High efficiency roller shade and method for setting artificial stops

• US 9,018,868 B2
• Filed: 02/20/2013
• Issued: 04/28/2015
• Est. Priority Date: 02/23/2010
• Status: Active Grant

• Current Assignee: The Watt Stopper Incorporated (Legrand SA)
• Original Assignee: QMotion Advanced Shading Systems
• Inventors: Lucas, William Ashton, Mullet, Willis Jay, Mullet, Victoria Baynes, Rodriguez, Yan, Garcia, Ben L., Kirkland, Matthew Warren
• Primary Examiner(s): GLASS, ERICK DAVID
• Application Number:
  US13/771,994
• Publication Number:
  US 20130264976A1
• Time in Patent Office: 797 Days
• Field of Search: 318/255, 318/139, 318/260, 318/280, 160/133, 160/168.1, 160/309
• US Class Current: 318/255
• CPC Class Codes: E06B 2009/6818 using sensors
• CPC Class Codes: E06B 2009/6845 sensing position
• CPC Class Codes: E06B 2009/6872 using counters to determine shutter position
• CPC Class Codes: E06B 2009/6881 Mechanical counters
• CPC Class Codes: E06B 9/42 Parts or details of roller blinds, e.g. suspension devices, blind boxes brackets or adjustable mountings for roller blinds and drawable curtains A47H1/13
• CPC Class Codes: E06B 9/72 comprising an electric motor positioned inside the roller
• CPC Class Codes: G08C 17/02 using a radio link
• CPC Class Codes: G08C 2201/50 Receiving or transmitting feedback, e.g. replies, status updates, acknowledgements, from the controlled devices
• CPC Class Codes: G08C 2201/51 Remote controlling of devices based on replies, status thereof
• CPC Class Codes: G08C 23/04 using light waves, e.g. infrared
• CPC Class Codes: H02P 3/08 for stopping or slowing a dc motor

Abstract

The present invention advantageously provides a motorized roller shade that includes a shade tube, a motor/controller unit and a power supply unit. The motor/controller unit is disposed within the shade tube, and includes a bearing, rotatably coupled to a support shaft, and a DC gear motor. The output shaft of the DC gear motor is coupled to the support shaft such that the output shaft and the support shaft do not rotate when the support shaft is attached to the mounting bracket.

Claims

1. A method of setting the operational limits of a motorized shade or blind having a travel path, comprising:

translating or moving the motorized shade or blind upward to a first position or open position within the travel path;

translating or moving the motorized shade from said first position downward a first distance to a second position and back to said first position;

translating or moving the motorized shade or blind downward a second distance to a third position within the travel path;

translating or moving the motorized shade or blind to a fourth position within the travel path to set this position a recalled position;

wherein the motorized roller shade comprises;

a counter; and

a microprocessor, wherein the counter and the microprocessor are configured to count a number of revolutions of the shade or blind to each of the first artificial stop, the second artificial stop and the third artificial stop.

2. The method according to claim 1, wherein said first distance is about three (3) inches and said second distance is about two (2) inches.

3. The method according to claim 1, wherein the counter is a Hall Effect sensor assembly comprising a Hall Effect sensor and Hall Effect magnet.

4. The method according to claim 1, wherein the counter is a chopper wheel and an optical encoder.

5. The method according claim 1 wherein the counter is a magnetic reed.

6. The method according claim 1 wherein the counter is a potentiometer.

7. The method according to claim 1, wherein the motorized shade further comprises:

a shade tube, including;

an outer surface upon which a shade is attached, and

an inner surface defining an inner cavity;

a motor/controller unit, disposed within the shade tube inner cavity and mechanically coupled to the shade tube inner surface, including;

a support shaft attachable to a mounting bracket;

at least one bearing rotatably coupled to the support shaft,

a DC gear motor having an output shaft coupled to the support shaft such that the output shaft and the support shaft do not rotate when the support shaft is attached to the mounting bracket, and

a controller, coupled to the motor, to control the motor; and

a power supply unit, electrically coupled to the motor/controller unit, disposed within the shade tube inner cavity and mechanically coupled to the shade tube inner surface, including a support shaft attachable to a mounting bracket.

8. The motorized roller shade according to claim 7, wherein the motor/controller unit includes a wireless receiver, coupled to the controller, to receive wireless signals.

9. The motorized roller shade according to claim 8, wherein the motor/controller unit includes a wireless transmitter, coupled to the controller, to send wireless signals.

10. The motorized roller shade according to claim 7, wherein the motor/controller unit includes:

an end cap, mechanically coupled to the inner surface of the shade tube, in which the bearing is disposed; and

a mount, mechanically coupled to the inner surface of the shade tube, for mounting the DC gear motor.

11. The motorized roller shade according to claim 7, wherein the motor/controller unit includes an intermediate shaft disposed between the motor gear reducer assembly and the support shaft.

12. The motorized roller shade according to claim 11, wherein the motor/controller unit includes:

a fixed perch attached to the DC gear motor and mechanically coupled to the inner surface of the shade tube;

a rotating perch attached to the intermediate shaft; and

a spring attached to the fixed perch and the rotating perch.

13. The motorized roller shade according to claim 7, wherein the motor/controller unit includes at least one circuit board upon which the controller is mounted.

14. The motorized roller shade according to claim 13, wherein the motor/controller unit includes a circuit board housing in which the circuit board is mounted.

15. The motorized roller shade according to claim 13, wherein the motor/controller unit includes a housing, mechanically coupled to the inner surface of the shade tube, in which the bearing, the DC gear motor and the circuit board are contained.

16. The motorized roller shade according to claim 15, wherein the motor/controller unit includes at least one power spring attached to the support shaft.

17. The motorized roller shade according to claim 13, wherein the motor/controller unit includes:

a motor shaft extending from the DC gear motor;

a multi-pole magnet attached to the motor shaft; and

at least one sensor, mounted to the circuit board, to detect the rotation of the multi-pole magnet.

18. The motorized roller shade according to claim 7, wherein the power supply unit includes a battery tube, electrically coupled to the motor/controller unit, for housing at least one battery.

19. The motorized roller shade according to claim 18, wherein the power supply unit includes:

at least one bearing rotatably coupled to the support shaft;

an outer end cap, mechanically coupled to the inner surface of the shade tube, in which the bearing is disposed, the outer end cap having a first terminal electrically coupled to the battery tube; and

an inner end cap, mechanically coupled to the inner surface of the shade tube, having a first terminal electrically coupled to the battery tube and a second terminal,

wherein, when the battery is installed in the battery tube, the first terminal of the outer end cap is electrically coupled to a first terminal of the battery, and the second terminal of the inner end cap is electrically coupled to a second terminal of the battery.

20. The motorized roller shade according to claim 7, wherein the power supply unit includes a power coupling, electrically coupled to the motor/controller unit, to receive power from an external power supply.