High efficiency roller shade and method for setting artificial stops

• US 9,410,369 B2
• Filed: 12/08/2014
• Issued: 08/09/2016
• Est. Priority Date: 02/23/2010
• Status: Active Grant

• Current Assignee: The Watt Stopper Incorporated (Legrand SA)
• Original Assignee: The Watt Stopper Incorporated (Legrand SA)
• Inventors: Mullet, Willis Jay, Rodriguez, Yan, Garcia, Ben L., Mullet, Victoria Baynes, Kirkland, Matthew Warren
• Primary Examiner(s): Glass, Erick
• Application Number:
  US14/562,946
• Publication Number:
  US 20150090409A1
• Time in Patent Office: 610 Days
• Field of Search: 318/255, 318/265, 318/286
• US Class Current: 1/1
• CPC Class Codes: E06B 2009/6809 Control
• 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 2009/725 with epicyclic or planetary gear train
• 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 9/44 Rollers therefor; Fastening roller blinds to rollers
• CPC Class Codes: E06B 9/60 Spring drums operated only by closure members
• CPC Class Codes: E06B 9/62 Counterweighting arrangements E06B9/60 takes precedence
• CPC Class Codes: E06B 9/68 Operating devices or mechanisms, e.g. with electric drive
• CPC Class Codes: E06B 9/72 comprising an electric motor positioned inside the roller
• CPC Class Codes: E06B 9/74 adapted for selective electrical or manual operation
• 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 1/06 Manually-operated multi-position starters
• CPC Class Codes: H02P 3/06 for stopping or slowing an individual dynamo-electric motor or dynamo-electric converter
• 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 motorized roller shade comprising:

a shade tube extending a length from a first end to a second end;

a shade attached to the shade tube such that rotation of the shade tube changes the position of the shade;

a motor positioned within the shade tube;

the motor operatively connected to the shade tube such that activation of the motor causes rotation of the shade tube;

a motor controller operatively connected to the motor;

an antenna operatively connected to the motor controller;

a remote control device wirelessly connected to the antenna; and

wherein the shade is movable to a different position by manual movement of the shade, as well as by transmitting a wireless signal to the shade using the remote control device.

2. The motorized roller shade of claim 1 wherein the shade is further movable to a different position by a tug, which is a manual displacement less than a predetermined maximum displacement.

3. The motorized roller shade of claim 1 wherein manual movement is a manual displacement greater than a predetermined maximum displacement.

4. The motorized roller shade of claim 1 wherein manual movement is detected by a sensor.

5. The motorized roller shade of claim 1 wherein a tug is detected by measuring a rotation of an output shaft of the motor using a magnetic, an optical or a mechanical encoder.

6. The motorized roller shade of claim 1 wherein when a tug is detected the motor controller energizes the motor which rotates the shade tube.

7. The motorized roller shade of claim 1 wherein when a manual movement is detected the motor controller does not energize the DC gear motor.

8. The motorized roller shade of claim 1 wherein when a manual movement is detected the motor controller tracks the distance moved using a counter operatively connected to the motor controller.

9. The motorized roller shade of claim 1 further comprising at least one counterbalance spring positioned within the shade tube.

10. A motorized roller shade comprising:

a shade tube extending a length from a first end to a second end;

a shade attached to the shade tube such that rotation of the shade tube changes the position of the shade;

a motor positioned within the shade tube;

the motor operatively connected to the shade tube such that activation of the motor causes rotation of the shade tube;

a motor controller operatively connected to the motor;

an antenna operatively connected to the motor controller;

a counterbalance spring positioned within the shade tube;

the counterbalance spring operatively connected to the shade tube;

a remote control device wirelessly connected to the antenna; and

wherein the shade is movable to a different position by a manual movement of the shade, as well as by transmitting a wireless signal to the shade using the remote control device.

11. The motorized roller shade of claim 10 wherein a tug is a manual displacement less than a maximum displacement.

12. The motorized roller shade of claim 10 wherein manual movement is a manual displacement greater than a maximum displacement.

13. The motorized roller shade of claim 10 wherein a tug is detected by a sensor.

14. The motorized roller shade of claim 10 wherein a tug is detected by measuring a rotation of an output shaft of the motor using a magnetic, an optical or a mechanical encoder.

15. The motorized roller shade of claim 10 wherein when a tug is detected the motor controller energizes the motor which rotates the shade tube.

16. The motorized roller shade of claim 10 wherein when a manual movement is detected the motor controller does not energize the DC gear motor.

17. The motorized roller shade of claim 10 wherein when a manual movement is detected the motor controller tracks the distance moved using a counter operatively connected to the motor controller.

18. The motorized roller shade of claim 10 further comprising at least one counterbalance spring positioned within the shade tube.

19. A motorized roller shade comprising:

a shade tube extending a length from a first end to a second end;

a shade attached to the shade tube such that rotation of the shade tube changes the position of the shade;

a motor positioned within the shade tube;

the motor operatively connected to the shade tube such that activation of the motor causes rotation of the shade tube;

a motor controller operatively connected to the motor;

an antenna operatively connected to the motor controller;

a remote control device wirelessly connected to the antenna;

wherein the shade is movable to a different position by manual movement of the shade as well as by motorized movement of the shade; and

wherein when the shade is moved by manual movement or motorized movement a sensor system detects the movement and a counter tracks the movement.

20. The motorized roller shade of claim 19 wherein the sensor system includes a magnetic encoder.

21. The motorized roller shade of claim 19 wherein the sensor system includes at least one Hall Effect sensor.

22. The motorized roller shade of claim 19 wherein the sensor system includes a multi-pole magnet connected to a rotatable shaft of the motor.

23. The motorized roller Shade of claim 19 wherein the counter accumulates pulses received from the sensor system.

24. The motorized roller shade of claim 19 wherein a microprocessor associated with the motor controller determines a position of the shade based upon signals received from the sensor system.

25. The motorized roller shade of claim 19 wherein the counter accumulates pulses from an encoder of the sensor system.

26. The motorized roller shade of claim 19 wherein the counter resets upon encountering a hard stop.

27. The motorized roller shade of claim 19 further comprising a gear reducing assembly operatively connected to the motor, the gear reducing assembly having a gear ratio of forty to one (40:

1) or less.

28. The motorized roller shade of claim 19 wherein the shade is further movable to a different position by a tug, which is a manual displacement less than a predetermined maximum displacement.

29. The motorized roller shade of claim 19 wherein manual movement is a manual displacement greater than a predetermined maximum displacement.

30. The motorized roller shade of claim 19 wherein manual movement is detected by measuring, a rotation of an output shaft of the motor using a magnetic, an optical or a mechanical encoder.

31. The motorized roller shade of claim 19 wherein when a tug is detected the motor controller energizes the motor which rotates the shade tube.

32. The motorized roller shade of claim 19 wherein when a manual movement is detected the motor controller does not energize the DC gear motor.

33. The motorized roller shade of claim 19 wherein when a manual movement is detected the motor controller tracks the distance moved.

34. The motorized roller shade of claim 19 further comprising at least one counterbalance spring positioned within the shade tube.

35. The motorized roller shade of claim 19 further comprising a power source positioned within the shade tube.

36. A motorized roller shade comprising:

a shade tube extending a length from a first end to a second end;

a shade attached to the shade tube such that rotation of the shade tube changes the position of the shade;

a motor operatively connected to the shade tube such that activation of the motor causes rotation of the shade tube;

a motor controller operatively connected to the motor;

a gear reducing assembly operatively connected to the motor, the gear reducing assembly having a gear ratio of forty to one (40;

1) or less;

an antenna operatively connected to the motor controller;

a remote control device wirelessly connected to the antenna;

wherein the shade is movable to a different position by manual movement as well as by motorized movement of the shade; and

wherein when the shade is moved by manual movement or motorized movement a sensor system detects the movement and a counter tracks the movement.

37. The motorized roller shade of claim 36 wherein the sensor system includes a magnetic encoder.

38. The motorized roller shade of claim 36 wherein the sensor system includes at least one Hall Effect sensor.

39. The motorized roller shade of claim 36 wherein the sensor system includes a multi-pole magnet connected to a rotatable shaft of the motor.

40. The motorized roller shade of claim 36 wherein the counter accumulates pulses received from the sensor system.

41. The motorized roller shade of claim 36 wherein a microprocessor associated with the motor controller determines a position of the shade based upon signals received from the sensor system.

42. The motorized roller shade of claim 36 wherein the counter accumulates pulses from an encoder of the sensor system.

43. The motorized roller shade of claim 36 wherein the counter resets upon encountering a hard stop.

44. The motorized roller shade of claim 36 further comprising a gear reducing assembly operatively connected to the motor, the gear reducing assembly having a gear ratio of forty to one (40:

1) or less.

45. The motorized roller shade of claim 36 wherein the shade is further movable to a different position by a tug, which is a manual displacement less than a predetermined maximum displacement.

46. The motorized roller shade of claim 36 wherein manual movement is a manual displacement greater than a predetermined maximum displacement.

47. The motorized roller shade of claim 36 wherein manual movement is detected by measuring a rotation of an output shaft of the motor using a magnetic, an optical or a mechanical encoder.

48. The motorized roller shade of claim 36 wherein when a tug is detected the motor controller energizes the motor which rotates the shade tube.

49. The motorized roller shade of claim 36 wherein when a manual movement is detected the motor controller does not energize the DC gear motor.

50. The motorized roller shade of claim 36 wherein when a manual movement is detected the motor controller tracks the distance moved.

51. The motorized roller shade of claim 36 further comprising at least one counterbalance spring positioned within the shade tube.

52. The motorized roller shade of claim 36 further comprising at a power source positioned within the shade tube.