Low-deflection roller shade tube for large openings

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. provisional patent application No. 62/159,132, filed May 8, 2015, which is incorporated herein by reference in its entirety.

BACKGROUND

A window treatment may be mounted in front of one or more windows, for example to prevent sunlight from entering a space and/or to provide privacy. Window treatments may include, for example, roller shades, roman shades, venetian blinds, or draperies. A roller shade typically includes a flexible shade fabric wound onto an elongated roller tube. Such a roller shade may include a weighted hembar located at a lower end of the shade fabric. The hembar may cause the shade fabric to hang in front of one or more windows that the roller shade is mounted in front of.

Advances in window construction technology have enabled the manufacture of windows in ever increasing sizes, such as windows that may be 8 or more feet wide. Such large windows may require similarly large window treatments. For example, a roller shade configured to cover such a wide window may require an unusually long roller tube.

It may be desirable, in manufacturing a roller shade for a wide window, to maintain the aesthetics of a related roller shade that is sized for a smaller window. However, the roller tube of a roller shade that is simply supported at opposed ends of the tube may exhibit increasing deflection from the ends of the tube to the middle of the tube. This phenomenon may be referred to as tube sag. Tube sag may present a limitation to how long the roller tube of a roller shade may be made. And tube sag may become more pronounced as roller tube length increases.

An excess of tube sag may cause a roller shade to exhibit undesirable aesthetic and/or operational characteristics. For example, tube sage may cause visible sag lines to appear in the shade material. Additionally, tube sag may cause the shade material of a roller shade to wrinkle as the shade rolls up. In a roller shade with little to no tube sag, the shade material typically rolls up perpendicular to the roller tube. However, when a roller tube exhibits tube sag, the right half of the shade material may travel leftward and/or the left half of the shade material may travel rightward as the shade rolls up. This may introduce wrinkles into the rolled up shade material.

Known solutions for addressing tube sag in a roller shade may have one or more undesirable characteristics. For example, a first solution may be to increase the tube diameter of a roller tube to achieve an increased stiffness. However, such an enlarged roller tube may require additional space, which may negatively impact the aesthetic of an installation of the roller shade. In another solution, the shade material may be supported at one or more locations along the length of the roller tube. However, movement of the shade material over the supports may cause undesirable wear to the shade material.

SUMMARY

As described herein, the roller tube of a motorized roller shade may be configured as a low deflection roller tube for use in covering a large opening, such as an opening that is 8 feet wide or wider. The roller tube may define opposed first and second ends, and may be configured to be supported at the first and second ends.

The roller shade may include a covering material that is attached to the roller tube. The covering material may be operable between a raised position and a lowered position via rotation of the roller tube by the motor drive unit. The roller shade may include a hembar that is attached to a lower end of the covering material.

In accordance with an example motorized roller shade, the roller tube of the roller shade may be configured for use in covering an opening that is 10 feet wide. The roller tube may have a length of 10 feet along a longitudinal direction. The roller tube may have an outer diameter that does not exceed 2 inches. The roller tube may be configured such that when the covering material is in a lowered position and the roller tube is supported at the first and second ends, deflection of the roller tube does not exceed ⅛ of an inch relative to the unloaded position of the roller tube.

In accordance with another example motorized roller shade, the roller tube of the roller shade may be configured for use in covering an opening that is 12 feet wide. The roller tube may have a length of 12 feet along a longitudinal direction. The roller tube may have an outer diameter that does not exceed 2 inches. The roller tube may be configured such that when the covering material is in a lowered position and the roller tube is supported at the first and second ends, deflection of the roller tube does not exceed ¼ of an inch relative to an unloaded position of the roller tube.

The example low-deflection roller tubes may define respective pluralities of splines that extend from the inner surface. The plurality of splines may be configured to operatively engage with complementary grooves defined by a drive hub of the motor drive unit. The splines of each roller tube may extend parallel to an axis of rotation of the roller tube, and may be spaced apart from each other equally or unequally along a circumference of the inner surface. Each of the plurality of the splines may extend from the first end to the second end of the roller tube.

The example low-deflection roller tubes may be manufactured of carbon fiber. For example, a low-deflection roller tube may comprise a plurality of layers of carbon fiber. At least one layer of the plurality of layers may comprise high modulus carbon fiber. For example, an outermost layer of the plurality of layers may comprise high modulus carbon fiber.

In addition, the example low-deflection roller tubes may be two-part roller tubes that each include a first tube and a second tube. The first tube may be an inner tube that is made of a first material such as aluminum, steel, or the like. The first tube may be configured to operatively engage with complementary grooves defined by the drive hub of the motor drive unit. For example, the first tube may define a plurality of splines that extend from an inner surface of the first tube, may include one or more engagement members that extend from the inner surface, or may otherwise be configured to operatively engage with the motor drive unit. The second tube may made of carbon fiber material, and may be an outer tube that is attached to an outer surface of the inner tube. The second tube may be additively constructed on the first tube, for example by filament winding carbon fiber material onto the first tube.

An example process of manufacturing a low-deflection carbon fiber roller tube may include applying a first layer of carbon fiber fabric to a cylindrical mandrel. The mandrel may be elongate along a central axis, and may be tapered between opposed first and second ends thereof. An outer surface of the mandrel may define a plurality of grooves that extend parallel to the central axis.

The first layer of carbon fiber fabric may be oriented such that fibers thereof are parallel to the central axis. The first layer of carbon fiber fabric may be applied to the mandrel such that respective portions of the first layer of carbon fiber fabric are disposed into corresponding grooves of the mandrel. The example process may include applying a second layer of carbon fiber fabric to the first layer of carbon fiber fabric. The second layer of carbon fiber fabric may be oriented such that fibers thereof are angularly offset relative to the central axis, for example by 7°.

The example process may include applying a third layer of carbon fiber fabric to the second layer of carbon fiber fabric. The third layer of carbon fiber fabric may be oriented such that fibers thereof are angularly offset by forty five degrees relative to the central axis.

The example process may include applying a fourth layer of carbon fiber fabric to the third layer of carbon fiber fabric. The fourth layer of carbon fiber fabric may be oriented such that fibers thereof are angularly offset by ninety degrees relative to the central axis.

The example process may include applying a fifth layer of carbon fiber fabric to the fourth layer of carbon fiber fabric. The fifth layer of carbon fiber fabric may be oriented such that fibers thereof are angularly offset by forty five degrees relative to the central axis.

The example process may include applying a sixth layer of carbon fiber fabric to the fifth layer of carbon fiber fabric. The sixth layer of carbon fiber fabric may be oriented such that fibers thereof are angularly offset by seven degrees relative to the central axis.

The example process may include curing the first, second, third, fourth, fifth, and sixth layers of carbon fiber fabric. At least one of the first, second, third, fourth, fifth, and sixth layers of carbon fiber fabric may comprise high modulus carbon fiber. For example, the sixth layer of carbon fiber fabric may comprise high modulus carbon fiber.

BRIEF DESCRIPTION OF THE DRAWINGS

<figref idref="DRAWINGS">FIG. 1A</figref> is an exploded view of an example battery-powered roller shade for use in an oversized opening, the battery-powered roller shade including an example low-deflection roller tube.

<figref idref="DRAWINGS">FIG. 1B</figref> is a perspective view of the example battery-powered roller shade depicted in <figref idref="DRAWINGS">FIG. 1A</figref>, with the shade in a raised position.

<figref idref="DRAWINGS">FIG. 1C</figref> is a perspective view of the example battery-powered roller shade depicted in <figref idref="DRAWINGS">FIG. 1A</figref>, with the shade in a lowered position.

<figref idref="DRAWINGS">FIG. 2A</figref> is a perspective view of an example low-deflection roller tube, with the roller tube in an unloaded position.

<figref idref="DRAWINGS">FIG. 2B</figref> is a perspective view of the example low-deflection roller tube depicted in <figref idref="DRAWINGS">FIG. 2A</figref>, depicting deflection of the roller tube when simply supported and with a covering material attached thereto.

<figref idref="DRAWINGS">FIG. 3</figref> depicts an example process for manufacturing a low-deflection roller tube.

<figref idref="DRAWINGS">FIG. 4</figref> is an end view of another example low-deflection roller tube.

<figref idref="DRAWINGS">FIG. 5</figref> is an end view of still another example low-deflection roller tube.

<figref idref="DRAWINGS">FIG. 6</figref> depicts another example process for manufacturing a low-deflection roller tube.

<figref idref="DRAWINGS">FIGS. 7A-7D</figref> depict the respective carbon fiber weave patterns of example layers of carbon fiber fabric that may be used in the example processes depicted in <figref idref="DRAWINGS">FIGS. 3 and 6</figref>.

<figref idref="DRAWINGS">FIG. 8</figref> is a graph depicting total deflection versus length for roller tubes of various materials.

<figref idref="DRAWINGS">FIG. 9</figref> is a graph depicting components of deflection at 12 foot tube length for roller tubes of various materials.

<figref idref="DRAWINGS">FIG. 10</figref> is a graph depicting components of deflection as percentage of total deflection for roller tubes of various materials.

DETAILED DESCRIPTION

<figref idref="DRAWINGS">FIGS. 1A-1C</figref> depict an example window treatment, in the form of a motorized roller shade <b>100</b>, that may be mounted in front of a large opening, such as one or more windows that span 8 feet or more in width, to prevent sunlight from entering a space and/or to provide privacy. The motorized roller shade <b>100</b> may be mounted to a structure that is proximate to the opening, such as a window frame, a wall, or other structure. As shown, the motorized roller shade <b>100</b> includes a shade assembly <b>110</b>, a battery compartment <b>130</b>, and a housing <b>140</b> that may be configured to support the shade assembly <b>110</b> and the battery compartment <b>130</b>. The housing <b>140</b> may be configured as a mounting structure and/or a support structure for one or more components of the motorized roller shade <b>100</b>.

As shown, the housing <b>140</b> includes a rail <b>142</b>, a first housing bracket <b>150</b>, and a second housing bracket <b>160</b>. The illustrated rail <b>142</b> is elongate between a first end <b>141</b> and an opposed second end <b>143</b>. The rail <b>142</b>, the first housing bracket <b>150</b>, and the second housing bracket <b>160</b> may be configured to attach to one another in an assembled configuration. For example, the first housing bracket <b>150</b> may be configured to be attached to the first end <b>141</b> of the rail <b>142</b>, and the second housing bracket <b>160</b> may be configured to be attached to the second end <b>143</b> of the rail <b>142</b>. As shown, the first housing bracket <b>150</b> defines an attachment member <b>152</b> that is configured to engage the first end <b>141</b> of the rail <b>142</b>, and the second housing bracket <b>160</b> defines an attachment member <b>162</b> that is configured to engage the second end <b>143</b> of the rail <b>142</b>. It should be appreciated that the rail <b>142</b>, the first housing bracket <b>150</b>, and the second housing bracket <b>160</b> are not limited to the illustrated attachment members.

One or more of the rail <b>142</b>, the first housing bracket <b>150</b>, or the second housing bracket <b>160</b>, may be sized for mounting to a structure. For example, the rail <b>142</b> may be sized such that, with the first and second housing brackets <b>150</b>, <b>160</b> attached to the rail <b>142</b>, the rail <b>142</b> may be mounted to a structure in an opening (e.g., to a window frame). In such an example configuration, the rail <b>142</b> may define a length, for example as defined by the first and second ends <b>141</b>, <b>143</b>, such that the housing <b>140</b> may fit snugly in a window frame (e.g., with little clearance between the first and second housing brackets <b>150</b>, <b>160</b> and adjacent structure of a window frame). This configuration may be referred to as an internal mount configuration. In another example, the rail <b>142</b> may be sized such that, with the first and second housing brackets <b>150</b>, <b>160</b> attached to the rail <b>142</b>, the rail <b>142</b> may be mounted to a structure above an opening (e.g., to a surface above a window). In such an example configuration, the rail <b>142</b> may define a length that is substantially equal to (e.g., slightly longer than) a width of the window opening. In still another example, one or more of the rail <b>142</b>, the first housing bracket <b>150</b>, or the second housing bracket <b>160</b> may be sized such that the motorized roller shade <b>100</b> may be mounted within a cavity defined by a window treatment pocket that may be mounted to a structure, such as structure surrounding a window. It should be appreciated, however, that the motorized roller shade <b>100</b> is not limited to these example mounting configurations.

The rail <b>142</b> may define any suitable shape. As shown, the rail <b>142</b> includes a rear wall <b>144</b> and an upper wall <b>146</b> that extends outward from an upper edge of the rear wall <b>144</b> along a direction that is substantially perpendicular to the rear wall <b>144</b>. One or both of the rear wall <b>144</b> and the upper wall <b>146</b> may be configured to be mounted to a structure. The rail <b>142</b>, the first housing bracket <b>150</b>, and the second housing bracket <b>160</b>, when in an assembled configuration, may define a cavity. The shade assembly <b>110</b> and the battery compartment <b>130</b> may be disposed in the cavity, for example when the motorized roller shade <b>100</b> is in an assembled configuration (e.g., as shown in <figref idref="DRAWINGS">FIGS. 1B and 1C</figref>). When the motorized roller shade <b>100</b> is in an assembled configuration, the housing <b>140</b> may be open at the front and bottom, such that the shade assembly <b>110</b> and the battery compartment <b>130</b> are exposed. The motorized roller shade <b>100</b> may optionally include a fascia (not shown) that is configured to conceal one or more components of the motorized roller shade <b>100</b>, such as the battery compartment <b>130</b> and portions of the shade assembly <b>110</b>.

As shown, the shade assembly <b>110</b> includes a roller tube <b>112</b>, a motor drive unit <b>118</b>, an idler <b>120</b>, a covering material <b>122</b> (e.g., a shade fabric), and a hembar <b>126</b>. The roller tube <b>112</b> may have a tube body <b>114</b> that is elongate along a longitudinal direction L from a first end <b>113</b> to an opposed second end <b>115</b>. The tube body <b>114</b> may define any shape, such as the illustrated cylindrical shape. As shown, the roller tube <b>112</b> is hollow, and open at the first and second ends <b>113</b>, <b>115</b>. The roller tube <b>112</b> may be configured to at least partially receive the motor drive unit <b>118</b>, and to at least partially receive the idler <b>120</b>. As shown, the roller tube <b>112</b> is configured such that a portion of the motor drive unit <b>118</b> may be disposed in the first end <b>113</b>, and such that a portion of the idler <b>120</b> may be disposed in the second end <b>115</b>.

The tube body <b>114</b> may define an inner surface <b>116</b> that is configured to operatively engage with the motor drive unit <b>118</b>. For example, as shown, the tube body <b>114</b> defines a plurality of splines <b>117</b> that extend radially inward from the inner surface <b>116</b>. The roller tube <b>112</b> may be configured to operatively engage with the motor drive unit <b>118</b> via the plurality of splines <b>117</b>. For example, the splines <b>117</b> may be configured to operatively engage with a component of the motor drive unit <b>118</b>, such that rotational torque may be transferred to the roller tube <b>112</b> from the motor drive unit <b>118</b>, thereby causing the roller tube <b>112</b> to rotate about an axis of rotation AR. The axis of rotation AR of the roller tube <b>112</b> may also be referred to as a central axis of the roller tube <b>112</b>.

The splines <b>117</b> may extend parallel to the longitudinal direction L, and may be spaced apart from each other equally, as shown, or unequally along a circumference of the inner surface <b>116</b> of the roller tube <b>112</b>. Each of the illustrated splines <b>117</b> extends from the first end <b>113</b> to the second end <b>115</b> of the tube body <b>114</b>. It should be appreciated that the roller tube <b>112</b> is not limited to illustrated configuration and/or geometry of splines <b>117</b>. It should further be appreciated that the roller tube <b>112</b> may be alternatively configured to operably engage with the motor drive unit <b>118</b>. For example, in accordance with an alternative configuration of the roller tube <b>112</b>, the tube body <b>114</b> may define a smooth inner surface <b>116</b>, and may define an opening that extends through the tube body <b>114</b> at a location such that the roller tube <b>112</b> may be operatively coupled to the motor drive unit <b>118</b> via one or more fasteners that may be disposed into the opening and that may engage the motor drive unit <b>118</b> (e.g., such as screws, pins, clips, or the like).

The illustrated motor drive unit <b>118</b> may be configured to be disposed into the first end <b>113</b> of the roller tube <b>112</b>. One or more components of the motor drive unit <b>118</b> may be configured to engage with the plurality of splines <b>117</b> of the roller tube <b>112</b>. As shown, the motor drive unit includes a drive hub <b>119</b> that defines a plurality of grooves that are configured to operably engage with corresponding ones of the splines <b>117</b>, such that operation of the motor drive unit <b>118</b> may cause the roller tube <b>112</b> to rotate. The motor drive unit <b>118</b> may further include an integrated idler <b>121</b> that defines a plurality of grooves that are configured to engage with corresponding ones of the splines <b>117</b>. The idler <b>120</b> may similarly define a plurality of grooves that are configured to engage with corresponding ones of the splines <b>117</b>. The grooves of the drive hub <b>119</b> and the idler <b>120</b> may be spaced apart from each other equally, as shown, or unequally along the circumferences of respective outer surfaces of the drive hub <b>119</b> and the idler <b>120</b>.

The covering material <b>122</b> may define an upper end (not shown) that is configured to be operably attached to the roller tube <b>112</b>, and an opposed lower end <b>124</b> that is configured as a free end. Rotation of the roller tube <b>112</b> about the axis of rotation AR, for example rotation caused by the motor drive unit <b>118</b>, may cause the covering material <b>122</b> to wind onto, or to unwind from, the roller tube <b>112</b>. In this regard, the motor drive unit <b>118</b> may adjust the covering material <b>122</b>, for instance between raised and lowered positions of the covering material <b>122</b> as shown in <figref idref="DRAWINGS">FIGS. 1B and 1C</figref>, respectively.

Rotation of the roller tube <b>112</b> in a first direction about the axis of rotation AR may cause the covering material <b>122</b> to unwind from the roller tube <b>112</b>, for example as the covering material <b>122</b> is operated to a lowered position relative to an opening (e.g., a window). <figref idref="DRAWINGS">FIG. 1C</figref> depicts the motorized roller shade <b>100</b> with the covering material <b>122</b> in a lowered position. Rotation of the roller tube <b>112</b> in a second direction, about the axis or rotation AR, that is opposite the first direction may cause the covering material <b>122</b> to wind onto the roller tube <b>112</b>, for example as the covering material <b>122</b> is operated to a raised position relative to the opening. <figref idref="DRAWINGS">FIG. 1B</figref> depicts the motorized roller shade <b>100</b>, with the covering material <b>122</b> in a raised position.

The covering material <b>122</b> may be made of any suitable material, or combination of materials. For example, the covering material <b>122</b> may be made from one or more of “scrim,” woven cloth, non-woven material, light-control film, screen, or mesh. The hembar <b>126</b> may be attached to the lower end <b>124</b> of the covering material <b>122</b>, and may be weighted, such that the hembar <b>126</b> causes the covering material <b>122</b> to hang (e.g., vertically) in front of one or more windows.

The motor drive unit <b>118</b> may be configured to enable control of the rotation of the roller tube <b>112</b>, for example by a user of the motorized roller shade <b>100</b>. For example, a user of the motorized roller shade <b>100</b> may control the motor drive unit <b>118</b> such that the covering material <b>122</b> is moved to a desired position. The motor drive unit <b>118</b> may include a sensor that monitors a position of the roller tube <b>112</b>. This may enable the motor drive unit <b>118</b> to track a position of the covering material <b>122</b> relative to respective upper and lower limits of the covering material <b>122</b>. The upper and lower limits may be specified by an operator of the motorized roller shade <b>100</b>, and may correspond to the raised and lowered positions of the covering material <b>122</b>, respectively.

The motor drive unit <b>118</b> may be manually controlled (e.g., by actuating one or more buttons) and/or wirelessly controlled (e.g., using an infrared (IR) or radio frequency (RF) remote control unit). Examples of motor drive units for motorized roller shades are described in greater detail in U.S. Pat. No. 6,983,783, issued Jan. 10, 2006, entitled “Motorized Shade Control System,” U.S. Pat. No. 7,839,109, issued Nov. 23, 2010, entitled “Method Of Controlling A Motorized Window Treatment,” U.S. Pat. No. 8,950,461, issued Jan. 21, 2015, entitled “Motorized Window Treatment,” and U.S. Patent Application Publication No. 2013/0153162, published Jun. 20, 2013, entitled “Battery-Powered Motorized Window Treatment Having A Service Position,” the entire contents of each of which are incorporated herein by reference. It should be appreciated, however, that any motor drive unit or drive system may be used to control the roller tube <b>112</b>.

The motorized roller shade <b>100</b> may include an antenna (not shown) that is configured to receive wireless signals (e.g., RF signals from a remote control device). The antenna may be in electrical communication with the motor drive unit <b>118</b> (e.g., via a control circuit or PCB), such that one or more wireless signals received from a remote control unit may cause the motor drive unit <b>118</b> to move the covering material <b>122</b> (e.g., between the lowered and raised positions). The antenna may be integrated with (e.g., pass through, be enclosed within, and/or be mounted to) one or more of the shade assembly <b>110</b>, the battery compartment <b>130</b>, the housing <b>140</b>, or respective components thereof.

The battery compartment <b>130</b> may be configured to retain one or more batteries <b>132</b>. The illustrated battery <b>132</b> may be, for example, a D cell (e.g., IEC R20) battery. One or more components of the motorized roller shade <b>100</b>, such as the motor drive unit <b>118</b>, may be powered by the one or more batteries <b>132</b>. However, it should be appreciated that the motorized roller shade <b>100</b> is not limited to the illustrated battery-powered configuration. For example, the motorized roller shade <b>100</b> may be alternatively configured such that one or more components thereof, such as the motor drive unit <b>118</b>, may be powered by an alternating current (AC) source, a direct current (DC) source, or any combination of power sources.

The battery compartment <b>130</b> may be configured to be operable between an opened position and a closed position, such that one or more batteries <b>132</b> may be accessible when the battery compartment <b>130</b> is in the opened position. Examples of battery compartments for motorized roller shades are described in greater detail in U.S. Patent Application Publication No. 2014/0305602, published Oct. 16, 2014, entitled “Integrated Accessible Battery Compartment For Motorized Window Treatment,” the entire contents of which is incorporated herein by reference.

The housing <b>140</b> may be configured to support one or both of the shade assembly <b>110</b> and the battery compartment <b>130</b>. For example, the first and second housing brackets <b>150</b>, <b>160</b> may be configured to support the shade assembly <b>110</b> and/or the battery compartment <b>130</b>. As shown, the first and second housing brackets <b>150</b>, <b>160</b> are configured to support the shade assembly <b>110</b> and the battery compartment <b>130</b> such that the battery compartment <b>130</b> is located (e.g., is oriented) above the shade assembly <b>110</b> when the motorized roller shade <b>100</b> is mounted to a structure. It should be appreciated that the motorized roller shade <b>100</b> is not limited to the illustrated orientation of the shade assembly <b>110</b> and the battery compartment <b>130</b>. For example, the housing <b>140</b> may be alternatively configured to otherwise support the shade assembly <b>110</b> and the battery compartment <b>130</b> relative to each other (e.g., such that the battery compartment <b>130</b> is located below the shade assembly <b>110</b>).

As shown, the first housing bracket <b>150</b> defines an upper portion <b>151</b> and a lower portion <b>153</b>, and the second housing bracket <b>160</b> defines an upper portion <b>161</b> and a lower portion <b>163</b>. The upper portion <b>151</b> of the first housing bracket <b>150</b> may be configured to support a first end of the battery compartment <b>130</b>, and the upper portion <b>161</b> of the second housing bracket <b>160</b> may be configured to support a second end of the battery compartment <b>130</b>. The upper portions <b>151</b>, <b>161</b> of the first and second housing brackets <b>150</b>, <b>160</b>, respectively, may be configured to operably support the support the battery compartment <b>130</b>, such that the battery compartment <b>130</b> is operable to provide access to one or more batteries <b>132</b> when the motorized roller shade <b>100</b> is mounted to a structure.

The lower portion <b>153</b> of the first housing bracket <b>150</b> may be configured to support the idler <b>121</b>, and thus the first end <b>113</b> of the tube body <b>114</b> of the roller tube <b>112</b>. The lower portion <b>163</b> of the second housing bracket <b>160</b> may be configured to support the idler <b>120</b>, and thus the second end <b>115</b> of the tube body <b>114</b> of the roller tube <b>112</b>. The lower portions <b>153</b>, <b>163</b> of the first and second housing brackets <b>150</b>, <b>160</b>, respectively, may be configured to operably support the support the shade assembly <b>110</b>, such that the covering material <b>122</b> may be moved (e.g., between the lowered and raised positions). Because the roller tube <b>112</b> is supported at the first and second ends <b>113</b>, <b>115</b> of the tube body <b>114</b>, it may be stated that the shade assembly <b>110</b>, and thus the roller tube <b>112</b>, is simply supported by the housing <b>140</b>.

The housing <b>140</b> may be configured to be mounted to a structure using one or more fasteners (e.g., one or more screws). For example, one or more of the rail <b>142</b>, the first housing bracket <b>150</b>, or the second housing bracket <b>160</b> may define one or more respective apertures that are configured to receive fasteners.

The components of the housing <b>140</b> may be made of any suitable material or combination of materials. For example, the rail <b>142</b> may be made of metal and the first and second housing brackets <b>150</b>, <b>160</b> may be made of plastic. Although the illustrated housing <b>140</b> includes separate components, it should be appreciated that the housing <b>140</b> may be otherwise constructed. For example, the rail <b>142</b>, the first housing bracket <b>150</b>, and the second housing bracket <b>160</b> may be monolithic. In another example, the rail may include first and second rail sections that may be configured to attach to one another. In such an example configuration, the first rail section may include an integrated first housing bracket and the second rail section may include an integrated second housing bracket. One or more components of the housing <b>140</b> (e.g., one or more of the rail <b>142</b>, the first housing bracket <b>150</b>, or the second housing bracket <b>160</b>) may be wrapped in a material (e.g., fabric), for instance to enhance the aesthetics of the housing <b>140</b>.

The motorized roller shade <b>100</b> may be configured for use in covering an atypically large opening, such as a window, or cluster of windows, having a width greater than 8 feet, and up to about 15 feet wide, such as about 12 feet wide. In such an application, the roller tube <b>112</b> may be susceptible to an amount of tube sag that may negatively impact the aesthetic of the covering material <b>122</b> and/or the functionality of the motorized roller shade, such as raising or lowering the covering material <b>122</b>. One or more components of the motorized roller shade <b>100</b> may be configured to mitigate the occurrence of tube sag. For example, the roller tube <b>112</b> may be configured as a low-deflection roller tube.

<figref idref="DRAWINGS">FIGS. 2A and 2B</figref> depict an example low-deflection roller tube <b>112</b>. The roller tube <b>112</b> may be used in covering a wide opening (e.g., an opening that is 8 feet wide or wider). As shown, the tube body <b>114</b> of the roller tube <b>112</b> may define a length L<b>1</b> along the longitudinal direction L, for example defined by the first and second ends <b>113</b>, <b>115</b> of the roller tube <b>112</b>. The roller tube <b>112</b> may be configured such that an outer diameter OD of the tube body <b>114</b> does not exceed 2 inches, for example to maintain an aesthetic of the motorized roller shade <b>100</b>, and/or to ensure that when the covering material <b>122</b> is fully wound onto the roller tube <b>112</b>, the roller tube <b>112</b> and covering material <b>122</b> do not exceed a desired volume (e.g., the volume within a pocket in which the motorized roller shade <b>100</b> is installed). The tube body <b>114</b> may define an outer diameter OD of about 1.67 inches to about 2 inches, such as 2 exactly inches, and an inner diameter ID of about 1.53 inches to about 1.75 inches, such as exactly 1.75 inches.

<figref idref="DRAWINGS">FIG. 2A</figref> depicts the roller tube <b>112</b> in an unloaded position, for instance with the covering material <b>122</b> detached and the roller tube <b>112</b> separated from the housing <b>140</b>. This position may be referred to a non-deflected, relaxed state of the roller tube <b>112</b>. When the roller tube <b>112</b> is operably attached to the housing <b>140</b> (e.g., such that the first end <b>113</b> of the tube body <b>114</b> is supported by the lower portion <b>153</b> of the first housing bracket <b>150</b> and the second end <b>115</b> of the tube body <b>114</b> is supported by the lower portion <b>163</b> of the second housing bracket <b>160</b>) and the covering material <b>122</b> is attached to the roller tube <b>112</b>, one or more portions of the roller tube <b>112</b> may deflect downward, such that the roller tube <b>112</b> may exhibit tube sag, for example as shown in <figref idref="DRAWINGS">FIG. 2B</figref>. It should be appreciated that the deflection of the roller tube <b>112</b>, as shown in <figref idref="DRAWINGS">FIG. 2B</figref>, is exaggerated for the purposes of illustration.

In accordance with a first example configuration of the roller tube <b>112</b>, the roller tube <b>112</b> may define a length L<b>1</b> of at least 10 feet, such as 10 feet. When the covering material <b>122</b> is attached to the roller tube <b>112</b> and the roller tube <b>112</b> is supported only at the first and second ends <b>113</b>, <b>115</b>, deflection δ of the tube body <b>114</b> does not exceed ⅛ of an inch at any location along the tube body <b>114</b>, relative to the unloaded position of the roller tube <b>112</b>.

In accordance with a second example configuration of the roller tube <b>112</b>, the roller tube <b>112</b> may define a length L<b>1</b> of at least 12 feet, such as 12 feet. When the covering material <b>122</b> is attached to the roller tube <b>112</b> and the roller tube <b>112</b> is supported only at the first and second ends <b>113</b>, <b>115</b>, deflection δ of the tube body <b>114</b> does not exceed ¼ of an inch at any location along the tube body <b>114</b>, relative to the unloaded position of the roller tube <b>112</b>.

In order to achieve the deflection characteristics of the example configurations of the roller tube <b>112</b>, the tube body <b>114</b> may be constructed of a material that has high strength and low density, such as carbon fiber. For example, the tube body <b>114</b> may be constructed from one or more layers of carbon fiber material, such as a plurality of layers of carbon fiber fabric that are applied in succession, for example filament wound onto a mandrel, such that the tube body <b>114</b> is built-up via the layers of carbon fiber fabric. One or more of the carbon fiber fabric layers of the tube body <b>114</b> may comprise high modulus carbon fiber, for example that exhibits a tensile modulus of 55 million pounds per square inch (MSI) or higher.

<figref idref="DRAWINGS">FIG. 3</figref> depicts an example process <b>300</b> for constructing an example low-deflection carbon fiber roller tube, such as the roller tube <b>112</b> depicted in <figref idref="DRAWINGS">FIGS. 2A and 2B</figref>, for example. In accordance with the example process <b>300</b>, one or more layers of carbon fiber material (e.g., carbon fiber fabric) may be applied to a mandrel, in order to additively construct the tube body <b>114</b> of the roller tube <b>112</b>. The mandrel may have a solid, cylindrical shaped mandrel body that extends along a central axis from a first end to an opposed second end. The central axis of the mandrel may extend parallel to the longitudinal direction L, and may be coincident with the axis or rotation AR of the roller tube <b>112</b>.

The mandrel body may define a plurality of grooves that extend into an outer peripheral surface of the mandrel body. The grooves may extend parallel to the central axis of the mandrel body, and may be spaced apart from each other equally or unequally along a circumference of the outer surface. The grooves may extend along substantially an entirety of a length of the mandrel. The mandrel may be tapered between the first and second ends, to facilitate removal of the finished roller tube <b>112</b> from the mandrel. For example, the mandrel may preferably be tapered at about 1/1000 of an inch per foot of length of the mandrel, from the first end to the second end.

At <b>302</b>, a first layer of carbon fiber fabric may be applied to the mandrel. The first layer of carbon fiber fabric may comprise, for example, low modulus carbon fiber (e.g., exhibiting a tensile modulus of about 34 MSI), intermediate modulus carbon fiber (e.g., exhibiting a tensile modulus of about 42 MSI), or the like. During application to the mandrel, the first layer of carbon fiber fabric may be oriented such that fibers of the first layer of carbon fiber fabric are parallel to the central axis of the mandrel (e.g., as shown in <figref idref="DRAWINGS">FIG. 7A</figref>). Stated differently, the first layer of carbon fiber fabric may be oriented such that fibers of the first layer of carbon fiber fabric are not angularly offset relative to the central axis of the mandrel. The first layer of carbon fiber fabric may be applied to the mandrel such that carbon fiber fabric is disposed into (e.g., pressed into) each of the grooves of the mandrel body. The carbon fiber fabric disposed in the grooves of the mandrel body may form the splines <b>117</b> of the tube body <b>114</b> of the roller tube <b>112</b>.

One or more additional layers of carbon fiber fabric may be applied to the first layer of carbon fiber fabric, so as to additively construct the tube body <b>114</b> of the roller tube <b>112</b>. For example, at <b>304</b>, a second layer of carbon fiber fabric may be applied to the first layer of carbon fiber fabric (e.g., on top of the first layer of carbon fiber fabric). The second layer of carbon fiber fabric may comprise, for example, low modulus carbon fiber, intermediate modulus carbon fiber, or the like. The second layer of carbon fiber fabric may be oriented such that fibers of the second layer of carbon fiber fabric are angularly offset by a shallow angle, for example by approximately 5° to 10°, such as by about 7°, relative to the central axis of the mandrel (e.g., as shown in <figref idref="DRAWINGS">FIG. 7B</figref>). The second layer of carbon fiber fabric may enhance one or more stiffness characteristics of the roller tube <b>112</b>.

At <b>306</b>, a third layer of carbon fiber fabric may be applied to the second layer of carbon fiber fabric (e.g., on top of the second layer of carbon fiber fabric). The third layer of carbon fiber fabric may comprise, for example, low modulus carbon fiber, intermediate modulus carbon fiber, or the like. The third layer of carbon fiber fabric may be oriented such that fibers of the third layer of carbon fiber fabric are angularly offset by approximately 30° to 45°, such as by about 45°, relative to the central axis of the mandrel (e.g., as shown in <figref idref="DRAWINGS">FIG. 7C</figref>). The third layer of carbon fiber fabric may serve as a transition layer, for example between the second layer of carbon fiber fabric and a fourth layer of carbon fiber fabric.

At <b>308</b>, a fourth layer of carbon fiber fabric may be applied to the third layer of carbon fiber fabric (e.g., on top of the third layer of carbon fiber fabric). The fourth layer of carbon fiber fabric may comprise, for example, low modulus carbon fiber, intermediate modulus carbon fiber, or the like. The fourth layer of carbon fiber fabric may be oriented such that fibers of the fourth layer of carbon fiber fabric are angularly offset by about 60° to 90°, such as by about 90°, relative to the central axis of the mandrel. Stated differently, the fourth layer of carbon fiber fabric may be oriented such that fibers of the fourth layer of carbon fiber fabric are perpendicular to the central axis of the mandrel (e.g., as shown in <figref idref="DRAWINGS">FIG. 7D</figref>). The fourth layer of carbon fiber fabric may enhance cracking resistance of the roller tube <b>112</b>.

At <b>310</b>, a fifth layer of carbon fiber fabric may be applied to the fourth layer of carbon fiber fabric (e.g., on top of the fourth layer of carbon fiber fabric). The fifth layer of carbon fiber fabric may comprise, for example, low modulus carbon fiber, intermediate modulus carbon fiber, or the like. The fifth layer of carbon fiber fabric may be oriented such that fibers of the fifth layer of carbon fiber fabric are angularly offset by approximately 30° to 45°, such as by about 45°, relative to the central axis of the mandrel (e.g., as shown in <figref idref="DRAWINGS">FIG. 7C</figref>). The fifth layer of carbon fiber fabric may be further oriented such that fibers of the fifth layer of carbon fiber fabric are aligned with fibers of the third layer of carbon fiber fabric, for example such that the fibers of the fifth layer of carbon fiber fabric are symmetric with the fibers of the third layer of carbon fiber fabric. The fifth layer of carbon fiber fabric may serve as a transition layer, for example between the fourth layer of carbon fiber fabric and a sixth layer of carbon fiber fabric.

At <b>312</b>, a sixth layer of carbon fiber fabric may be applied to the fifth layer of carbon fiber fabric (e.g., on top of the fifth layer of carbon fiber fabric). The sixth layer of carbon fiber fabric may comprise, for example, low modulus carbon fiber, intermediate modulus carbon fiber, or the like. The sixth layer of carbon fiber fabric may be oriented such that fibers of the sixth layer of carbon fiber fabric are angularly offset by approximately 5° to 10°, such as by about 7°, relative to the central axis of the mandrel (e.g., as shown in <figref idref="DRAWINGS">FIG. 7B</figref>). The sixth layer of carbon fiber fabric may be further oriented such that fibers of the sixth layer of carbon fiber fabric are aligned with fibers of the second layer of carbon fiber fabric, for example such that the fibers of the sixth layer of carbon fiber fabric are symmetric with the fibers of the second layer of carbon fiber fabric. The sixth layer of carbon fiber fabric may comprise high modulus carbon fiber. Accordingly, at least one layer of carbon fiber fabric of the tube body <b>114</b>, such as the outermost layer of carbon fiber fabric, may comprise high modulus carbon fiber. The sixth layer of carbon fiber fabric may further enhance one or more stiffness characteristics of the roller tube <b>112</b>.

At <b>314</b>, the first, second, third, fourth, fifth, and sixth layers of carbon fiber fabric may be cured. Once the layers of carbon fiber fabric are cured, the mandrel may be removed from the roller tube <b>112</b>, for example by biasing the thicker first end of the mandrel out of the roller tube <b>112</b>. In accordance with the example process <b>300</b>, the first, third, fourth, and fifth layers of carbon fiber fabric may be of approximately the same thickness, and may be thinner than the second and sixth layers of carbon fiber fabric. The second and sixth layers of carbon fiber fabric may be of approximately the same thickness.

It should be appreciated that in accordance with the illustrated example process <b>300</b>, the first, second, third, fourth, and fifth layers of carbon fiber fabric may comprise low modulus carbon fiber, intermediate modulus carbon fiber, or the like, in any combination. It should further be appreciated that the sixth layer of carbon fiber fabric is not limited to high modulus carbon fiber. For example, the sixth layer of carbon fiber fabric may alternatively comprise low modulus carbon fiber, intermediate modulus carbon fiber, or the like.

It should further still be appreciated that manufacture of the roller tube <b>112</b> is not limited to the example process <b>300</b>. For example, the tube body <b>114</b> of the roller tube <b>112</b> may be alternatively constructed using more or fewer layers of carbon fiber fabric, having any suitable combination of modulus types, fiber orientations relative to each other and to the central axis of the mandrel, and thicknesses. It should further still be appreciated that the mandrel is not limited to grooves that will produce the illustrated splines <b>117</b> of the tube body <b>114</b>. For example, the mandrel may be alternatively configured to differently configure the inner surface <b>116</b> to operatively engage with the motor drive unit <b>118</b>. Alternatively still, the mandrel may be smooth, such that the tube body <b>114</b> of the resulting roller tube <b>112</b> may define a smooth inner surface <b>116</b>.

<figref idref="DRAWINGS">FIG. 4</figref> depicts an end view of another example low-deflection roller tube <b>400</b>. The roller tube <b>400</b> may be used in covering a wide opening (e.g., an opening that is 8 feet wide or wider). The roller tube <b>400</b> may be implemented, for example, in the motorized roller shade <b>100</b> (e.g., in the place of the roller tube <b>112</b>). As shown, the roller tube <b>400</b> may be a two-part roller tube that includes a first tube <b>402</b> and a second tube <b>406</b>. The first tube <b>402</b> may be referred to as an inner tube of the roller tube <b>400</b>, and the second tube <b>406</b> may be referred to as an outer tube of the roller tube <b>400</b>. The first and second tubes <b>402</b>, <b>406</b> may be elongate between respective opposed first and second ends that are spaced apart from each other along the longitudinal direction L. The first and second tubes <b>402</b>, <b>406</b> may be of the same or different lengths (e.g., as defined by the respective first and second ends). The first tube <b>402</b> may be made of any suitable material, such as aluminum, steel, or the like.

The first tube <b>402</b> may define an inner surface <b>401</b> and an opposed outer surface <b>403</b> that is radially spaced from the inner surface <b>401</b>. The inner surface <b>401</b> of the first tube <b>402</b> may be configured to operatively engage with a motor drive unit, such as the motor drive unit <b>118</b> of the motorized roller shade <b>100</b>. For example, as shown, the first tube <b>402</b> defines a plurality of splines <b>404</b> that extend radially inward from the inner surface <b>401</b>. The roller tube <b>400</b> may be configured to operatively engage with the motor drive unit <b>118</b> via the plurality of splines <b>404</b>. For example, the splines <b>404</b> may be configured to operatively engage with respective grooves of the drive hub <b>119</b> and the idler <b>121</b>.

The splines <b>404</b> may extend parallel to the longitudinal direction L, and may be spaced apart from each other equally, as shown, or unequally along a circumference of the inner surface <b>401</b> of the first tube <b>402</b>. Each of the illustrated splines <b>404</b> may extend from the first end to the second end of the first tube <b>402</b>. It should be appreciated that the first tube <b>402</b> is not limited to illustrated configuration and/or geometry of splines <b>404</b>. It should further be appreciated that the first tube <b>402</b> may be alternatively configured to operably engage with the motor drive unit <b>118</b>.

The second tube <b>406</b> may be made of a different material than the first tube <b>402</b>. In this regard, the roller tube <b>400</b> may be referred to as a hybrid roller tube. As shown, the second tube <b>406</b> may be made of a carbon fiber material. The second tube <b>406</b> may define an inner surface <b>405</b> and an opposed outer surface <b>407</b> that is radially spaced from the inner surface <b>405</b>. The second tube <b>406</b> may be attached to the first tube <b>402</b>. For example, the second tube <b>406</b> may be constructed from one or more layers of carbon fiber material, such as a plurality of layers of carbon fiber fabric that are applied in succession, for example filament wound, onto the outer surface <b>403</b> of the first tube <b>402</b> such that the second tube <b>406</b> is built-up via the layers of carbon fiber fabric. For example, the second tube <b>406</b> may be constructed in accordance with the example process <b>600</b> depicted in <figref idref="DRAWINGS">FIG. 6</figref>. One or more of the carbon fiber fabric layers of the second tube <b>406</b> may comprise high modulus carbon fiber, for example that exhibits a tensile modulus of 55 million pounds per square inch (MSI) or higher. In accordance with an example construction in which the second tube <b>406</b> is filament wound onto the first tube <b>402</b>, the inner surface <b>405</b> of the second tube <b>406</b> may be attached to the outer surface <b>403</b> of the first tube <b>402</b>, for example during a curing process of the carbon fiber material.

One or both of the first and second tubes <b>402</b>, <b>406</b> may be configured such that an outer diameter OD of the second tube <b>406</b>, and thus of the roller tube <b>400</b>, does not exceed 2 inches, for example to maintain an aesthetic of the motorized roller shade <b>100</b>, and/or to ensure that when the covering material <b>122</b> is fully wound onto the roller tube <b>400</b>, the roller tube <b>400</b> and covering material <b>122</b> do not exceed a desired volume (e.g., the volume within a pocket in which the motorized roller shade <b>100</b> is installed). The second tube <b>406</b> may define an outer diameter OD of about 1.67 inches to 2 inches, such as 2 inches for example.

<figref idref="DRAWINGS">FIG. 5</figref> depicts an end view of still another example low-deflection roller tube <b>500</b>. The roller tube <b>500</b> may be used in covering a wide opening (e.g., an opening that is 8 feet wide or wider). The roller tube <b>500</b> may be implemented, for example, in the motorized roller shade <b>100</b> (e.g., in the place of the roller tube <b>112</b>). As shown, the roller tube <b>500</b> may be a two-part roller tube that includes a first tube <b>502</b> and a second tube <b>510</b>. The first tube <b>502</b> may be referred to as an inner tube of the roller tube <b>500</b>, and the second tube <b>510</b> may be referred to as an outer tube of the roller tube <b>500</b>. The first and second tubes <b>502</b>, <b>510</b> may be elongate between respective opposed first and second ends that are spaced apart from each other along the longitudinal direction L. The first and second tubes <b>502</b>, <b>510</b> may be of the same or different lengths (e.g., as defined by the respective first and second ends). The first tube <b>502</b> may be made of any suitable material, such as aluminum, steel, or the like.

The first tube <b>502</b> may define an inner surface <b>501</b> and an opposed outer surface <b>503</b> that is radially spaced from the inner surface <b>501</b>. The first tube <b>502</b> may be configured to operatively engage with a motor drive unit, such as the motor drive unit <b>118</b> of the motorized roller shade <b>100</b>. For example, the first tube <b>502</b> may define one or more engagement members that extend from the inner surface <b>501</b>. As shown, the first tube <b>502</b> may define a plurality of engagement arms <b>504</b> that extend radially inward from the inner surface <b>501</b>, and that extend between the first and second ends of the first tube <b>502</b>, for example from the first end to the second end. Each engagement arm <b>504</b> may include an engagement pad <b>506</b> that defines one or more splines <b>507</b>. The engagement pads <b>506</b> may be spaced from the inner surface <b>501</b>, such that the second tube <b>510</b> is located in a favorable location to maximize a moment of inertia of the second tube <b>510</b>. As shown, each engagement pad <b>506</b> defines a pair of splines <b>508</b>. The roller tube <b>500</b> may be configured to operatively engage with the motor drive unit <b>118</b> via the plurality of splines <b>508</b>. For example, the splines <b>508</b> may be configured to operatively engage with respective grooves of the drive hub <b>119</b> and the idler <b>121</b>.

The splines <b>508</b> may extend parallel to the longitudinal direction L. The engagement arms <b>504</b> may be spaced apart from each other equally, as shown, or unequally along a circumference of the inner surface <b>501</b> of the first tube <b>502</b>. Each of the illustrated splines <b>508</b> may extend from the first end to the second end of the first tube <b>502</b>. It should be appreciated that the first tube <b>502</b> is not limited to illustrated configuration and/or geometry of engagement members (e.g., engagement arms <b>504</b>) and/or splines <b>508</b>. It should further be appreciated that the first tube <b>502</b> may be alternatively configured to operably engage with the motor drive unit <b>118</b>.

The second tube <b>510</b> may be made of a different material than the first tube <b>502</b>. In this regard, the roller tube <b>500</b> may be referred to as a hybrid roller tube. As shown, the second tube <b>510</b> may be made of a carbon fiber material. The second tube <b>510</b> may define an inner surface <b>509</b> and an opposed outer surface <b>511</b> that is radially spaced from the inner surface <b>509</b>. The second tube <b>510</b> may be attached to the first tube <b>502</b>. For example, the second tube <b>510</b> may be constructed from one or more layers of carbon fiber material, such as a plurality of layers of carbon fiber fabric that are applied in succession, for example filament wound, onto the outer surface <b>503</b> of the first tube <b>502</b> such that the second tube <b>510</b> is built-up via the layers of carbon fiber fabric. For example, the second tube <b>510</b> may be constructed in accordance with the example process <b>600</b> depicted in <figref idref="DRAWINGS">FIG. 6</figref>. One or more of the carbon fiber fabric layers of the second tube <b>510</b> may comprise high modulus carbon fiber, for example that exhibits a tensile modulus of 55 million pounds per square inch (MSI) or higher. In accordance with an example construction in which the second tube <b>510</b> is filament wound onto the first tube <b>502</b>, the inner surface <b>509</b> of the second tube <b>510</b> may be attached to the outer surface <b>503</b> of the first tube <b>502</b>, for example during a curing process of the carbon fiber material.

One or both of the first and second tubes <b>502</b>, <b>510</b> may be configured such that an outer diameter OD of the second tube <b>510</b>, and thus of the roller tube <b>500</b>, does not exceed 2 inches, for example to maintain an aesthetic of the motorized roller shade <b>100</b>, and/or to ensure that when the covering material <b>122</b> is fully wound onto the roller tube <b>500</b>, the roller tube <b>500</b> and covering material <b>122</b> do not exceed a desired volume (e.g., the volume within a pocket in which the motorized roller shade <b>100</b> is installed). The second tube <b>510</b> may define an outer diameter OD of about 1.67 inches to 2 inches, such as 2 inches for example.

Constructing a roller tube as a hybrid roller tube, such as the roller tube <b>400</b> or the roller tube <b>500</b> that may include respective first tubes that are made of aluminum and second tubes that are made of carbon fiber, may reduce manufacturing and/or material costs in comparison to the construction of a roller tube made of carbon fiber, such as the roller tube <b>112</b>. For example, the roller tubes <b>400</b> and <b>500</b> may be made of less carbon fiber material than the roller tube <b>112</b>, for instance by using fewer and/or thinner layers of carbon fiber material. Additionally, the manufacturing process of the roller tubes <b>400</b> and <b>500</b> may be simpler than that of the roller tube <b>112</b>, for instance because the step of removing a mandrel from the finished roller tube is omitted. Moreover, additively constructing the carbon fiber portion of a roller tube on the outer surface of first tube that is not made of carbon fiber may allow the enhanced stiffness and other advantageous properties contributed by the carbon fiber material to be located where a maximum benefit will be derived therefrom (e.g., proximate the outer surface of the roller tube).

<figref idref="DRAWINGS">FIG. 6</figref> depicts another example process <b>600</b> for constructing an example low-deflection carbon fiber roller tube, such as the roller tubes <b>400</b> and <b>500</b> depicted in <figref idref="DRAWINGS">FIGS. 4 and 5</figref>, respectively. In accordance with the example process <b>600</b>, one or more layers of carbon fiber material (e.g., carbon fiber fabric) may be applied to a first tube (e.g., the first tube <b>402</b> or the first tube <b>502</b>) in order to additively construct a second tube (e.g., the second tube <b>406</b> or the second tube <b>510</b>) on the first tube. The first tube may define a hollow cylindrical body that extends along a central axis from a first end to an opposed second end. The central axis of the first tube may extend parallel to the longitudinal direction L, and may be coincident with the axis or rotation AR. The first tube may be made of any suitable material, such as aluminum or the like. The first tube may define a substantially smooth outer surface.

At <b>602</b>, a first layer of carbon fiber fabric may be applied to the first tube. The first layer of carbon fiber fabric may comprise, for example, low modulus carbon fiber (e.g., exhibiting a tensile modulus of about 34 MSI), intermediate modulus carbon fiber (e.g., exhibiting a tensile modulus of about 42 MSI), or the like. During application to the first tube, the first layer of carbon fiber fabric may be oriented such that fibers of the first layer of carbon fiber fabric are angularly offset by about 60° to 90°, such as by about 90°, relative to the central axis of the first tube. Stated differently, the first layer of carbon fiber fabric may be oriented such that fibers of the first layer of carbon fiber fabric are perpendicular to the central axis of the first tube (e.g., as shown in <figref idref="DRAWINGS">FIG. 7D</figref>).

One or more additional layers of carbon fiber fabric may be applied to the first layer of carbon fiber fabric, so as to additively construct the second tube. For example, at <b>604</b>, a second layer of carbon fiber fabric may be applied to the first layer of carbon fiber fabric (e.g., on top of the first layer of carbon fiber fabric). The second layer of carbon fiber fabric may comprise, for example, low modulus carbon fiber, intermediate modulus carbon fiber, or the like. The second layer of carbon fiber fabric may be oriented such that fibers of the second layer of carbon fiber fabric are angularly offset by a shallow angle, for example by approximately 5° to 10°, such as by about 7°, relative to the central axis of the first tube (e.g., as shown in <figref idref="DRAWINGS">FIG. 7B</figref>). The second layer of carbon fiber fabric may enhance one or more stiffness characteristics of the roller tube.

At <b>606</b>, a third layer of carbon fiber fabric may be applied to the second layer of carbon fiber fabric (e.g., on top of the second layer of carbon fiber fabric). The third layer of carbon fiber fabric may comprise, for example, low modulus carbon fiber, intermediate modulus carbon fiber, or the like. The third layer of carbon fiber fabric may be oriented such that fibers of the third layer of carbon fiber fabric are angularly offset by a shallow angle, for example by approximately 5° to 10°, such as by about 7°, relative to the central axis of the first tube (e.g., as shown in <figref idref="DRAWINGS">FIG. 7B</figref>). The third layer of carbon fiber fabric may enhance one or more stiffness characteristics of the roller tube.

At <b>608</b>, a fourth layer of carbon fiber fabric may be applied to the third layer of carbon fiber fabric (e.g., on top of the third layer of carbon fiber fabric). The fourth layer of carbon fiber fabric may comprise, for example, low modulus carbon fiber, intermediate modulus carbon fiber, or the like. The fourth layer of carbon fiber fabric may be oriented such that fibers of the fourth layer of carbon fiber fabric are angularly offset by about 60° to 90°, such as by about 90°, relative to the central axis of the first tube (e.g., as shown in <figref idref="DRAWINGS">FIG. 7D</figref>). The fourth layer of carbon fiber fabric may enhance cracking resistance of the roller tube.

At <b>610</b>, a fifth layer of carbon fiber fabric may be applied to the fourth layer of carbon fiber fabric (e.g., on top of the fourth layer of carbon fiber fabric). The fifth layer of carbon fiber fabric may comprise, for example, low modulus carbon fiber, intermediate modulus carbon fiber, or the like. The fifth layer of carbon fiber fabric may be oriented such that fibers of the fifth layer of carbon fiber fabric are angularly offset by a shallow angle, for example by approximately 5° to 10°, such as by about 7°, relative to the central axis of the first tube (e.g., as shown in <figref idref="DRAWINGS">FIG. 7B</figref>). The fifth layer of carbon fiber fabric may enhance one or more stiffness characteristics of the roller tube.

At <b>612</b>, a sixth layer of carbon fiber fabric may be applied to the fifth layer of carbon fiber fabric (e.g., on top of the fifth layer of carbon fiber fabric). The sixth layer of carbon fiber fabric may comprise, for example, low modulus carbon fiber, intermediate modulus carbon fiber, or the like. The sixth layer of carbon fiber fabric may be oriented such that fibers of the sixth layer of carbon fiber fabric are angularly offset by a shallow angle, for example by approximately 5° to 10°, such as by about 7°, relative to the central axis of the first tube (e.g., as shown in <figref idref="DRAWINGS">FIG. 7B</figref>). The sixth layer of carbon fiber fabric may enhance one or more stiffness characteristics of the roller tube.

At <b>614</b>, a seventh layer of carbon fiber fabric may be applied to the sixth layer of carbon fiber fabric (e.g., on top of the sixth layer of carbon fiber fabric). The seventh layer of carbon fiber fabric may be oriented such that fibers of the seventh layer of carbon fiber fabric are angularly offset by about 60° to 90°, such as by about 90°, relative to the central axis of the first tube (e.g., as shown in <figref idref="DRAWINGS">FIG. 7D</figref>). The seventh layer of carbon fiber fabric may comprise high modulus carbon fiber. Accordingly, at least one layer of carbon fiber fabric of the second tube, such as the outermost layer of carbon fiber fabric, may comprise high modulus carbon fiber. The seventh layer of carbon fiber fabric may further enhance one or more stiffness characteristics of the roller tube.

At <b>616</b>, the first, second, third, fourth, fifth, sixth, and seventh layers of carbon fiber fabric may be cured. During curing of the layers of carbon fiber fabric, the second tube may attach to (e.g., bond with) the outer surface of the first tube. The first, second, third, fourth, fifth, sixth, and seventh layers of carbon fiber fabric may be of approximately the same thickness or may have differing thicknesses.

It should be appreciated that in accordance with the illustrated example process <b>600</b>, the first, second, third, fourth, fifth, and sixth layers of carbon fiber fabric may comprise low modulus carbon fiber, intermediate modulus carbon fiber, or the like, in any combination. It should further be appreciated that the seventh layer of carbon fiber fabric is not limited to high modulus carbon fiber. For example, the seventh layer of carbon fiber fabric may alternatively comprise low modulus carbon fiber, intermediate modulus carbon fiber, or the like.

It should further still be appreciated that manufacture of the roller tube is not limited to the example process <b>600</b>. For example, the second tube of the roller tube may be alternatively constructed using more or fewer layers of carbon fiber fabric, having any suitable combination of modulus types, fiber orientations relative to each other and to the central axis of the first tube, and thicknesses.

<figref idref="DRAWINGS">FIG. 8</figref> is a graph depicting total deflection versus length for roller tubes of various materials. <figref idref="DRAWINGS">FIG. 9</figref> is a graph depicting components of deflection at 12 foot tube length for roller tubes of various materials. <figref idref="DRAWINGS">FIG. 10</figref> is a graph depicting components of deflection as percentage of total deflection for roller tubes of various materials.

It should be appreciated that the example motorized roller shade <b>100</b> illustrated and described herein is not limited to use as a window treatment, and that the motorized roller shade <b>100</b> may be implemented for uses other than covering openings (e.g., windows). For instance, the example motorized roller shade <b>100</b> having a low-deflection carbon fiber roller tube may be alternatively configured to function as a motorized projection screens (e.g., by replacing the covering material with a projection screen material).