Arcuate Nonwoven Slat Forming for Insulative Window Coverings
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Solution Overview
Problem
Existing methods for forming semi-rigid slats for architectural opening coverings, such as Venetian and Roman shades, lack an efficient process for producing elongated, arcuate transverse cross-section slats that are both aesthetically pleasing and insulative.
Innovation Solution
A process involving a roll of heat-formable strip material is heated above a predetermined temperature using tensioning and preheating rollers, then molded around an arcuate extrusion within a heat chamber, followed by cooling to create a semi-rigid state, using a combination of binder and matrix fibers with a resin coating to achieve the desired shape and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional methods are used to form slats for architectural coverings, then the manufacturing process is simple, but the resulting slats lack the desired arcuate shape and insulative properties
Solution Approach 1:
The patent applies parameter changes by heating the strip material to a temperature where it becomes pliable and can be formed into the desired arcuate shape, then cooling it to set the new shape. This temperature parameter change enables the transformation from a flat strip to a curved slat with insulative properties.
Solution Approach 2:
The patent utilizes phase transitions by heating the strip material to transition it from a rigid state to a pliable state that can be molded, then cooling it to transition back to a rigid state that maintains the formed shape. This phase change approach enables efficient formation of complex arcuate geometries.
2Manufacturing precision
If heat forming process is applied to create arcuate slats, then the aesthetic appearance and insulative properties are improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges the heating and cooling operations into an integrated forming process. The heat chamber and cooling station work in sequence within a single manufacturing line, combining multiple functions (heating, forming, cooling) into one continuous process that produces uniformly shaped slats.
Solution Approach 2:
The patent uses an intermediary forming surface within the heat chamber that defines the desired arcuate shape. This intermediary tool or mold acts as a mediator between the heated material and the final formed product, ensuring consistent and precise geometric formation.
3Strength
If strip material is heated and molded to form semi-rigid slats, then the structural rigidity and insulative properties are enhanced, but the processing time and energy consumption increase
Solution Approach 1:
The patent maintains continuous useful action by processing the strip material through heating, forming, and cooling in an uninterrupted sequence. The material moves continuously through the heat chamber and cooling station without stopping, maximizing the efficiency of energy input and minimizing idle time.
Solution Approach 2:
The patent applies preliminary action by preheating the strip material before it enters the main forming zone. This preliminary heating prepares the material in advance, reducing the total energy required during the main forming process and enabling more efficient subsequent shaping operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method allows for the production of elongated, arcuate slats that are both aesthetically appealing and insulative, with controlled thickness and smooth surfaces, enabling efficient and uniform formation for architectural opening coverings.
Implementation Method 1
the strip of heat formable material is heated above a predetermined temperature so that it deforms as it is pulled across a forming extrusion
Implementation Method 2
it passes through a cooling station where fans blow ambient air onto the strip material to cool it from the semi-molten state it existed in within the heat chamber to a fairly rigid or semi-rigid molded state
Data Source
AI summary
A slat for use in a covering for an architectural opening is made from a base material of binder and matrix fibers which are formed into a nonwoven material by melting at least a portion of the binder fibers to thermally bond the binder and matrix fibers. A coating of resin is then applied to the thermally bonded base before the composite material is passed through a forming apparatus where the material is heated over a convex support having the desired curvature for the slat and subsequently cooled.