Room Darkening Curtain System

Info

Publication number: 20220218140
Type: Application
Filed: Nov 1, 2021
Publication Date: Jul 14, 2022
Inventors: Matthew Berman (Chicago, IL), Alan Arthur Ford (Sturgis, MI), Jason Moss (Libertyville, IL)
Application Number: 17/516,062

Abstract

There is disclosed a curtain rod system including an inner rod and an outer rod for mounting at a window. The outer rod is mounted substantially parallel to the inner rod along the length thereof and spaced apart from the inner rod forming a gap therebetween. A first portion of a drape is anchored to the inner rod and a second portion of the drape is laid over the outer rod to span the gap between the inner and outer rods.

Description

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 63/115,077, filed Nov. 18, 2020, which is hereby incorporated herein by reference in its entirety.

FIELD

This disclosure relates to curtain rod systems, and in particular, to room darkening curtain rod systems.

BACKGROUND

Curtain rods are often mounted along the top portion of a window. One or more curtains are attached to the curtain rod such that they can be drawn along the length of the rod. The curtains may be drawn to cover the window to inhibit those outside the window from seeing inside and/or to reduce the amount of light entering a room. A shortcoming exists in that curtains permit too much light to enter a room.

Room darkening curtains have been used to reduce the amount of light entering a room. Darkening curtains are heavier than non-darkening curtains, often containing additional layers of fabric, a foam backing, or thicker fabrics than non-darkening curtains.

Some curtain rod systems include an inner rod and an outer rod. A drape or curtain is hung from the outer rod and a sheer is hung from the inner rod. Other curtain rods include a rod that is curved at either end such that a curtain attached to the rod may be brought into contact with the wall on either side of the window. However, when drawn to cover the window, these curtains still permit light to enter a room through the top of the curtain rod systems as shown in FIG. 1.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a prior art curtain rod system permitting light to enter a room around the top and sides of a curtain;

FIG. 2 is a top perspective view of an end portion of a room darkening curtain rod system;

FIG. 3A is a top perspective view of the curtain rod system of FIG. 2 shown without the curtain;

FIG. 3B is a bottom perspective view of the curtain rod system of FIG. 3A;

FIG. 4A is a bottom perspective view of a mounting plate of the curtain rod system of FIG. 2;

FIG. 4B is a top perspective view of the mounting plate of FIG. 4A;

FIG. 4C is a rear perspective view of the mounting plate of FIG. 4A;

FIG. 4D is a front elevation view of the mounting plate of FIG. 4A;

FIG. 4E is a top plan view of the mounting plate of FIG. 4A;

FIG. 4F is a side elevation view of the mounting plate of FIG. 4A;

FIG. 5A is a top perspective view of a left rods support bracket of the curtain rod system of FIG. 2;

FIG. 5B is a bottom perspective view of the left rods support bracket of FIG. 5A;

FIG. 5C is a top plan view of the left rods support bracket of FIG. 5A;

FIG. 5D is a front elevation view of the left rods support bracket of FIG. 5A;

FIG. 5E is a side elevation view of the left rods support bracket of FIG. 5A;

FIG. 5F is a bottom plan view of the left rods support bracket of FIG. 5A;

FIG. 6A is a top plan view of a right rods support bracket of the curtain rod system of FIG. 2;

FIG. 6B is a front elevation view of the right rods support bracket of FIG. 6A;

FIG. 6C is a side elevation view of the right rods support bracket of FIG. 6A;

FIG. 6D is a bottom plan view of the right rods support bracket of FIG. 6A;

FIG. 7A is a perspective view of a left drape connection rod connector of the curtain rod system of FIG. 2;

FIG. 7B is a front elevation view of the left drape connection rod connector of FIG. 7A;

FIG. 7C is a cross-section view of the left drape connection rod connector of FIG. 7A taken along lines 7C-7C of FIG. 7B;

FIG. 7D is a side elevation view of the left drape connection rod connector of FIG. 7A;

FIG. 7E is a bottom plan view of the left drape connection rod connector of FIG. 7A;

FIG. 7F is a cross-section view of a left drape connection rod connector of the curtain rod system of FIG. 2 according to a second embodiment taken similarly to that shown in FIG. 7C;

FIG. 8A is a perspective view of a right drape connection rod connector of the curtain rod system of FIG. 2;

FIG. 8B is a front elevation view of the right drape connection rod connector of FIG. 8A;

FIG. 8C is a cross-section view of the right drape connection rod connector of FIG. 8A taken along lines 8C-8C of FIG. 8B;

FIG. 8D is a side elevation view of the right drape connection rod connector of FIG. 8A;

FIG. 8E is a bottom plan view of the right drape connection rod connector of FIG. 8A;

FIG. 8F is a cross-section view of a right drape connection rod connector of the curtain rod system of FIG. 2 according to a second embodiment taken similarly to that shown in FIG. 8C;

FIG. 9 is an exploded cross-section view of a drape connection rod, the left drape connection rod connector of FIG. 7A, and the right drape connection rod connector of FIG. 8A;

FIG. 10A is a top plan view of the curtain rod system of FIG. 2;

FIG. 10B is a top plan view of the curtain rod system of FIG. 10A shown in an expanded configuration;

FIG. 11A is a top plan view of a curtain rod system according to a second embodiment;

FIG. 11B is a top plan view of the curtain rod system of FIG. 11A shown in an expanded configuration;

FIG. 12A is a side elevation view of a center rods support bracket;

FIG. 12B is a top plan view of the center rods support bracket of FIG. 12A;

FIG. 12C is a rear elevation view of the center rods support bracket of FIG. 12A; and

FIGS. 13A-D show example steps for assembling the curtain rod systems of FIGS. 2 and 11A-B.

DETAILED DESCRIPTION

Regarding FIG. 1, there is illustrated a conventional curtain rod system 20. The curtain rod system 20 includes a rod 22 and curtains 24 attached to the rod 22. The curtain rod system 20 permits sidelight 26 and top light 28 to enter the room on the top and sides of the curtain rod system 20.

With respect to FIG. 2, there is illustrated a curtain rod system 100 that blocks sidelight and top light from entering a room. The curtain rod system 100 includes a drape connection rod 102 and a drape support rod 104. The drape connection rod 102 is positioned closer to the wall or window to which the curtain rod system 100 is mounted than the drape support rod 104. A drape or curtain 106 is attached to the drape connection rod 102. The drape 106 may include a sleeve or pocket along an end through which the drape connection rod 102 extends for attaching or anchoring the drape 106 to the drape connection rod 102. The top edge of the drape 106 may include a hem or edge portion along the sleeve or pocket that extends toward the wall from the pocket of the drape 106 when the curtain rod system 100 is assembled. The drape 106 may be attached to the drape connection rod 102 such that the drape 106 may be slid along the length of the drape connection rod 102 to cover or uncover the window with which the curtain rod system 100 is associated. The drape 106 is laid over the drape support rod 104. Where the drape 106 includes a top edge portion above the pocket, laying the drape 106 over the drape support rod 104 may orient the top edge portion of the drape 106 to point horizontally towards the wall, which may reduce or eliminate any gap between the drape 106 and the wall or window frame. The end of the drape 106 opposite the end attached to the drape connection rod 102 may hang substantially vertically from the drape support rod 104. The drape 106 thus covers the gap between the drape connection rod 102 and the drape support rod 104.

In FIG. 2, the drape 106 is shown to be transparent or partially see-through. In other embodiments, the drape 106 may be made of an opaque material to prevent most if not all light from passing through the drape 106. The drape 106, for example, may be made of a darkening fabric, such as those used in room darkening or blackout curtains. The use of a drape 106 made from a darkening fabric may reduce the amount of light that enters the room through the drape 106, reduce the amount of noise from entering the room from the outside, and/or aid in preventing heat from entering or exiting the room through the window. Room darkening curtains are made in a variety of forms. In one form, room darkening curtains include a fabric layer with a rubberized layer applied to the back of the fabric. In another form, the room darkening curtains are formed from a single-layer woven fabric that includes black warp yarns. In yet another form, the room darkening curtains include multiple layers of fabric. Where multiple layers of fabric are used, the fabric may include multiple layers sewn together, with one or more layers made of a woven fabric that may include light-blocking warp yarns. The room darkening curtains may also include a polymer layer to block 100% of the light from passing through the curtain.

Due to the increase in layers and/or material used to create room darkening curtains, room darkening curtains weigh substantially more than traditional non-darkening curtains. The table below provides examples of the weight differences measured between room darkening curtains that include a darkening component (e.g., a lining layer or foam panel) and non-darkening curtains made of the same fabric type without the darkening component.

TABLE 1 Curtain Weight Comparison Facing Fabric Darkening Total % Panel Weight Component Weight weight Fabric Type Size (grams) Weight (grams) (grams) increase Jacquard Fabric 38″ × 84″ 450 250 (includes liner 700 56 (Soho) with a weight of 135 gsm) Jacquard Fabric 38″ × 84″ 450 0 (no liner) 450 (Soho) Faux Silk (Belle) 38″ × 84″ 200 250 (includes liner with 450 125 a weight of 135 gsm) Faux Silk (Belle) 38″ × 84″ 200 0 (no liner) 200 Faux Linen 38″ × 84″ 550 300 (includes liner with 850 55 (Jeffrey) a weight of 135 gsm) Faux Linen 38″ × 84″ 550 0 (no liner) 550 (Jeffrey) Jacquard Fabric 37″ × 84″ 347 340 (includes foamback 687 98 (Aster) panel with a weight of 290 gsm) Jacquard Fabric 37″ × 84″ 347 0 (no foamback panel) 347 (Aster) Jacquard Fabric 37″ × 84″ 302 340 (includes foamback 642 112.6 panel with a weight of 270 gsm) Jacquard Fabric 37″ × 84″ 302 0 (no foamback panel) 302 Jacquard Fabric 37″ × 84″ 275 339 (includes foamback 614 123.3 panel with a weight of 258 gsm) Jacquard Fabric 37″ × 84″ 275 0 (no foamback panel) Woven Jacquard 37″ × 84″ 404 169 (includes black 573 41.8 (Clair) room darkening yarn for a weight of 230 gsm) Woven Jacquard 37″ × 84″ 404 0 (no black room 404 (Clair) darkening yarn) Woven Jacquard 37″ × 84″ 385 173 (includes black 558 44.9 (Wyatt) room darkening yarn for a weight of 240 gsm) Woven Jacquard 37″ × 84″ 385 0 (no black room 385 (Wyatt) darkening yarn)

As shown in Table 1, the room darkening curtains, (i.e., those with liners, foamback panels, or black room darkening yarn) are substantially heavier than their non-room darkening counterparts. Thus, the curtain rod system 100 includes design features to support the increased weight of drapes 106 made of a room darkening material. For instance, the drape connection rod 102 and the drape support rod 104 may be formed of hollow tubes that provide increased support strength over traditional curtain support structures such as wires and C-shaped cross-section rod having rolled edges. The drape connection rod 102 and/or drape support rod 104 may be a roll form rod having a circular cross section. Using a cylindrical rod increases weight the curtain rod system 100 can support due to the hoop stress characteristics associated with the cylindrical shape. For increased strength, the seam of the rolled rod may be welded along the length thereof. In other embodiments the, seam of the rolled rod may be folded or zipped together along the length thereof. In other embodiments, the drape connection rod 102 and drape support rod 104 may be extruded. In one form, the drape connection rod 102 and drape support rod 104 are extruded solid rods. In another form, the drape connection rod 102 and drape support rod 104 are extruded into hollow tubes having an uninterrupted outer wall.

The drape connection rod 102 includes a first rod 180 and a second rod 280 having a smaller diameter than the first rod 180 such that the second rod 280 may be received telescopically within the first rod 180 (see FIGS. 9 and 10A-B). The first and second rods 180, 280 may be moved relative to one another along the axis of the drape connection rod 102 to adjust the overall length of the drape connection rod 102. The drape support rod 104 similarly includes a first rod 190 and a second rod 290 having a smaller diameter that is received telescopically within the first rod (see FIGS. 10A-B). The first and second rods 190, 290 may be moved along the axis of the drape support rod 104 to adjust the overall length of the drape support rod 104.

With respect to FIGS. 3A-B, the left portion of the curtain rod system 100 is shown without the drape 106. As shown, the curtain rod system 100 further includes a left mounting plate 108, a left rods support bracket 110, and a left drape connection rod connector 112. While not shown in FIGS. 3A-B, the curtain rod system 100 also includes the same components on a right end of the curtain rod system 100 that are similar to and mirror image of those at the left end of the curtain rod system 100. Those components include a right mounting plate 208, a right rods support bracket 210 (see FIGS. 6A-D), and a right drape connection rod connector 212 (see FIGS. 8A-E).

The left and right mounting plates 108, 208 may be fastened to a wall or window frame on either side of a window. As shown, the left rods support bracket 110 is attached to the left mounting plate 108. The drape connection rod 102 is attached to the left rods support bracket 110 via the left drape connection rod connector 112. The drape support rod 104 is also attached to the left rods support bracket 110. While not shown in FIGS. 3A-B, the right side of the curtain rod system 100 may be similarly assembled such that the right side mirrors the left side of the curtain rod system 100. For example, the right rods support bracket 210 is attached to the right mounting plate 208. The end of the drape connection rod 102 opposite the left end is connected to the right rods support bracket 210 via the right drape connection rod connector 212. The end of the drape support rod 104 opposite the left end may be attached to the right rods support bracket 210.

With reference to FIGS. 4A-F, the left mounting plate 108 is shown. The left mounting plate 108 may be identical to the right mounting plate 208, and thus, any discussion of the left mounting plate 108 also applies to the right mounting plate 208. The left mounting plate 108 includes a support leg 114 and a mounting portion 116. The support leg 114 extends from the mounting portion 116 and terminates at an arcuate tip 118. The back surface 120 of the mounting plate 108 may be flat across both the support leg 114 and the mounting portion 116 to provide a flat surface for mounting to a surface, such as a flat wall. The mounting plate 108 includes a support flange 122 that is formed by a step between the front surface 124 of the support leg 114 and a front surface 130 of the mounting portion 116. The support flange 122 may engage a surface of the left and right rods support brackets 110, 210 when attached to the mounting plate 108 to support the rods support brackets 110, 210.

The mounting portion 116 extends from the support flange 122 to the top edge 125. The mounting portion 116 defines two holes 126 therethrough. The holes 126 are spaced apart from one another and at a top portion of the mounting portion 116 to provide increased support for the curtain rod system 100. The two holes 126 may have a configuration similar to that disclosed in U.S. patent application Ser. No. 16/749,770, which is incorporated by reference herein in its entirety. The holes 126 may have an annular chamfer 128 about the circumference of the holes 126 on the front surface 130 of the mounting portion 116 to create countersunk holes for a head portion of a wall fastener. The mounting portion 116 has angled side edges 132, 134 to form a male portion of a dovetail joint with the rods support brackets 110, 210.

In one non-limiting example, the mounting plate 108 has a maximum width of 1.692 inches and a height of 2.0 inches. The thickness of the support leg 114 is 0.163 inches. The thickness of the mounting portion 116 is 0.1 inches.

With regard to FIGS. 5A-F, the left rods support bracket 110 includes a base 140, an inner connector support arm 142, and an outer rod support connector 144. The base 140 is a plate from which the inner connector support arm 142 and the outer rod support connector 144 extend. The inner connector support arm 142 is at a first end portion 146 of the base 140, and the outer rod support connector 144 is on at a second end portion 148 of the base 140. The distance between the inner connector support arm 142 and the outer rod support connector 144 may be the desired distance between the drape connection rod 102 and the drape support rod 104. The back surface 150 of the base 140 includes a recessed connection portion 152 having angled side edges 154, 156 that form a female portion of the dovetail joint with the mounting plate 108. More specifically, the angled side edges 154, 156 are spaced apart and angle complementary to the male portion of the dovetail joint of the mounting plate 108 such that the male portion of the dovetail joint of the mounting plate 108 may be received within the recessed connection portion 152. The base 140 of the left rods support bracket 110 includes a bottom surface 159 that rests on the support flange 122 of the mounting plate 108 when assembled via the dovetail joint to support the support bracket 110 vertically when mounted to a wall.

The inner connector support arm 142 extends substantially perpendicularly to the base 140. The inner connector support arm 142 includes a tab 158 that defines holes 160. In some forms, the holes 160 are threaded holes. While three holes are shown, other embodiments having any number of holes are also contemplated. Having more holes 160 may increase the number of positions the drape connection rod 102 may be set to relative to the window as described in further detail below. The end of the inner connector support arm 142 opposite the base 140 is an arcuate tip 162 which may aid in guiding the inner connector support arm 142 into the drape connection rod connectors 112, 212 when assembling the curtain rod system 100.

The outer rod support connector 144 extends substantially perpendicularly to the base 140. The outer rod support connector 144 is cylindrical and has a diameter slightly smaller than the diameter of a left end of the drape support rod 104. The outer rod support connector 144 may be inserted into the left end of the drape support rod 104 to support the drape support rod 104. The outer rod support connector 144 defines a threaded hole 164. The threaded hole 164 may be used in conjunction with a screw to secure the drape support rod 104 to the outer rod support connector 144 to prevent the two components from becoming unintentionally decoupled. The threaded hole 164 may be positioned on the bottom side of the outer rod support connector 144 when mounted to the mounting plate 108 to provide access to an installer.

In one non-limiting example, the base 140 of the left rods support bracket 110 has a maximum length of 2.582 inches and a width of 0.750 inches. The outer rod support connector 144 has an outer diameter of 0.750 inches and extends 1.438 inches from the back surface 150 of the base 140. The threaded hole 164 of the outer rod support connector 144 has a diameter of 0.138 inches. The inner connector support arm 142 has a width of 0.505 inches and extends 1.029 inches from the base 140. The holes 160 of the inner connector support arm 142 have a diameter of 0.180 inches. The center of holes 160 of the inner connector support arm 142 may be spaced apart from one another by 0.288 inches.

With regard to FIGS. 6A-D, the right rods support bracket 210 is shown. The right rods support bracket 210 has the same features as the left rods support bracket 110 shown in FIGS. 5A-F but arranged generally as a mirror image to the left rods support bracket 110. For simplicity, the features of the right rods support bracket 210 that correspond to features of the left rods support bracket 110 are shown with a “2” replacing the leading “1” of the reference numeral of the left rods support bracket 110. For example, a feature having reference numeral “140” in the left rods support bracket 110 has reference numeral “240” in the right rods support bracket 210. As noted, the right rods support bracket 210 is a mirror image of the left rods support bracket 110, except that the outer diameter of the outer rod support connector 244 is smaller than the outer diameter of the outer rod support connector 144 of the left rods support bracket 110. The smaller diameter enables the outer rod support connector 244 to fit within a smaller end of the drape support rod 104.

In one non-limiting example the dimensions of the features of the right rods support bracket 210 are the same as those of the left rods support bracket 210, except that the diameter of the outer rod support connector 244 has an outer diameter of 0.531 inches.

With reference to FIGS. 7A-E, the left drape connection rod connector 112 is shown. The left drape connection rod connector 112 has an elbow shape formed by an arcuate outer wall 168. The left drape connection rod connector 112 includes a base 170 and a support arm receiving end 172 that are positioned at an approximate right angle relative to one another. The base 170 is cylindrical and has an outer diameter that is similar to the outer diameter of the first rod 180 of the drape connection rod 102 such that the base 170 abuts the left end of the first rod 180 and is flush with the first rod 180. In other embodiments, the base 170 has an outer diameter that is slightly smaller than the inner diameter of the first rod 180 of the drape connection rod 102 such that the base 170 may be inserted into the left end of the drape connection rod 102. The base 170 defines a threaded hole 174 that extends into the left drape connection rod connector 112. As shown in FIG. 9, a threaded stud 186 may be threaded into the threaded hole 174 to attach the left drape connection rod connector 112 to the drape connection rod 102.

The outer wall 168 defines a socket 174. Within the socket 174 are two ribs 176 that extend along the interior side of the outer wall 168. An interior wall 178 extends across the socket 170 formed by the outer wall 168 substantially parallel to the ribs 176. The space between the ribs 176 and the interior wall 178 forms a connection socket 177 that is sized to receive the inner connector support arm 142 of the left rods support bracket 110. The interior wall 178 defines a threaded hole 179 therethrough. The threaded hole 179 may be aligned with one of the holes 160 of the inner connector support arm 142 (which may also be threaded holes) for attaching the left drape connection rod connector 112 to the left rods support bracket 110. As shown in FIG. 9, a screw 188 may be threaded into hole 179 to attach the left drape connection rod connector 112 to the left rods support bracket 110. The screw 188 may be extended through any one of holes 160 to set the distance between the base 170 and the surface to which the curtain rod system 100 is mounted, thereby setting the position of the drape connection rod 102 relative to the mounting surface. The distance or gap between the drape connection rod 102 and the mounting surface or window frame may need to be adjusted to accommodate drapes having different thicknesses and/or material density and allow enough space for the drape 106 to be drawn to the sides of the window to allow light to enter the room when desired. The gap between the drape connection rod 102 and the mounting surface or window frame may need to be decreased to bring the top edge of the drape 106 closer to or in contact with the mounting surface or window frame to reduce or eliminate top light from entering the room.

In one non-limiting example, left drape connection rod connector 112 has a length of 1.089 inches, a width is 1.006 inches, and a height of 0.625 inches. The outer diameter of the base 170 is 0.625 inches, and the diameter of the threaded hole 174 is 0.220 inches. The diameter of the hole 179 in the internal wall 178 is 0.138 inches.

With reference to FIG. 7F, a left drape connection rod connector 112′ is shown according to a second embodiment. The left drape connection rod connector 112′ is similar to the left drape connection rod connector 112 shown in FIGS. 7A-E, with the primary difference being that the socket 174′ does not include ribs (such as ribs 176 of FIGS. 7A-E) along the internal surface of the socket 174′ that form a socket (such as connection socket 177 of FIGS. 7A-E) for receiving the inner connector support arm 142 of the left rods support bracket 110.

With regard to FIGS. 8A-E, the right drape connection rod connector 212 is shown. The right drape connection rod connector 212 has the same features as the left drape connection rod connector 112 shown in FIGS. 7A-E and is generally a mirror image of left drape connection rod connector 112 when installed. For simplicity, the features of the right rods support bracket 210 that correspond to features of the left rods support bracket 110 are shown with a “2” replacing the leading “1” of the reference numeral of the left rods support bracket 110. For example, a feature having reference numeral “170” in the left drape connection rod connector 112 has reference numeral “270” in the right drape connection rod connector 212.

A difference between the right drape connection rod connector 212 and the left drape connection rod connector 112 is the base 270 of the right drape connection rod connector 212 may be a different size than the base 170 of the left drape connection rod connector 112. As shown in FIGS. 8A-E, the diameter of the base 270 of the right drape connection rod connector 212 is smaller than the base 170 of the left drape connection rod connector 112. The base 270 may have an outer diameter similar the outer diameter of the second rod 280 such that the base 270 abuts the second rod 280 and is flush with the second rod 280. In embodiments where the base 270 is inserted into the right end of the drape connection rod 102, the outer diameter of the base 270 may be sized to fit within the second rod 280 of the drape connection rod 102.

In one non-limiting example, the dimensions of the features of the right drape connection rod connector 212 are the same as those of the left drape connection rod connector 112, except that the diameter of the base 270 has an outer diameter of 0.500 inches.

With reference to FIG. 8F, a right drape connection rod connector 212′ is shown according to a second embodiment. The right drape connection rod connector 212′ is similar to the right drape connection rod connector 212 shown in FIGS. 8A-E, with the primary difference being that the socket 274′ does not include ribs (such as ribs 276 of FIGS. 8A-E) along the internal surface of the socket 274′ that form a socket (such as connection socket 277 of FIGS. 8A-E) for receiving the inner connector support arm 242 of the right rods support bracket 210.

With reference to FIG. 9, the drape connection rod 102 and left and right drape connection rod connectors 112, 212 are shown. The drape connection rod 102 includes the first rod 180 and the second rod 280. The second rod 280 has a diameter slightly smaller than the first rod 180 such that the second rod 280 may be received telescopically within the first rod 180. The overall combined length of the first and second rods 180, 280 may be adjusted by sliding the first and second rods 180, 280 relative to one another along the axis of the drape connection rod 102. Circular plates 182, 282 may be fixed inside each of the first and second rods 180, 280. The circular plates 182, 282 may be fixed at an end portion of the first and second rods 180, 280. In embodiments where the bases 170, 270 of the left and right drape connection rod connectors 112, 212 are inserted into the ends of the drape connection rod 102, the circular plate 182 of the first rod 180 may act as a stop to inhibit the base 170 of the left drape connection rod connector 112 from being inserted too far within the first rod 180;likewise, the circular plate 282 of the second rod 280 may act as a stop to inhibit the base 270 of the right drape connection rod connector 212 from being inserted too far within the second rod 280. The circular plates 182, 282 define threaded holes 184, 284, respectively, therethrough. The threaded hole 184 receives a threaded stud 186 to attach the left drape connection rod connector 112 to the left end of the drape connection rod 102. The threaded hole 284 receives a threaded stud 286 to attach the right drape connection rod connector 212 to the right end of the drape connection rod 102.

With reference to FIGS. 10A-B, the curtain rod system 100 is shown. In FIG. 10A, the curtain rod system 100 is shown in a contracted state with the second rod 280 of the drape connection rod 102 positioned almost entirely within the first rod 180 of the drape connection rod 102. Likewise, the second rod 290 of the drape support rod 104 is shown almost entirely within a first rod 190 of the drape support rod 104. In FIG. 10B, the curtain rod 100 is shown in an expanded configuration, with the second rods 280, 290 partially withdrawn from the first rods 180, 190 of the drape connection rod 102 and the drape support rod 104. By moving the curtain rod system 100 between the contracted configuration of FIG. 10A and the expanded configuration of FIG. 10B, the overall combined length of the curtain rod system 100 may be variably adjusted therebetween.

In one non-limiting example, the curtain rod system 100 has a length between the first end 146 of the left rods support bracket 110 and the first end 246 of the right rods support bracket 210 in a fully contracted configuration of 36.0 inches. The curtain rod system 100 in a fully expanded configuration has a length between the first end 146 of the left rods support bracket 110 and the first end 246 of the right rods support bracket 210 of about 66 inches.

With reference to FIGS. 11A-B, a curtain rod system 300 according to a second embodiment is shown. The curtain rod system 300 is similar in many respects to curtain rod system 100 with a difference being that the drape connection rod 102 includes a third rod 380 and drape support rod 104 includes a third rod 390. The curtain rod system 300 may be used in connection with windows having a greater width and/or windows that require two drapery panels to cover. In this embodiment, the first and second rods 180, 280 may be the same length and have the same diameter as discussed above. Alternatively, the first and second rods 180, 280 may have the same diameter. In this case, the base 170 of left drape connection rod connector 112 of the curtain rod system 300 has the same diameter as the base 270 of the right drape connection rod connector 212. In either case, the third rod 380 of the drape connection rod 102 has a smaller diameter such that it may be slidingly received into both the first and second rods 180, 280, as shown in FIG. 11A-B. In other examples, the third rod 380 has a larger diameter than the first and second rods 180, 280 such that the first and second rods 180, 280 may be slidingly received therein.

Similarly, the first and second rods 190, 290 of the drape support rod 104 may be the same length and have the same diameter as discussed above. Alternatively, the first and second rods may have the same diameter. In this case, the left rods support bracket 110 of the curtain rod system 300 has an outer rod support connector 144 that has the same diameter as the outer rod support connector 244 of the right rods support bracket 210. In either case, the third rod 390 of the drape support rod 104 may have a smaller diameter such that it may be slidingly received into both the first and second rods 190, 290, as shown in FIG. 11A-B. In other examples, the third rod 390 has a larger diameter than the first and second rods 190, 290 such that the first and second rods 190, 290 may be slidingly received therein.

As shown in FIG. 11A, the curtain rod system 300 is shown in a contracted state with the third rod 380 of the drape connection rod 102 positioned almost entirely within the first and second rods 180, 280 of the drape connection rod 102. Likewise, the third rod 390 of the drape support rod 104 is shown almost entirely within the first and second rods 190, 290 of the drape support rod 104. In FIG. 11B, the curtain rod 300 is shown in an expanded configuration, with the third rods 380, 390 of the drape connection rod 102 and drape support rod 104 partially withdrawn from the first rods 180, 190 and second rods 280, 290 of the drape connection rod 102 and drape support rod 104. By moving the curtain rod system 300 between the contracted configuration of FIG. 11A and the expanded configuration of FIG. 11B, the overall combined length of the curtain rod system 300 may be variably adjusted therebetween.

In one non-limiting example, in a fully contracted configurations, the curtain rod system 300 has a length between the first end 146 of the left rods support bracket 110 and the first end 246 of the right rods support bracket 210 of 66.0 inches. The curtain rod system 300 in a fully expanded configuration has a length between the first end 146 of the left rods support bracket 110 and the first end 246 of the right rods support bracket 210 of 120 inches.

With respect to FIGS. 12A-C a center rods support bracket 302 of the curtain rod system 300 is shown. The center rods support bracket 302 may be positioned in the center of the curtain rod system 300 to provide support to the drape connection rod 102 and drape support rod 104. A first drape panel may be attached to the drape connection rod 102 on the portion of the rod 102 extending to the left of the center rods support bracket 302 and a second drape panel may be attached to the drape connection rod 102 on the portion of the rod 102 extending to the right of the center rods support bracket 302.

The center rods support bracket 302 includes a mounting base 304 from which a support arm 306 extends. The mounting base 304 is a plate having a front surface 308 and a rear surface 310. The rear surface 310 contacts a surface such as a wall or window frame when mounted. The mounting base 304 defines mounting holes 305 through which a fastener, such as a screw, may be inserted to mount the center rods support bracket 302 to a surface.

The support arm 306 extends from the mounting base 304 at an approximately right angle. The support arm 306 defines a drape support rod hole 312 through which the drape support rod 104 extends. The drape support rod hole 312 may have a diameter sized to receive the third rod 390 of the drape support rod 104. The diameter of hole 312 may also be large enough to receive the first and second rods 190, 290 of the drape support rod 104. A tab 314 extends perpendicularly from the support arm 306 in proximity to the drape support rod hole 312. The tab 314 defines a threaded locking hole 316 through which a locking screw 318 extends. The locking screw 318 may be tightened against the drape support rod 104 to prevent the rod 104 from unintentional movement.

The support arm 306 further defines overlapping circular holes 320 through which the drape connection rod 102 may extend. The drape connection rod 102 may extend through the one of the overlapping circular holes 320 that corresponds with the hole of the holes 160 of the left and right rods support brackets 110, 210 that screws 188, 288 were inserted into. This maintains a constant distance from the wall along the support arm 306. For example, if screws 188, 288 were inserted into the hole 160 closest to the window, then the drape connection rod 102 is inserted into the hole of the overlapping circular holes 320 closest to the window. The diameter of each of the overlapping circular holes 320 may be sized to receive the third rod 380 of the drape connection rod 104. The diameter of each of the overlapping circular holes 320 may also be large enough to receive the first and second rods 190, 290 of the drape connection rod 102. The distance between the center of each of the overlapping circular holes may be the same as the distance between the holes 160 of the inner connector support arm 142 of the left and right rods support brackets 110, 210. While overlapping circular holes are shown, in other embodiments a slot may be used. A tab 322 protrudes perpendicularly to the support arm 306. The tab 322 defines three threaded locking holes 324. The center of the three locking holes 324 is aligned with the center of each of the overlapping circular holes 320. A locking screw 326 may be inserted into one of the locking holes 324 to secure the drape connection rod 102 from unintentional movement.

In one non-limiting example, the center rods support bracket 302 has a length from the rear surface 310 to the center of the drape support rod hole 312 of 3.788 inches. The length from the rear surface 310 to the center of each of the overlapping holes 320 and the center of the corresponding locking holes 324 is 0.940 inches, 1.228 inches, and 1.516 inches. The base 304 of the center rods support bracket 302 has a height of 1.335 inches with a distance of 0.935 inches between the centers of the mounting holes 305. The center rods support bracket 302 may be made from 0.080 inches thick steel. The dimensions are referenced from an installed orientation.

With reference to FIGS. 13A-D, non-limiting steps for assembling and installing the curtain rod systems 100, 300 are shown. Regarding FIG. 13A, the back surface 120 of the mounting plate 108 is placed against the wall or window frame at the desired mounting position at the left side of the window. The top edge 125 of the mounting plate 108 is adjusted to be substantially horizontal. Fasteners, such as screws, are then inserted through holes 126 of the mounting portion 116 of the mounting plate 108. The screws may extend into the wall or window frame to which the back surface 120 of the mounting plate 108 contacts. The screws may be tightened such that the heads of the screws are within the countersunk portion of the holes 126. The heads of the screws may be flush with or behind the front surface 130 of the mounting portion 116 of the mounting plate 108.

The back surface 150 of the left rods support bracket 110 may be brought into contact with the surface to which the mounting plate 108 is mounted. The left rods support bracket 110 may be positioned such that the inner connector support arm 142 and an outer rod support connector 144 are substantially horizontal, with the outer rod support connector 144 to the outside of the inner connector support arm 142. The left rods support bracket 110 may be slid downward over the mounting portion 116 of the mounting plate 108 to attach the left rods support bracket 110 to the mounting plate 108. To slide the left rods support bracket 110 onto the mounting portion 116 of the mounting plate 108, the angled side edges 154, 156 of the recessed connection portion 152 of the left rods support bracket 110 are aligned with the complementary angled side edges 132, 134 of the mounting portion 116 of the mounting plate 108. The left rods support bracket 110 is then slid downward over the mounting portion 116 of the mounting plate until the bottom surface 159 of the left rods support bracket 110 contacts the support flange 122 of the mounting plate 108.

Regarding FIG. 13B, the left drape connection rod connector 112 is attached to the left rods support bracket 110. To do this, the arcuate tip 162 of the inner connector support arm 142 may be aligned with the interior wall 178 and the ribs 176 defining the connection socket 177 before insertion. The inner connector support arm 142 of the left drape connection rod connector 112 is inserted into the connection socket 177. The arcuate tip 162 may aid to guide the inner connector support arm 142 into the connection socket 177 of the left drape connection rod connector 112. Once inserted, the threaded hole 179 of the left drape connection rod connector 112 may be aligned with one of the holes 160 of the inner connector support arm 142. Aligning threaded hole 179 with one of the holes 160 near the base 140 of the left drape connection rod connector 112 will set the drape connection rod 102 close to the window frame. Aligning threaded hole 179 with one of the holes 160 near the arcuate tip 162 of the inner connector support arm 142 of the left drape connection rod connector 112 sets the drape connection rod 102 farther away from the window frame. The holes 160 thus provide adjustability to the proximity of the drape connection rod 102 to the window frame. Once the threaded hole 179 of the left drape connection rod connector 112 is aligned with the desired hole of holes 160 of the inner connector support arm 142, a screw may be inserted through threaded hole 179 and the desired hole 160 to secure the inner connector support arm 142 to the left drape connection rod connector 112.

As shown in FIG. 13C, the drape connection rod 102 may then be attached to the left drape connection rod connector 112. To do this, the threaded stud 186 is threaded into the threaded hole 174 of the base 170 of the left drape connection rod connector 112. The threaded hole 184 of the plate 182 of the drape connection rod 102 is aligned with the other end of the threaded stud 186. The drape connection rod 102 is rotated relative to the threaded stud 186 to threadingly engage the threaded stud 186. As the drape connection rod 102 is rotated relative to the threaded stud 186, the drape connection rod 102 is drawn closer to the left drape connection rod connector 112 until the base 170 of the left drape connection rod connector 112 is brought into contact with the drape connection rod 102. The drape connection rod 102 may be tightened until the base 170 applies a sufficient force to the drape connection rod 102 to secure the rod 102 to the left drape connection rod connector 112. In embodiments where the base 170 is inserted into the end of the drape connection rod 102, as the drape connection rod 102 draws closer, the base 170 is aligned with the end of the drape connection rod 102 such that the base 170 passes into the drape connection rod 102. The drape connection rod 102 may be tightened until the base 170 applies a sufficient force to the plate 182 to secure the rod 102 to the left drape connection rod connector 112.

With reference to FIG. 13D, the drape support rod 104 may be attached to the left rods support bracket 110. An end of the drape support rod 104 is fitted over the outer rod support connector 144. The drape support rod 104 is secured to the outer rod support connector 144 by a set screw. Once the drape support rod 104 has been moved to the desired position relative to the outer rod support connector 144, a set screw is inserted into a hole 105 in the side wall of the drape support rod 104. The hole 105 may be a threaded hole. The set screw is turned until the screw applies a sufficient amount of force between the drape support rod 104 and outer rod support connector 144 such that they are secured from unintentional movement relative to one another. Alternatively, the hole 105 of the drape support rod 104 is aligned with threaded hole 164 of the outer rod support connector 144 of the left rods support bracket 110. A fastener, such as a screw, is extended through hole 105 and into threaded hole 164 thereby securing the drape support rod 104 to the left rods support bracket 110.

Similar steps may be used to mount and assemble the right mounting plate 208, the right rods support bracket 110, and right drape connection rod connector 112. The length of the drape connection rod 102 may be set by moving the first rod 180 and second rod 280 (and in the curtain rod system 300, the third rod 380) relative to one another along the axis of the drape connection rod 102. Likewise, the length of the drape support rod 104 may be set by moving the first rod 190 and second rod 290 (and in the curtain rod system 300, the third rod 390) relative to one another along the axis of the drape support rod 104.

While the installation methods disclosed herein are described as being performed in a certain order, those having skill in the art will readily understand that the methods are not so limited.

The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While embodiments have been shown and described, it will be apparent to those skilled in the art that modifications may be made without departing from the broader aspects of the technological contribution. The actual scope of the protection sought is intended to be defined in the following claims.

Claims

1. A curtain rod system for supporting a drape comprising:

an inner rod for mounting at a window on a mounting surface and providing an anchor for a first portion a drape, the inner rod including a hollow tube; and

an outer rod for mounting to the mounting surface substantially parallel to the inner rod along the length thereof and spaced apart from the inner rod to form a first gap therebetween and providing support for a second portion of the drape such that the drape overlies the gap to substantially prevent light from passing through the gap, the outer rod including a hollow tube.

2. A curtain rod system of claim 1 further comprising a drape including a first portion anchored to the inner rod and a second portion laid over the outer rod to span the first gap between the inner rod and outer rod.

3. A curtain rod system of claim 2 wherein the drape includes a darkening component creating at least a 40% increase in weight over an equivalent drape without such darkening component.

4. The curtain rod system of claim 1 wherein the ends of the inner rod are mountable at a window on a mounting surface via adjustable elbows.

5. The curtain rod system of claim 2 wherein each adjustable elbow includes base portion to support an end of the inner rod and a connection portion substantially perpendicular to the base portion used in mounting the elbow at a window on a mounting surface at a plurality of positions to set a distance between the inner rod and the mounting surface.

6. The curtain rod system of claim 2 wherein the inner rod and a mounting surface at a window forms a second gap for the first portion of a drape to extend into.

7. The curtain rod system of claim 1 further comprising first and second mounting brackets, each including an attachment portion and an inner support arm, the first mounting bracket being capable of being attached to a mounting surface using the attachment portion and supporting a first end of the inner rod via the inner support arm, and the second mounting bracket being capable of being attached to a mounting surface using the attachment portion and supporting a second end of the inner rod via the inner support arm.

8. The curtain rod system of claim 1 wherein the first and second mounting brackets each include a base being separate from the attachment portion and capable of being mounted to a surface, the base including a set of opposing edges that are received in complementary grooves defined by the attachment portion to mount the attachment portion the base.

9. The curtain rod system of claim 7 further comprising a first elbow connector having an base for connecting to the first end of the inner rod and having a socket at an angle to the base for receiving at least a portion of the inner support arm of the first mounting bracket.

10. The curtain rod system of claim 9 wherein the connection portion of the first elbow connector is adjustably connected to the inner support arm of the first mounting bracket to set the distance between the first end of the inner rod and a mounting surface.

11. The curtain rod system of claim 10 wherein the inner support arm of the first mounting bracket is a tab extending from the attachment portion of the first mounting bracket, the tab defining a plurality of holes in a linear series, the first elbow connector defining a hole at the socket configured to be aligned with any one of the plurality of holes of the first mounting bracket tab to set the distance between the first end of the inner rod and a mounting surface.

12. The curtain rod system of claim 7 further comprising a center support bracket including a support arm that are capable of engaging the inner and outer rods to provide support thereto.

13. The curtain rod system of claim 12 wherein the support arm of the center support bracket defines a plurality of overlapping holes, each overlapping circular hole sized to receive the inner rod therethrough to set a distance between the inner rod and a mounting surface.

14. The curtain rod system of claim 1 wherein the length of the inner rod and the outer rod are adjustable, the inner rod and outer rods each comprising a first rod and a second rod sized to be slidingly received within the first rod.

15. The curtain rod system of claim 1 wherein each of the inner rod and the outer rod comprise an intermediate rod.

16. The curtain rod system of claim 1 wherein the end portions of the outer rod are curved to allow the drape to be along a mounting surface along a window.

17. A method of installing a curtain rod system, the method comprising:

attaching a drape to an inner rod, the inner rod including a hollow tube;

mounting the inner rod to a mounting surface at a top portion of a window;

mounting an outer rod to the mounting surface such that the outer rod is substantially parallel to the inner rod along the length thereof, the outer rod being spaced apart from the inner rod to form a gap therebetween, the outer rod including a hollow tube; and

laying the drape over the outer rod such that the drape spans the gap between the inner and outer rods.

18. The method of claim 17 further comprising adjusting the distance between the inner rod and the mounting surface to allow for the drape to be moved substantially to one end of the inner rod.

19. The method of claim 17 further comprising adjusting the length of the inner and outer rods.

20. The method of claim 17 wherein mounting the inner rod to a mounting surface includes:

mounting a first mounting bracket at a left side of the window;

mounting a second mounting bracket at a right side of the window; and

attaching the inner rod to the first and second mounting brackets.

21. The method of claim 20 wherein attaching the inner rod to the first and second mounting brackets includes:

attaching a first elbow connector to a first end of the inner rod and attaching the first elbow connector to the first mounting bracket; and

attaching a second elbow connector to a second end of the inner rod and attaching the second elbow connector to the second mounting bracket.

22. The method of claim 21 further comprising adjusting the distance between the inner rod and the mounting surface by adjusting the attachment point of the first elbow connector to the first mounting bracket and adjusting the attachment point of the second elbow connector to the second mounting bracket.

23. The method of claim 20 wherein mounting the outer rod to the mounting surface includes attaching the outer rod to the first and second mounting brackets.

24. The method of claim 17 further comprising the steps of:

mounting a center support bracket to the mounting surface at the top portion of a window; and

connecting the inner and outer rods to the center support bracket.