Window covering parts and apparatus and methods for making the same

Abstract

A hollow, rigid window covering component for use as a slat or otherwise, generally used as an alternative to wood, the component being filled with a foam using a substantially continuous manufacturing process. The apparatus used for this process comprises a die having a substantially toroid-shaped resin chamber and a channel or void through which to inject a core material into the enclosed perimeter of the hollow window covering component.

1 . A method of forming a window covering component comprising the steps of 
 Feeding an extrudable material into a die, said die comprising 
 An input channel,  
 A chamber,  
 An exit aperture through which said extrudable material exits said die to form a hollow window covering component having an unbroken cross-sectional perimeter, and  
 Means for accessing the hollow interior of the window covering component;  
   Injecting a core material through said accessing means of said die into the interior of said window covering component in a substantially continuous process as it exits said die.    
   
   
       2 . A method of forming a window covering component comprising the steps of 
 Feeding a melted extrudable material into a die, said die comprising 
 An input channel into which said melted extrudable material is fed,  
 A chamber, said chamber comprising an inner perimeter and an outer perimeter; and  
 An exit aperture through which said melted extrudable material exits said die to form the exterior shell of said window covering component;  
   Inserting a delivery device into the space within said inner perimeter of said die;    Injecting a core material into the interior of said shell of said window covering component using said delivery device;    Forming said window covering component into a desired shape; and    Cooling said window covering component.    
   
   
       3 . The method of  claim 2  in which said melted extrudable material is selected from the group consisting of ABS, ASA, PVC, polypropylene, polyethylene, PET, PETG, polycarbonate, polystyrene, and composites includes any of the foregoing.  
   
   
       4 . The method of  claim 2  in which said core material is selected from the group consisting of a thermoset plastic, a foamed thermoplastic resin, and composites includes either of the foregoing.  
   
   
       5 . A window covering component comprising 
 A shell and a core,    And formed using a process comprising the steps of    Obtaining an extrudable material;    Feeding said extrudable material into a die, said die comprising 
 An input channel,  
 A resin chamber, said resin chamber comprising an inner perimeter and an outer perimeter; and  
 An exit aperture through which said extrudable material exits said die to form said shell;  
   Inserting a delivery device into the space within said inner perimeter of said die; and    Injecting a core material through said delivery device into the interior of said shell to form said core; and    Forming said window covering component into a desired shape.    
   
   
       6 . The window covering component of  claim 5  in which said extrudable material is selected from the group consisting of ABS, ASA, PVC, polypropylene, polyethylene, PET, PETG, polycarbonate, polystyrene, and composites includes any of the foregoing.  
   
   
       7 . The window covering component of  claim 5  in which said core material is selected from the group consisting of a thermoset plastic, a foamed thermoplastic resin, and composites includes either of the foregoing.