An apparatus and method are disclosed for forming cellular or non-cellular window shades directly from raw stock to the final desired window shade color, height and width to fit a particular window size, with essentially no wasted material. The shade is fabricated from a bonded array of a predetermined number of stacked, identically shaped and sized, elements or preforms of uniform length corresponding to one of the height or width dimensions of the desired window covering. The number of preforms is selected so that the length of the fully expanded array will correspond with the other of the height or width dimensions of the window covering. The raw stock is in the form of a continuously fed narrow strip of uncolored fabric to which the necessary coloring, folding, cutting-to-length, stacking and bonding steps are applied within the disclosed apparatus.

A covering for an architectural feature having generally horizontal vane elements coupled to and located between generally front and rear generally vertical support members, which in preferred embodiments are adjustable to control the amount of light transmitted through the covering. In one embodiment the covering has three dimensional multi-layered, cellular vanes, and in another embodiment, the one or more support members are formed of a dark color, the rear support member(s) may be formed of material that is darker than the front support member(s), or vise versa. In another embodiment, the support members, e.g., sheers, have an openness factor, preferably as low as about sixty-five percent (65%) to as large as about ninety percent (90%). Other embodiments include structure, assemblies and methods for controlling the closure of the covering as well as embodiments of bottom rail assemblies. Also provided is a method of manufacturing the covering.

A covering for an architectural feature having generally horizontal vane elements coupled to and located between generally front and rear generally vertical support members, which in preferred embodiments can adjust and control the amount and quality of light transmitted through the covering is described. In one embodiment the covering has three dimensional multi-layered, cellular vanes, which are aesthetically appealing and practically useful for privacy and shading purposes. In another embodiment, the one or more support members are formed of a dark color, and in one example, the support members may be black, grey and/or brown, and in a further example, the rear support member(s) may be formed of material that are darker than the front support member(s), or vise versa. In another embodiment, the support members, e.g., sheers, have an openness factor, preferably as low as about sixty-five percent (65%) to as large as about ninety percent (90%). Other embodiments include structure, assemblies and methods for controlling the closure of the covering as well as embodiments of bottom rail assemblies. Also provided is a method of manufacturing the covering.

In one aspect, a method for manufacturing a continuous sheet for use within a roller shade may generally include positioning a portion of a first sheet web adjacent to a mandrel, positioning a portion of a second sheet web adjacent to the mandrel and winding the first and second sheet webs around the mandrel such that a folded segment of the first sheet web is secured to a base segment of the second sheet web.

A shade member and a window blind including multiple such shade members are provided. The shade member is made by welding a first shade element, a second shade element, and a third shade element together. The second shade element is situated on a first region of the first shade element, while the first shade element and the second shade element are unified by longitudinally overlapping and ultrasonic welding. The third shade element is situated on a second region of the first shade element, while the first shade element and the third shade element are unified by longitudinally overlapping and ultrasonic welding. Such a structure allows the shade member to easily include distinct portions made of different materials, so that the window blind including such shade members can provide a variety of appearance designs and texture combinations while lowering the production cost and increasing the production efficiency.

In one aspect, a method for manufacturing a continuous sheet for use within a roller shade may generally include positioning a portion of a first sheet web adjacent to a mandrel, positioning a portion of a second sheet web adjacent to the mandrel and winding the first and second sheet webs around the mandrel such that a folded segment of the first sheet web is secured to a base segment of the second sheet web.