleated shade has a zigzag cross-section and is connected at a first end to a shade support 50. The other end of the pleated shade is attached to an actuator-controlled moveable rail member 25 which provides for expansion and contraction of the shade 7 across the porthole in a manner explained below.

[0036] Guide holes are provided near the left-side and right-side edges of the pleated shade 7, through which a left-side shade alignment cord 52 (Fig. 3) and a right-side shade alignment cord (not shown in Fig. 3) are provided to ensure proper alignment of the pleats in the shade 7 as the shade is expanded and contracted. Each alignment cord is fixed at a first anchor point 53 on the shade support 50 and at a second anchor point 54 (see Fig. 2) positioned near the bottom of the porthole 3, as explained more fully below.

[0037] The rail member 25 operates in the following manner in the disclosed embodiments. For example, the rail member 25 is maintained between a left-side frame member and a right-side frame member (47, 49 in Fig. 1 of the subject application) and is attached to a flexible drive member, e.g., a synchronous cable or timing belt, driven by the manual actuator as described hereinbelow. A timing belt may be, for example, a flexible rubber belt with a smooth surface on the one side (possibly including grooves or protrusions) and gear-like teeth on the other side. A synchronous cable may be, for example, a cable having a straight center strand which is encased in nylon, or similar material, and having a helically wound outer strand encased in polyurethane, or similar material, with both cable strands having braided stainless steel cores. Such cables are sold under the name Synchromesh by Asahi Intecc of Aichi, Japan. Moving the actuator assembly in one direction will drive the synchronous cable in a first direction to raise the guide rail 25, thereby collapsing the pleated shade 7. Moving the actuator assembly in the opposite direction will drive the synchronous cable in an opposite direction to expand the pleated shade across the porthole 3.

[0038] The opaque shade 5 has a fixed end attached to a spring roller 72 positioned above porthole 3. The fixed end of opaque shade 5 can be attached to the spring roller 72 in any known manner, such as by an adhesive or fastener. A leading edge of the opaque shade is fixed to a moveable rail member 25a (see Fig. 2) such that, during normal operation, the opaque shade will extend across and retract from the porthole 3 based on motion of the rail member 25a in a manner similar to the operation of rail member 25. [0039] The spring roller 72 operates in a manner such that so long as tension is applied to a free end of a shade material connected to such a roller mechanism, or the roller mechanism is otherwise locked to prevent rotation, the shade material will remain in its extended position. However, if the shade mechanism is unlocked or a force on a free end of the shade material is removed, the torsion spring will cause the shade material to roll up around the roller mechanism.

[0040] Focusing initially on the operation of the opaque shade 5, an axle, or shaft, 33a is configured to be inserted into a through-hole in the moveable rail member 25a. As best shown in Figs. 2 and 4, the ends of axle 33 protrude from the rail member so that they can carry gears. One such gear is identified as gear 35a and engages a rack 46 in the left-side frame member 47. Another gear (not shown) engages a rack 48 in the right-side frame member. Each gear is also connected to a carrier. In particular, an active carrier 36a is positioned about gear 35a and a passive carrier 38 is positioned about the right-side gear.

[0041 ] A flexible drive member, e.g., a synchronous cable, (not shown) is attached at both ends, via set screws to the active carrier 36a and is driven by a manual actuator mechanism 200 (see Figs. 1 , 6, 7) as explained below, to cause movement of the synchronous cable over a pulley 64 mounted at a left end of the opaque shade spring roller rod 72. When the window shade actuator mechanism 200 is operated, such as by manipulation of the actuator assembly 202a, the synchronous cable is moved which, in turn, will move the active carrier 36a via engagement of gear 35a with rack 46 to cause movement of the opaque shade. Because of the connection between the active carrier 36a to the passive carrier 38 by the axle 33a in rail member 25a, when the active carrier 36a is driven, the passive carrier 38 will move via the right-side gear against rack 48. [0042] A similar operating arrangement is provided for the translucent shade 7 except that a separate actuator assembly 202 (shown in Figs. 8a and 8b) is used to control a second synchronous cable to directly drive an active carrier 44 positioned in the right-side rack 48 which causes indirect movement, via a coupling with axle 33 in rail member 25, of a passive carrier 42 engaged with the left-side rack 47.

[0043] The terms "active" and "passive," in the context of the carriers, refer to the fact that the active carrier is driven directly by a flexible drive member, e.g., a synchronous cable, whereas the passive carrier at the other end of the rail member 25 is driven indirectly via the axle 33.

[0044] With reference to Figs. 4 and 5, and as described above, active and passive carriers 36a, 38 for the opaque and translucent shades 5, 7 are disposed for movement along a common pair of racks 46, 48. It is contemplated that each shade can be controlled independently of the other. Thus, actuator assembly 202a of the window shade actuator mechanism 200 can be manipulated to extend the translucent shade over the porthole 3 and then actuator assembly 202 of actuator mechanism 200 can be activated to extend the opaque shade partially (or completely) over the porthole.

[0045] However, because the carriers for both shades share a common set of racks, and the opaque shade carriers 42, 44 are positioned in the racks above the translucent shade carriers 36a, 38, the carriers 42, 44 for the opaque shade are configured as having an extension region 45 (see Fig. 5). The extension regions are dimensioned such that they can extend in a gap behind the active and passive carriers 36a, 38 of the translucent shade. This feature is best shown in Fig. 5 where the leading edge of the opaque shade 5 is affixed to the extension regions 45 such that both shades can be extended a distance coterminous with each other. Without extension region 45 the leading edge of the opaque shade 5 would not be capable of extending to the same vertical position of the translucent shade 7, thereby resulting in the unwanted result of not fully blocking the outside light from entering the porthole.

[0046] Turning now to Figs. 6 and 7, the manual actuator mechanism 200 is intended to be installed in a window shade cassette 210, or in a position proximate to the window shade cassette 210 (e.g., just below or in back of the cassette), for raising and lowering the window shades in the cassette in a manner described herein. The shade cassette 210 is mounted in a shade cassette frame 212 which, in turn, is coupled to a cassette frame mount 214 positioned about a window of an airplane. Once the manual actuator mechanism 200 is in place in its intended manner, a bezel 216 is overlaid over the window shade cassette 210. The bezel includes an access slot 218 through which actuator arms 220, 220a can extend for accessing the actuator assemblies 202, 202a through the bezel. For a two shade cassette, two actuator arms 220, 220a are provided, one for each actuator assembly (e.g. 202, 202a) for manipulating a respective shade (translucent or opaque). With the arms extending through the access slot 218, a slot panel 222 having a guide slot 224 is positioned in the access slot 218. Thereafter, a pair of guide knobs 226, 226a, one for each of the actuator arms, is attached to provide user control of the actuator assemblies 202, 202a.

[0047] With reference now to Figs. 7, 8a 8b, 8c, an explanation of the manual actuator mechanism 200 will be provided. The manual actuator mechanism includes a guide track 230 having bearing surfaces 232 formed therein, and a drive gearing assembly 219 positioned at each end of the guide track. The actuator assembly (e.g., assembly 202), includes a carrier block 234 which is received in the guide track and provides slidable coupling of the actuator assembly within the guide track as explained more fully below. An outer front surface of the guide track contains a plurality of engagement teeth 342 for interacting with a brake assembly 300 of the actuator assembly 300 as described below.

[0048] Each drive gearing assembly (only one is shown in Fig. 7) includes a gear box housing 236 in which an active gear 238 and a passive gear 240 are seated. In this context, the terms "active" and "passive" refer to the fact that the active gear is driven the flexible drive member and, as explained below, the active gear drives other gears to which it is connected. The passive gear, on the other hand, acts idler gear, i.e., it merely rotates when driven by the flexible drive member and does not drive other gears. The passive gear is used mainly to provide proper tension for the flexible drive member. The active and passive gears are contained in a gear guide 242 (Fig. 8c) which is mounted via set screws interfacing with set screw holes 244 to an edge of the window shade cassette 210 as shown in Fig. 1 . In the disclosed

embodiments, the active and passive gears are in opposite positions (i.e., inner versus outer position of the gear guide) at the opposite ends of the guide track.

[0049] The gear guide 242, actuator arms 220, 220a and knobs 226, 226a are absent in Figs. 8a and 8b for simplicity. A pair of step up gears 246, 248 - which are depicted as beveled gears - are provided for translating a linear, slideable motion of the actuator arms 220, 220a to rotational movement for rotating the drive pulley 250. As explained above, the drive pulley includes a drive pulley groove 252 in which a synchronous cable is mounted for controlling the raising and lowering of a shade.

[0050] As shown in Fig. 6, the window shade cassette 210 further includes a support rail 213 positioned near the bottom of the cassette. The support rail facilitates attachment of the guide track 230 in certain embodiments. In this regard a plurality of resilient tabs 215 are positioned along a bottom edge of the guide track (Fig. 8b) to provide receiving areas for receiving the support rail 213 such that the guide track is positioned along the bottom of the cassette.

[0051 ] With reference to Figs. 7 and 9, the actuator assembly 202 includes the brake assembly 300 which is mounted to the carrier block 234 for providing slideable movement of the brake assembly along the guide track 230. The brake assembly 300 includes a brake housing 302 having an offset portion 304 for seating within a receiving slot 336 formed in the carrier block (see Figs. 16a - 16c). The brake assembly 300 further includes a sliding block 306 in which a pair of brake pins 308a, 308b are connected via brake pin seats 310a, 310b respectively. The sliding block 306 is biased in a direction indicated by directional arrow X as shown in Fig. 10d by one or more coil springs 343 which biases the sliding block away from an inner edge 303 of the brake housing 302. The sliding block 306 is, in turn, mounted to an eccentric member 312 having a coupling region 314 and a convex region 316. The block and eccentric member are contained in a recess 313 on a underside of the brake housing 302 and covered with a cover plate 318. The recess has a front surface 305 which is in contact with the convex surface 316 of the eccentric member (Fig. 10d) such that movement of the eccentric member will move the moveable block in a direction against the biasing of the springs 343, i.e., opposite directional arrow X, to release the brake in a manner explained below.

[0052] With continued reference to Fig. 9, the actuator arm 220 is shown having a keyed end 322 which can be received or otherwise fastened to the coupling region 314 of the eccentric member 312. An actuator arm coupling region 324 contains a screw hole 326 for securing the actuator arm 220 to the eccentric member 312. The actuator arm 220 further includes an actuation end 328 containing a screw hole 329 for allowing attachment of the guide knob 226 thereto. As explained above, when the manual actuator mechanism is assembled in its intended manner and positioned about a window shade cassette and covered by a bezel 216, the guide knobs 226 will extend through the access slot 218 to allow for passenger manipulation of the shades in the shade cassette.

[0053] The actuator assembly 202 further includes a flexible drive member (e.g., a timing belt 334) coupler 330 having seat regions 332 for the ends of the timing belt 334 (Fig. 13). The timing belt coupler 330 also includes screw holes 333 for securing the timing belt coupler to the brake housing 302. As shown, each end of the timing belt extends about a post 335 on the timing belt coupler and overlaps with itself by interlocking teeth to secure the ends of the timing belt 334 to the timing belt coupler.

[0054] With reference again Figs. 7, 8a and 8b, when a first actuator arm 220, for example, to control movement of the translucent shade 7, is connected to coupling region 314 and is moved in a slideable manner (in a horizontal direction along guide slot 224 (Fig. 6), the timing belt 334 which is engaged with the brake housing 302 will engage gears 238, 240 and step-up gears 245, 248 to rotate drive pulley 250, thereby moving the synchronous cable to raise or lower the translucent shade (depending on the direction of movement of the arm).

[0055] It should be appreciated that because of the relatively rectangular shape of the shade cassette, the step up gearing is required for gears 246 and 248 to compensate for the differences in travel path lengths between the horizontal movement of the actuator arm 220 from the guide slot 224, on the one hand, and the vertical shade travel path across the window on the other hand. Thus, moving the actuator arm across the horizontal distance of the slot 224 will result in the full raising or lowering of the shade across the entire vertical length of the window. It is pointed out that if the shade cassette is designed such that the length of travel of the shade across the window is less than the length of travel of the actuator arm within the guide slot 224, a step-down gearing arrangement would be used as an alternative.

[0056] With reference to Figs. 16a-16c, the carrier block 234 is shown in various views having angled surfaces containing a plurality of bearings 340. It is preferred that eight bearings are provided, as shown, with two bearings disposed on each of four bearing surfaces dimensioned for slideable engagement within like opposing bearing surfaces on the guide track 230. This arrangement provides for a non- binding engagement between the carrier block and guide track. Screw holes 338 are provided for securing the carrier block 234 to the brake assembly.

[0057] With reference to Figs. 10d, 1 1 a, 1 1 b, 12a, 12b, 14a, 14b, 15a and 15b, a description of the operation of the actuator assembly 202 will be provided. As shown in Figs. 1 1 a, 12a, 14b, 16a and 16b, the carrier block 234 is attached to the brake housing 302 by inserting the offset portion 304 in the receiving slot 336 and then affixing the components to each other by screws via screw holes 338. Thereafter the actuator assembly is positioned within the guide track 230 by sliding it in an open end of the guide track 230. Thereafter a gearing assembly 219 is positioned on each end of the track and secured thereto to confine the carrier block within the track. When so positioned, the brake pins 308a and 308b are seated between teeth 342 formed on the outer edge of the guide slot 222 as shown in Fig. 1 1 a. As explained above, springs 343 in the sliding block 306 keep the pins seated between teeth 342. In particular, one end of each spring engages the seats and the other end of each spring engages an inside surface of the housing to bias the block 306 in an engaging position as shown by directional arrow X in Fig. 10d. This results in the seating of the brake pins 308a, 308b between the teeth 342 when the actuator arm 220 is stationary.

[0058] The eccentric member 312 is controlled by the actuator arm. When the arm is pivoted such as during normal operation of the actuator assembly 202, the eccentric member rotates and pushes the inner surface 305 of the brake housing 302 against the bias of the springs in the spring driven block 306 (Fig. 10d). This causes disengagement of the brake pins 308a, 308b from the teeth 342 and allows the carrier block to easily slide under the translational force applied to the lever, thereby causing the lifting or lowering of the shade. Once the lever is released, the brake pins are, again, engaged within the teeth to thereby maintain the shade in its then- current position.

[0059] As shown in Figs. 1 1 a and 1 1 b, the brake pins 308a, 308b are positioned in their engaged positions between teeth 342. Once the actuator arm is pivoted in its intended manner, as shown in Figs. 12a and 12b, the brake pins are unseated via movement of the sliding block 306 to allow for translational movement of the carrier block 234 within the guide track 230.

[0060] Figs. 14a 14b show side and perspective views, respectively, of the brake assembly 300 in an engaged position. Specifically, brake pin 308b is shown being seated between teeth 342 when actuator arm 220 is in its rest position. Figs. 15a, 15b show side and perspective views, respectively, of the brake assembly 300 in the disengaged position. As shown, the arm 220 is in a pivoted position such that brake pin 308b is disengaged from teeth 342 to allow the carrier block to slide within guide track 230.

[0061 ] In a preferred embodiment, and as explained above, two actuator assemblies 202, 202a are provided, one for an opaque shade and one for a translucent shade. Because the carrier block for each actuator assembly is disposed in the same guide track, the actuator assemblies are positioned relative to each other (see Fig. 8a) such that a first actuator, e.g. the one controlling the translucent shade, will be actuated to fully deploy the translucent shade, whereupon the second actuator can then be used to deploy the opaque shade.

[0062] Although example embodiments have been shown and described in this specification and figures, it would be appreciated by those skilled in the art that changes may be made to the illustrated and/or described example embodiments without departing from their principles and spirit.