Cellular window covering having seamless cells and method for making same

Abstract

A cellular window covering is made from multiple seamless tubular cells which are preferably extruded, cut to the desired length, stacked and glued together. The method can include extruding a plurality of tubular cells then stacking and bonding the cells together to form the fabric of the window covering. The extrusion step can include continuously extruding the tubular cell material and cutting the material at the desired length of the cells. Additional steps can include applying an adhesive to the outer surface of the cell after or sequentially with the extrusion and subsequently coating the outer surface with chopped fibers or powder after the adhesive is applied. The tubular cells can be extruded as single tubes or multiple tubes having internal ligaments which divide the extrusion into two or more connected tubular cells. Alternatively, each tubular cell can be formed from extruded half-cells which are joined together form the tubular cell. The outer surface of the tubular cells can be texturized by abrading or embossing. Additionally, fabric or thin sheets of veneer can be attached to all, or only part, of the outer surface of each tubular cell. The tubular cells can be bonded in a single row or there can be multiple rows of tubular cells bonded together to form double cell, triple cell or other configurations.