Methods for manufacturing continuous sheets for roller shades

1. A method for manufacturing a continuous sheet for use within a roller shade, the method comprising:

positioning a portion of a first sheet web adjacent to a mandrel, the first sheet web including an upper face and a lower face extending between a folded end and a base end, the first sheet web defining a first fold edge between its folded and base ends such that the first sheet web includes a first folded segment extending between the first fold edge and its folded end and a first base segment extending between the first fold edge and its base end;

positioning a portion of a second sheet web adjacent to the mandrel, the second sheet web including an upper face and a lower face extending between a folded end and a base end, the second sheet web defining a second fold edge between its folded and base ends such that the second sheet web includes a second folded segment extending between the second fold edge and its folded end and a second base segment extending between the second fold edge and its base end; and

winding the first and second sheet webs around the mandrel such that the first folded segment of the first sheet web is secured to the second base segment of the second sheet web at a location adjacent to the base end of the second sheet web.

2. The method of claim 1 , further comprising positioning the second sheet web relative to the first sheet web such that the second base segment of the second sheet web is secured to the portion of the lower face of the first sheet web that extends along the first folded segment.

3. The method of claim 1 , further comprising positioning the second sheet web relative to the first sheet web such that the second base segment of the second sheet web is secured to the portion of the upper face of the first sheet web that extends along the first folded segment.

4. The method of claim 1 , further comprising positioning the first and second sheet webs such that the first and second folded segments extend inwardly towards one another.

5. The method of claim 1 , further comprising applying adhesive to at least one of the first folded segment or the second base segment to allow the first and second sheets to be attached to one another at the location adjacent to the base end of the second sheet web.

6. The method of claim 1 , further comprising applying adhesive to an unwound portion of one of the first sheet web or the second sheet web such that the unwound portion is secured to a previously wound portion of the other of the first sheet web or the second sheet web as the first and second sheet webs are wound around the mandrel.

7. The method of claim 6 , wherein applying adhesive to the unwound portion of one of the first sheet web or the second sheet web comprises applying adhesive to an unwound portion of one of the first folded segment or the second folded segment.

8. The method of claim 6 , further comprising temporarily stopping application of the adhesive to the unwound portion for a complete revolution of the mandrel.

9. The method of claim 1 , wherein positioning the portion of the second sheet web adjacent to the mandrel comprises stacking the portion of the second sheet web on top of the first sheet web such that the second sheet web is positioned between the first sheet web and the mandrel.

10. The method of claim 1 , wherein the first and second sheet webs are formed from the same material or from different materials.

11. The method of claim 10 , wherein the different materials have differing light transmittance values.

12. The method of claim 1 , wherein the first and second sheets webs are colored differently.

13. The method of claim 1 , wherein the first folded segment has an overlapped, configuration relative to the first base segment when the first sheet web is wound around the mandrel such that the portion of the upper face of the first sheet web extending along the first folded segment faces towards the portion of the upper face of the first sheet web extending along the first base segment.

14. The method of claim 1 , wherein the second folded segment has an overlapped configuration relative to the second base segment when the second sheet web is wound around the mandrel such that the portion of the upper face of the second sheet web extending along the second folded segment faces towards the portion of the upper face of the second sheet web extending along the second base segment.

15. The method of claim 1 , wherein winding the first and second sheet webs around the mandrel comprises continuously winding the first and second sheet webs around the mandrel such that an assembly of alternating layers of portions of the first and second sheets is formed on the mandrel.

16. The method of claim 15 , further comprising cutting through the assembly of alternating layers in a cross-wise direction to form a roller sheet defining a width.

17. The method of claim 16 , wherein the width of the roller sheet corresponds to an outer dimension of the mandrel.

18. A method for manufacturing a continuous sheet for use within a roller shade, the method comprising:

positioning a portion of a first sheet web adjacent to a mandrel, the first sheet web including an upper face and a lower face extending between a folded end and a base end, the first sheet web defining a first fold edge between its folded and base ends such that the first sheet web includes a first folded segment extending between the first fold edge and its folded end and a first base segment extending between the first fold edge and its base end;

stacking a portion of a second sheet web on top of the first sheet web such that the second sheet web is positioned between the first sheet web and the mandrel, the second sheet web including an upper face and a lower face extending between a folded end and a base end, the second sheet web defining a second fold edge between its folded and base ends such that the second sheet web includes a second folded segment extending between the second fold edge and its folded end and a second base segment extending between the second fold edge and its base end;

securing the first folded segment of the first sheet web to the second base segment of the second sheet web at a location adjacent to the base end of the second sheet web; and

continuously winding the first and second sheet webs around the mandrel such that an assembly of alternating layers of portions of the first and second sheets is formed on the mandrel.

19. The method of claim 18 , further comprising cutting through the assembly of alternating layers in a cross-wise direction to form a roller sheet defining a width.

20. The method of claim 18 , further comprising applying adhesive to an unwound portion of one of the first sheet web or the second sheet web such that the unwound portion is secured to a previously wound portion of the other of the first sheet web or the second sheet web as the first and second sheet webs are wound around the mandrel so as to form the assembly of alternating layers of portions of the first and second sheets.