Flat-web roller blind cover

Abstract

A roller blind cover for an aperture in a vehicle interior. The roller blind cover has a carrier layer, a decorative layer, and a coating that covers the visible surface of the decorative layer. The overlay coating may be elastic with a layer thickness of at least 0.3 mm. The overlay coating may be permanently bonded to the visible surface of the decorative layer.

Description

CROSS REFERENCE TO RELATED APPLICATION

Foreign priority benefits are claimed under 35 U.S.C. §119(a)-(d) or 35 U.S.C. §365(b) of German Application No. 10 2005 050 825.1, filed Oct. 24, 2005, which is hereby incorporated by reference in its entirety.

BACKGROUND

1. Field

The present invention relates to a roller blind cover for an aperture, and more particularly to a flat-web roller blind cover for an aperture in the interior of a vehicle.

2. Discussion of Related Art

Roller blind covers, such as flat-web roller blind covers, are generally known in the art for use in vehicles. For example, roller blind covers can be used to cover stowage compartments, such as described in DE 20 2004 006 649.1. Such roller blind covers usually have a single or multi-ply carrier layer that is flexible in only one plane. The carrier layer serves as the supporting structure of the roller blind cover. In use, the carrier layer is typically guided along opposed longitudinal edges by sliding block guides that lie along opposed edges of the aperture that is being covered.

The carrier layer used in prior art roller blinds is typically a simple, flexible plastic or sheet steel plate that may be reinforced with crosswise ribs, a woven wire and/or textile fabric.

The carrier layer is often covered with a decorative layer to provide a desired appearance for the roller blind. Decorative layers are known that comprise layers of textile material, carbon, plastic, and leather. The choice of such decorative layers has been limited to materials with grain, layer thickness, and elasticity that are capable of withstanding the bending and stretching strains that are incurred when used in roller blind covers constructed according to the prior art.

A protective lacquer layer, typically only a few microns thick, is often applied to the visible surface of the decorative layer.

There is a need in the art for a roller blind cover design that allows the use of hard and/or less flexible materials as a decorative layer.

SUMMARY

According to one aspect of the invention a roller blind cover for an aperture in a vehicle interior is disclosed. The roller blind cover comprises a carrier layer and a decorative layer. The decorative layer has a visible surface and is attached to the carrier layer. An overlay coating covers the decorative layer and provides a view of the visible surface. The overlay coating is permanently bonded to the visible surface and has a thickness of at least 0.3 mm.

According to another aspect of the invention a roller blind cover for a vehicle interior is disclosed. The roller blind cover comprises a carrier layer, a decorative layer, and an overlay coating. The decorative layer is positioned between the carrier layer and the overlay coating and lies along a neutral axis of the roller blind cover when the roller blind cover is flexed during use.

Also disclosed is a method of forming a roller blind cover for a vehicle interior. The method comprises providing a carrier layer. The method also comprises providing a decorative layer that comprises decorative material that is less elastic than the carrier layer. The decorative material is coupled to an intermediate layer of the decorative layer. The decorative layer is rendered more flexible while the decorative material is held by the intermediate layer. The method also comprises assembling the decorative layer to the carrier layer.

Various embodiments of the present invention provide certain advantages. Not all embodiments of the invention share the same advantages and those that do may not share them under all circumstances.

Further features and advantages of the present invention, as well as the structure of various embodiments of the present invention are described in detail below with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labelled in every drawing. Various embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 shows a perspective view of a flat-web roller blind cover according to one embodiment of the invention; and

FIG. 2 shows a schematic cross-sectional view of the flat-web roller blind cover shown in FIG. 1.

DETAILED DESCRIPTION

Aspects of the present invention provide a roller blind cover that may be used to cover an aperture in the interior of a vehicle. Embodiments of the roller blind cover enable the decorative layer of the roller blind to be made of hard and/or less flexible materials.

Broadly speaking, illustrative embodiments of the roller blind cover include a carrier layer that may ride in sliding block guides positioned on opposed lateral edges of an aperture. The aperture may lie in the interior of a vehicle. A decorative layer may be positioned on top of the carrier layer and may comprise a thickness that is greater than that used in prior art roller blind covers. An overlay may be placed on top of the decorative layer to provide protection while allowing the decorative layer to be viewed. The thickness and mechanical characteristics of each of the carrier layer, the decorative layer, and the overlay layer, along with any other intermediate layers, may be configured such that the decorative layer lies on or near the neutral axis of the roller blind cover when flexed during use to open and close the aperture. In this regard, the decorative layer may be subjected to fewer strains and/or stresses, which enables the use of a wider variety of materials.

According to some illustrative embodiments, the roller blind cover enables hard and/or less flexible materials to be used as a decorative layer. In some embodiments, the decorative layer is less elastic than one or both of the carrier layer and/or an overlay layer of the roller blind cover.

In some embodiments, the overlay layer may be elastic. The overlay layer may also have a thickness of at least 0.3 mm, or at least 0.5 mm, or at least 1.0 mm, or at least 2.0 mm, or at least 3.0 mm or even greater thicknesses, as aspects of the invention are not limited in this respect. Overlay layers may also be permanently bonded to the visible surface of the decorative layer, although they are not required to be, as aspects of the invention are not limited in this respect.

The decorative layer, according to illustrative embodiments, may be sandwiched between the carrier layer and an overlay layer to form a layered laminate. In the layered laminate, the decorative layer may be positioned close to or centered on the neutral axis of the roller blind cover. The neutral axis, as the term is used herein, refers to the line or plane along which minimal or no strain occurs when the roller blind cover is flexed about a curved surface during use. In many embodiments, the neutral line or plane will be positioned between areas that experience tension and areas that experience compression when the roller blind cover is flexed about the curved surface.

The decorative layer may have different thicknesses according to different embodiments of the invention. In some embodiments, the decorative layer has a thickness of 0.2 mm. Still, in other embodiments, the decorative layer has a thickness of about 1.5 mm. It is to be appreciated that other thicknesses are a possible, such as those that lie between 0.2 mm and 1.5 mm, or thicknesses that lie outside of this range of thicknesses, as the present invention is not limited in this respect.

The overlay layer may comprise various types of material. In some illustrative embodiments, the overlay layer is chosen for its elastic properties. The overlay material may also have optical properties that allow or even enhance an external view of the decorative layer. For instance, the overlay layer may be transparent or translucent. However, in other embodiments the overlay layer may be opaque, as aspects of the invention are not limited in this respect. The overlay layer may have various types of finishes, such as high gloss, low gloss, matte and, in some embodiments, may even include a textured surface. The overlay may be specially adjusted as a soft formulation and polyurethane (PUR) coatings are particularly useful in such applications.

Illustrative embodiments of the invention also allow the use of relatively hard decorative materials as components of the decorative layer. By way of example, in some embodiments, a real wood veneer layer, such as a veneer made of oak, among other woods, maybe used as a decorative layer. Such hard woods have not been used in prior art roller blind covers. Illustrative embodiments may also include a stone veneer layer as a decorative layer, or any other type of material, as aspects of the invention are not limited in this regard.

Materials that comprise the decorative layer may be made more flexible prior to being applied to the carrier layer. For instance, in the case of a stone veneer, the veneer may be broken down, even until the point where cracks begin to form in the veneer. In some embodiments, this may be accomplished by placing the veneer on an intermediate layer that will hold the decorative layer together while the decorative layer is broken down or “flexibilised”. When assembled, the intermediate layer will typically be positioned adjacent to the carrier layer, although other configurations are also possible.

According to some embodiments, cracks that may form during flexibilization of a relatively hard decorative layer may not be visible, particularly after the elastic overlay is positioned on top of the decorative layer. In other embodiments, cracking that occurs in a decorative layer may be allowed and may even be desired, particularly where the cracking appears to be natural. It is also possible to counteract the visual impression of any cracks formed in the decorative layer by dying. In one embodiment, the side of the carrier layer that faces towards the decorative layer may be dyed to suppress the appearance of cracking. Still, other techniques may be used to suppress the appearance of cracking, as aspects the invention are not limited in this respect.

Illustrative embodiments may also include a coupling agent layer positioned between the visible surface of a decorative layer and the overlay layer. Such coupling agent layers may help insure that the laminate or portions of the laminate are permanently layered together, particularly in embodiments that have hard decorative layers, such as those made of stone veneer.

Turn now to the figures, and initially FIG. 1, which shows a flat-web roller blind cover 1 that may be used to open and close an aperture 2 of a vehicle interior equipment part 3. Aperture 2 of interior equipment part 3 is bordered by a pair of sliding block guides 4 and 5. The sliding block guides extend parallel to one another along opposing sides of the aperture 2 and serve to guide opposed edges of the roller blind cover 1.

As illustrated, sliding block guides 4 and 5 of aperture 2 lie substantially in a common plane. Near aperture edge 6, as shown in the top left hand portion of FIG. 1, the sliding block guides 4 and 5 curve into a slot, although other configurations are possible. The slot of the interior equipment part 3 receives the flat-web roller blind cover when the cover is positioned to provide access to aperture 2. When moving into the slot, the roller blind cover may be placed in bending. Bending in this manner may place an outermost surface (e.g., an overlay layer) of the roller blind cover in tension while placing an inner most portion (e.g., a carrier layer) in compression. A neutral line or plane, that experiences insubstantial compression or tension, may exist between the outermost and inner most layers, as one of skill in the art may appreciate.

Illustrated embodiments of roller blinds may also have features to facilitate movement. As shown in FIG. 1, the roller blind has a handle 7 which facilitates pushing the roller blind cover along sliding blocks 4 and 5. Other configurations of handles are also possible, as aspects of the invention are not limited in this respect.

The roller blind cover 1 may comprise a layered laminate of various layers, as is shown in FIG. 2. A carrier layer 8 may provide for the structural stability of the roller blind cover 1. As illustrated, the carrier layer may comprise ribs that extend crosswise over aperture 2 in the direction of arrow II shown in FIG. 1. (i.e., in a direction extending from a first sliding block guide 5 to a second sliding block guide 4). The ribs may be joined to one another by a supporting layer 9, as is also illustrated. However, it is to be appreciated that not all carrier layers require ribs and/or a supporting layer as shown in the figures, as aspects of the invention are not limited in this regard. By way of example, in some embodiments, the carrier layer may comprise a single-ply, and in other embodiments, the carrier layer may comprise multiple-plys.

As discussed herein, an intermediate layer 11 may be positioned next to the carrier layer 8. The intermediate layer 11 may prove particularly beneficial in embodiments that utilize relatively hard decorative materials, such as stone veneers, hard wood veneers, and the like. The intermediate layer may help hold such decorative layers together during flexibilization prior to the decorative layer being joined to the carrier layer.

The intermediate layer may be joined to the carrier layer through various features and techniques. According to one embodiment, adhesive bonding is used to hold the decorative layer to the carrier layer, although other features and techniques are possible, as the present invention is not limited in this respect.

In the illustrated embodiment, a coupling agent layer 12 is positioned on the visible side of decorative layer 10. The coupling agent layer 12 carries overlay 13. The overlay 13 may be transparent, although it is not required to be, and in some cases may be translucent. The overlay may be designed with an appropriate thickness to provide a depth effect due to a corresponding lens action. This may convey a special appearance to the visible surface of the decorative layer. In other embodiments, the overlay may have a thickness that allows light to be transmitted there through, so as to illuminate the roller blind cover.

The overlay may also be made of an elastic material. In this respect, the elastic material can better accommodate any strains that the overlay is exposed to during use. It is to be appreciated that not all overlays need be elastic and that different embodiments may have overlays with varying elastic properties, as the present invention is not limited in this regard.

According to illustrative embodiments, the carrier layer 8, decorative layer 10, and overlay layer 13 form a layered laminate with a decorative layer sandwiched towards a central portion of the blind cover. In particular embodiments, the decorative layer is positioned on or near neutral lines or planes of the roller blind cover. This allows less flexible and even very hard materials to be used as the decorative layer.

Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modification, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the description and drawings herein are by way of example only.

Claims

1. A roller blind cover for an aperture in a vehicle interior, the roller blind cover comprising:

a carrier layer;

a decorative layer having a visible surface, the decorative layer being attached to the carrier layer; and

an overlay coating that covers the decorative layer and that provides a view of the visible surface;

wherein the overlay coating is permanently bonded to the visible surface and has a thickness of at least 0.3 mm.

2. The roller blind cover according to claim 1, wherein the overlay coating is a transparent, high-gloss plastic layer with a layer thickness selected between about 0.3 mm and about 3 mm.

3. The roller blind cover according to claim 2, wherein the elastic overlay is a soft formulation PUR layer.

4. The roller blind cover according to claim 1, wherein the decorative layer has a layer thickness of between about 0.2 mm and about 1.5 mm.

5. The roller blind cover according to claim 4, wherein the decorative layer is a real wood veneer layer.

6. The roller blind cover according to claim 4, wherein the decorative layer is a stone veneer layer.

7. The roller blind cover according to claim 1, further comprising:

a coupling agent layer disposed between the visible surface of the decorative layer and the overlay coating.

8. The roller blind cover according to claim 1, wherein the decorative layer includes an intermediate layer positioned next to the carrier layer.

9. The roller blind cover according to claim 1, wherein the carrier layer is a multi-ply layer.

10. A roller blind cover for a vehicle interior, the roller blind cover comprising:

a carrier layer;

a decorative layer; and

an overlay coating;

wherein the decorative layer is positioned between the carrier layer and the overlay coating and lies along a neutral axis of the roller blind cover when the roller blind cover is flexed during use.

11. The roller blind cover according to claim 10, wherein the overlay coating has a layer thickness selected between about 0.3 mm and about 3.0 mm.

12. The roller blind cover according to claim 10, wherein the decorative layer has a layer thickness between about 0.2 mm and about 1.5 mm.

13. The roller blind cover according to claim 10, wherein the decorative layer comprises material selected from the group consisting of: real wood and stone.

14. The roller blind cover according to claim 1, wherein the decorative layer includes an intermediate layer that holds the decorative layer together prior to the decorative layer being joined to the carrier layer.

15. A method of forming a roller blind cover for a vehicle interior, the method comprising:

providing a carrier layer;

providing a decorative layer that comprises decorative material that is less elastic than the carrier layer, the decorative material being coupled to an intermediate layer of the decorative layer;

rendering the decorative layer more flexible while the decorative material is held by the intermediate layer; and

assembling the decorative layer to the carrier layer.

16. The method according to claim 15, further comprising:

assembling an overlay layer to the decorative layer.

17. The method according to claim 15, wherein the decorative material comprises stone.

18. The method according to claim 15, wherein the decorative material comprises real wood.

19. The method according to claim 15, wherein rendering the decorative material more flexible comprises breaking down the decorative layer.

20. The method according to claim 15, further comprising:

positioning the decorative layer along a neutral axis of the roller blind cover.