Window covering component manufacturing systems, methods, and apparatuses

A window covering component manufacturing method comprising:

• feeding two opposing surface sheets through a first channel space formed between a bottom metering element and a top metering element followed by a second channel space formed between a bottom sizing element and a top sizing element, the first channel space having a first thickness, the second channel space having a second thickness, the first thickness less than the second thickness;
• depositing foam forming liquid chemicals between the two opposing surface sheets before entry of the two opposing surface sheets into the first channel space;
• forcing the foam forming liquid chemicals to spread widthwise at the first channel space;
• and
• facilitating a reaction of the foam forming liquid chemicals to form a foam material that expands in volume within the second channel space to press the opposing surface sheets against the bottom and top sizing elements and then cures to form a rigid core disposed between and bonded to the opposing surface sheets.

A window covering component manufacturing system comprising:

• a spread assembly forming a first channel space having a first thickness;
• a sizing assembly having two opposing sizing elements that form a second channel space having a second thickness, the first thickness less than the second thickness;
• a feed assembly configured to continuously feed two opposing surface sheets through the first channel space and then the second channel space;
• and
• a deposit assembly configured to continuously deposit foam forming liquid chemicals between the two opposing surface sheets before entry of the two opposing surface sheets into the first channel space;
• wherein the thickness of the first channel space formed by the spread assembly is configured to force the foam forming liquid chemicals to spread widthwise at the first channel space as the two opposing surface sheets are fed through the first channel space;
• wherein the foam forming liquid chemicals are configured to react to form a foam material that expands in volume within the second channel space to press the two opposing surface sheets against the opposing sizing elements and then cures to form a rigid core disposed between and bonded to the two separate opposing surface sheets.