Adjustable traverse rod assembly
BACKGROUND OF THE INVENTION 
     In adjustable traverse rods, the inner rod is smaller than the outer rod to be telescopically receivable therein and, during opening and closing of the drapery, at least some of the drapery carriers move across the transition between the inner and outer rods. It is known, for example as disclosed in U.S. Pat. Nos. 1,878,526, 2,863,505 and 4,276,920, to form the inner and outer rods such that, when the rods are telescoped, the edges of the metal strips from which the inner and outer rods are formed, are disposed alongside each other and at substantially the same level to guide the drapery carriers. While this construction provides a relatively smooth transition for the drapery carriers as they move between the inner and outer rods, the drapery carriers are supported on the slit edges of the strips and this produces wear and drag on the drapery carriers. 
     It is known, for example as disclosed in U.S. Pat. Nos. 2,683,891, 3,314,100 and 3,344,463, that the provision of hemmed edges on the inner and outer telescoping rods would reduce wear and drag on the drapery carriers. However, the provision of hemmed edges markedly complicates the problem of providing a smooth transition for the drapery carriers as they move between the inner and outer rod sections. In these patents, the rods have a rearwardly opening slot and the track and drapery carrier arrangements disclosed in these patents are unsuitable for use with rods having a downwardly opening slot. Further, the track and drapery carrier arrangements disclosed in these patents could not be used in one-way draw installations since the drapery carriers that move along the track of the outer rod section could not move along the track on the inner rod section, and vice versa. 
     It is frequently necessary to support the traverse rod at one or more locations intermediate its ends and various arrangements have heretofore been proposed for attaching the intermediate bracket to the rod in a manner to minimize visibility of the intermediate bracket from the front of the rod. For example, in the aforementioned U.S. Pat. No. 4,276,920, the intermediate bracket extends across the top of the rod and has portions engaging ribs on the front and rear sides of the rod. In U.S. Pat. No. 3,344,463, the intermediate bracket has a nose portion that engages in a dovetail groove at the top of the rod and a latch portion that engages a rearwardly projecting flange on the rod. In U.S. Pat. No. 3,470,578, the inner and outer rods are formed with a dovetail section at the rear of the rod and the mounting bracket has portions that grip the dovetail portion on the rod to support the rod from the rear side thereof. While this arrangement effectively concealed the intermediate bracket from view from the front side of the rod, the rod in this patent has a rearwardly opening slot or trackway disposed below the dovetail portion and the weight of the draperies suspended from the drapery carriers can pull the lower portion of the track downwardly away from the upper dovetail portion of the rod. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide an adjustable traverse rod of the type having a downwardly opening slot and in which the rails on the inner and outer rods support the carriers on rounded edges that provide the same support height in both inside and outside rods and which assure that the slides do not have to move sideways more than a single metal thickness at the transition point between the inner and outer rods. 
     Another object of this invention is to provide an adjustable traverse rod in accordance with the foregoing object and which can be used in one-way draw installations. 
     A further object of this invention is to provide an adjustable traverse rod of the type having a downwardly opening slot in the bottom and in which the inner and outer rods have reentrant angles in the top and bottom rearwardly of the slot in the rod, and mounting brackets for engaging the reentrant angle to provide a concealed support for the rod at the rear of the rod. 
     In accordance with one aspect of the present invention, the traverse assembly comprises telescopically adjustable inner and outer rods formed of sheet metal and each including a top wall means, front wall means, rear wall means, and forward and rear bottom wall means spaced apart to define a downwardly opening slot therebetween. The forward and rear bottom wall means of the outer rod have respective forward and rear carrier guide rails extending upwardly along opposite sides of the slot in the outer rod and terminating in hemmed upper edges with the hems disposed at the side of the associated rail remote from the slot in the outer rod. The forward and rear bottom wall means of the inner rod have respective forward and rear guide rails along opposite sides of the slot in the inner rod and the forward and rear guide rails on the inner rod each have upper guide portions disposed alongside and at substantially the same level as the hemmed upper edges of the forward and rear guide rails on the outer rod, and the forward and rear guide rails on the inner rod each having a lower guide portion horizontally and vertically offset from the upper guide portion on the associated rail to engage the respective forward and rear guide rails on the outer rod at a level below the hems on the upper edges thereof. A plurality of drapery carriers are mounted in the rod each having a head portion adapted to engage the hemmed upper edges of the rails on the upper rod and the upper guide portions of the rails on the inner rod, and shank portions that extend downwardly from the head portions through the slots in the inner and outer rods. 
     In accordance with another aspect of the present invention, the traverse rod assembly comprises inner and outer telescopically adjustable rods each having a downwardly opening slot at the bottom and forward and rear guide rails along opposite sides of the slot, and the inner and outer rods are provided with reentrant angles at the top and bottom at a location rearwardly of the slot in the rod, and a mounting bracket is formed to engage the top and bottom reentrant angles to provide a concealed support for the rod at the rear side thereof. The reentrant angle on the bottom wall means of the inner rod is advantageously formed so that its crest is disposed alongside and at the same level as the upper edge of the rear rail on the outer rod and the rear rail of the inner rod extends downwardly from the crest and terminates in a hemmed lower edge with the hem disposed at the side of the rear rail adjacent the slot in the inner rod. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an exploded perspective view of an adjustable traverse rod embodying the present invention; 
     FIG. 2 is a fragmentary perspective view of one end of the outer rod; 
     FIG. 3 is a fragmentary perspective view of one end of the inner rod; 
     FIG. 4 is a transverse sectional view through the telescoped inner and outer rod and illustrating a drapery carrier mounted therein; 
     FIG. 5 is a transverse sectional view through overlapping portions of the adjustable traverse rod assembly illustrating the rods on an enlarged scale; 
     FIG. 6 is a transverse sectional view through a modified form of adjustable traverse rod. 
    
    
     DETAILED DESCRIPTION 
     Reference is now made more specifically to FIG. 1 of the drawings wherein there is illustrated a traverse rod assembly embodying the present invention. In general, the adjustable traverse rod assembly is of the type having a downwardly opening slot in the bottom thereof and includes an outer rod 10 and an inner rod 11 telescopically receivable in the outer rod. Pulley housings 12 and 12&#39; are provided at opposite ends of the traverse rod assembly and the pulley housings are supported on mounting brackets 13 adapted for attachment to the supporting surface such as a wall, window or the like. One or more intermediate rod engaging brackets 14 are provided for engaging the rod assembly intermediate its ends and the intermediate rod engaging bracket is mounted on an intermediate support bracket 15 for attachment to a supporting surface. One or more master carriers, herein shown two in number and designated 16, 16&#39; are mounted for movement along the rod assembly and the master carriers are operated by traverse cords having runs 17, 17&#39; extending lengthwise of the rod assembly and entrained over pulleys 18, 18&#39; in the pulley housings 12 and 12&#39; respectively. The traverse cords are operatively connected to the master carriers to effect movement of the master carriers along the rod assembly and the master carriers 16 and 16&#39; have drapery support arms 19, 19&#39; for supporting the lead edge of the drapery panels. A plurality of auxiliary drapery carriers 20 are also slidably supported in the rod assembly to support the drapery panel at locations intermediate the master carrier and the pulley housings at the ends of the rod assembly. 
     The outer and inner hollow rods 10 and 11 are formed of strip metal and are illustrated in FIGS. 2-5 on enlarged scale to better illustrate the construction and clearances between the inner and outer rods. For example, the adjustable rod assembly is preferably formed with a small cross-sectional profile, for example about 0.75 inches from front to rear of the outer rod and 0.575 inches from top to bottom of the outer rod, and the illustrations in FIG. 5 is on a scale about 4.75 times full size. The inner and outer rods may, for example, be formed of sheet stock having a thickness of the order of 0.020 inches and the inner rod dimensioned sufficiently smaller than the outer rod to provide a small clearance between corresponding walls of the inner and outer rods of the order of the thickness of the sheet metal stock, for example a nominal clearance of the order 0.020 inches. 
     The outer rod 10 includes top wall means 21, front wall means 22, rear wall means 23, and forward and rear bottom wall means 24 and 25 that are spaced apart to define a downwardly opening slot at the bottom of the outer rod. The inner rod 11 includes a top wall means 31, front wall means 32, rear wall means 33, and forward and rear bottom wall means 34 and 35 that are spaced apart to define a downwardly opening slot at the bottom of the inner rod. As shown in FIGS. 4 and 5, the top wall means 31, front wall means 32, rear wall means 33, and forward and rear bottom wall means 34 and 35 of the inner rod extend alongside corresponding wall means of the outer rod, when the inner rod is telescoped into the outer rod. 
     The forward bottom wall means 24 extends rearwardly from the lower edge of the front wall 22 and has a forward guide rail 24a extending upwardly along one side of the slot in the outer wall and terminating in a hemmed upper edge 24b that is rolled or folded in a direction away from the slot so that the hem lies at the side of the rail 24a remote from the slot in the outer rod. The rear bottom wall means 25 of the outer rod has a rail 25a extending upwardly along the other side of the slot in the outer rod and which terminates in a hemmed upper edge 25b that is rolled or folded outwardly in a direction away from the slot in the outer rod so that the hem is disposed at the side of the rail 25a remote from the slot in the outer rod. The hemmed upper edges 24b and 25b of the rails 24a and 25a respectively are disposed at substantially the same level to guidably support the heads 20a  on the carriers 20 for movement along the outer rod. The rear wall means 25 of the outer rod also has a lengthwise extending reentrant angle formed by wall portions 25c and 25d and which define a downwardly opening channel adjacent the rear wall means 23 and rearwardly of the rear guide rail 25a. The top wall means 21 has a reentrant angle formed by wall portions 21a and 21b and which define an upwardly opening channel adjacent the rear wall means 23. As described more fully hereinafter, the reentrant angles formed in the rear bottom wall means and in the top wall means form a dovetail like configuration at the rear of the outer rod and which is adapted to be engaged by a rear mounting bracket. 
     The forward bottom wall means 34 of the inner rod 11 has a forward rail means extending upwardly along one side of the slot in the inner rod. The forward rail means on the inner rod includes a forward guide rail 34a that extends upwardly along one side of the slot in the inner rod and which terminates in a hemmed upper edge 34b with the hem rolled or folded outwardly away from the slot so that the hem is disposed at the side of the rail 34a remote from the slot in the inner rod. The rolled upper edge 34b on the forward rail of the inner rod is disposed at substantially the same level as the hemmed upper edge 24b on the forward rail 24a of the outer rod to underlie and support the head 20a of the drapery carriers as they move along the inner rod. The forward rail 34a also has a lower portion 34c of generally U-shaped cross-section that is horizontally and vertically offset from the hemmed upper edge 34b in a direction such that the crest of the U-shaped lower portion engages the forward rail 24a of the outer rod at a level below the hem 24b on the upper edge of that rail, when the inner rod is telescoped into the outer rod. The crest of the U-shaped lower portion 34c on the rail 34a of the inner rod is arranged to engage and laterally guide the shank portion 20b of the carriers 20 during movement along the inner rod. 
     The rear bottom wall means 35 of the inner rod has a reentrant angle defined by wall portions 35a and 35b and which form a downwardly opening channel adjacent the rear wall 33 of the inner rod. The wall portions 35a and 35b intersect at a crest 35c that is disposed at substantially the same level as the hemmed upper edge 25b of the rail 25a on the outer rod, and the wall portion 35b extends downwardly from the crest and defines a rear guide rail along the rear side of the slot in the inner rod. The rail 35b has a hemmed lower edge 35d with the hem rolled or folded forwardly so that the hem lies at the side of the rail 35b adjacent the slot in the inner rod. The hemmed lower edge 35d on the rail 35b of the inner rod is arranged to engage the rear rail 25a on the outer rod at a location below the hemmed upper edge 25b thereon, when the inner rod is telescoped into the outer rod, and the hemmed lower edge 35d laterally guides the carriers 20 during movement along the inner rod. The hemmed lower edge 35d is preferably disposed at a level adjacent the level of the forward bottom wall means 34 of the inner rod. 
     The top wall means 31 of the inner rod is formed with a reentrant angle defined by wall portions 31a and 31b and which form an upwardly opening channel adjacent the rear wall 33 of the inner rod. The upwardly and downwardly opening channels adjacent the rear wall of the inner rod form a dovetail like configuration which is adapted to be engaged by a rod mounting bracket. As will be seen from FIG. 4, the heads 20a of the carriers 20 are guidably supported by the hemmed upper edges 24b and 25b on the rails 24a and 25a, respectively during movement along the outer rod and the heads of the carriers are guidably supported on the rolled upper edge on the forward guide rail 34a and by the rolled crest portion 35c on the rear guide rail 35b during movement along the inner rod. Thus, the heads on the carriers are supported on rolled or hemmed edges during movement along the entire length of the rod assembly. The hemmed upper edges 24b and 25b  on the rails of the outer rod are disposed at the same level and the hemmed upper edge 34b and the crest 35c on the rails of the inner rod are disposed at substantially the same level as the hemmed upper edges 24b and 25b when the rods are telescoped together, with variation in height limited by the clearance between the inner and outer rods. As previously indicated, this clearance is very small, for example of the order of 0.020 inches. The shanks 20b of the carriers 20 are laterally guided during movement along the outer rod by the rails 24a and 25a and they are laterally guided during movement along the inner rod by the lower rail portion 34c and the lower hemmed edge 35d on the rails 34a and 35a respectively. The inner rod 11 is preformed so that the lower guide portion 34c on the forward rail of the inner rod and the hemmed lower edge 35d on the rear rail of the inner rod are spaced slightly less than the spacing between the outer faces of the rail portions 24a and 25a on the outer rod section so that the lower portions of the inner rod section have to spread slightly when the inner rod is telescoped into the outer rod to assure that the lateral guide portions of the inner rod engage the guide rails of the outer rod. Accordingly, when the inner rod is telescoped into the outer rod, the spacing between the rear hemmed edge 35d and the lower rail portion 34c on the inner rod exceeds the spacing between the rails 24a and 25a on the outer rod by no more than two times the thickness of the metal strip from which the rods are formed. Thus, the slides do not have to move sideways by more than a single metal thickness at the transition between the telescoped ends of the inner and outer rods. In order to further smooth the transition between the telescoped ends of the inner and outer rods and accommodate manufacturing tolerances, the ends of the rails 24a, 25a of the outer rod are beveled as shown at 24e and 25e in FIG. 2. The bevels 24e and 25e preferably extend from the respective bottom wall upwardly at an acute angle to the upper edge of the respective rail. The end of the rails 34a and 35b on the inner rods also have a beveled portion as shown in FIG. 3. This beveling can be easily achieved by forming V-notches in the strip at appropriate locations prior to roll forming the strip into the inner and outer rods. While it is only necessary to bevel the ends of the rails at the telescoped ends of the rod, opposite ends of each rod are conveniently similarly beveled. For convenience in illustrating, FIGS. 2 and 3 show the bevels on the left ends of the respective rod sections as viewed from the front, it being understood that the other ends of each rod are similarly beveled. 
     As previously described, the upwardly and downwardly opening channels in the top and bottom walls of the inner and outer rods form a dovetail like portion at the rear of each of the rods which is adapted for engagement by a rear mounting bracket. The mounting bracket may, for example, be of the type shown at 14, 15 in FIG. 1 and more fully disclosed and claimed in my co-pending application Ser. No. 943,377, filed Dec. 16, 1986. In general, the rod mounting bracket 14 comprises a rod engaging member 41 having upper and lower jaws 41a, 41a&#39; at one end adapted for engagement with the upper and lower channels in the outer rod section and jaws 41b, 41b&#39; at the other end adapted for engagement with the upper and lower channels in the inner rod section. The rod engaging member is adjustably mounted on the wall mounting bracket 15 to support either the outer or inner rod at a location intermediate its ends. 
     The runs 17, 17&#39; of the traverse cord extend between the pulleys 18, 18&#39; on the pulley housing along paths that are respectively forwardly and rearwardly of the slots in the inner and outer rods. The forward bottom wall 24 having an upwardly extending rail 24a forms a forward channel inside the rod and the rear bottom wall 25 and rail 25a forms a rear channel inside the outer rod for receiving the runs of the traverse cord and for retaining the same against drooping out of the slot in the outer rod. The forward bottom wall means 34 and rail 34a on the inner rod forms an upwardly extending channel at the front side of the inner rod and the upwardly inclined wall 35a forms an upwardly opening channel with the rear wall 33 inside the inner rod for receiving and retaining the rear run of the traverse cord. 
     From the foregoing it is thought that the construction and operation of the traverse rod assembly will be readily understood. During movement of the master and auxiliary carriers 16, 16&#39; and 20 along the rod, the heads on the carriers are supported on the hemmed upper edges 24b, 25b of the rails 24a and 25a during movement along the outer rod and the heads are supported on the hemmed upper edge 34b and the rolled surface 35c at the upper edge of the rails 34a and 35b of the inner rod section during movement along the latter. The shanks of the carriers are laterally guided between the rails 24a and 25a during movement along the outer rod section and are laterally guided by the lower rail portion 34c and the hemmed lower edge 35d on the rail 35b during movement along the inner rod. The carriers are supported at substantially the same level during movement along the inner and outer rods and the carriers do not have to move sideways a distance more than a single thickness of the metal used in forming the rods, during the transition from one rod to the other. Thus, the telescoping inner and outer rods overcome the problems of wear and drag that occur with prior telescoping rods in which the carriers are supported on the slit edges of the rods, while yet providing a smooth transition for the carriers as they move from one rod to the other. The reentrant angles in the top and bottom of the rod provide dovetail like portions on the inner and outer rods at a location rearwardly of the downwardly opening slot in the rods and which can be gripped by a rod support bracket so that the rod support bracket is concealed from view from the front of the rod. The inner and outer rods are also shaped to provide trap areas for the traverse cord at locations forwardly and rearwardly of the slot in the rods to prevent the cords from dropping out of the rod or becoming entangled with the carriers during movement along the rod. 
     A modified form of rod section is illustrated in FIG. 6, and like numerals followed by the postscript &#39; are used to designate corresponding parts. In this embodiment the outer rod 10&#39; has a top wall 21&#39;, front wall 22&#39;, rear wall 23&#39; and forward and rear bottom walls 24&#39; and 25&#39; that are spaced apart and define a slot therebetween. Forward and rear carrier guide rails 24a&#39; and 25a&#39; extend upwardly from the respective forward and rear bottom walls and terminate in hemmed upper edges 24b&#39; and 25b&#39; respectively, with the hems located at the sides of the associated rail remote from the slot in the outer rod. The inner rod 11&#39; has a top wall 31&#39;, front wall 32&#39;, rear wall 33&#39; and forward and rear bottom walls 34&#39; and 35&#39; that are spaced apart and define a slot therebetween. Forward and rear carrier guide rails 34a&#39; and 35a&#39; extend upwardly from the respective forward and rear bottom walls and terminate in hemmed upper edges 34 b&#39; and 35b&#39; respectively with the hems located at the sides of the associated rail remote from the slot in the inner rod. The hemmed upper edges 24b&#39; and 25b&#39; on the outer rod are disposed at the same level to underlie and support the head portion 20a on the carriers 20, and the hemmed upper edges 34b&#39; and 35b&#39; on the inner rod are disposed alongside and at substantially the same level as the upper edges 24b&#39; and 25b&#39; on the outer rod. The rails 34a&#39; and 35a&#39; on the inner rod have lower guide portions 34c&#39; and 35c&#39; respectively that are horizontally and vertically offset the hemmed upper edge on the associated rail to engage the respective forward and rear guide rails on the outer rod at the sides thereof remote from the slot in the outer rod and at a level below the hems on the upper edges thereof. As described in connection with the previous embodiment, the guide rails 24a&#39; and 25a&#39; are laterally spaced apart a distance slightly greater than thickness of the shank portion of the carriers to laterally guide the carriers during movement along the outer rod. The lower guide portions 34c&#39; and 35c&#39; on the inner rod are arranged to engage the outer sides of the rails on the outer rod and laterally guide the shank portions of the carriers during movement along the inner rod. The ends of the rails on the inner and outer rods are preferably beveled in the manner described in connection with the previous embodiment. 
     The carriers are supported at substantially the same level on hemmed upper edges during movement along the inner and outer rods and the carriers do not have to move sideways a distance more than a single thickness of the metal used in forming the rods during movement from one rod to the other. Thus, the telescoping inner and outer rods overcome the problems of wear and drag that occur with prior telescoping rods in which the carriers are supported on the slit edge of the rods, while yet providing a smooth transition for the carriers as they move from one rod to the other.