Cellular Shade Assemblies With Nested Collapse Profiles
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Solution Overview
Problem
Existing cellular shades are limited in width by the width of the material used, making it difficult to produce shades that can fit any architectural opening, and they often have a wide profile when contracted, requiring deep mounting spaces.
Innovation Solution
The cellular shade design allows for the use of multiple pieces of material to form each cell structure, enabling customization of width and length, with a lightweight back fabric that can pass light and a heavier front fabric for opacity, and a lift system for easy expansion and contraction, resulting in a narrow depth profile when collapsed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional single-material construction is used, then manufacturing is simpler, but the width is limited by the material roll width
Solution Approach 1:
The cellular shade is divided into multiple separate face materials (front face and back face) that can be independently selected and assembled. This segmentation allows each face to be cut to specific widths, enabling customization of the overall shade width beyond the limitations of a single material roll width.
Solution Approach 2:
The invention uses composite construction by joining different face materials together to form the cellular structure. The front face and back face can be made from different materials with different properties, allowing optimization of appearance, light transmission, and structural characteristics while achieving width customization.
2Shape
If both front and back of each cell collapse outwardly in opposite directions, then the cells cover the opening effectively when expanded, but the contracted profile becomes very wide requiring deep mounting space
Solution Approach 1:
The invention creates asymmetric collapse behavior where the front face and back face collapse in the same direction (toward the front of the shade) rather than in opposite directions. This asymmetric arrangement allows the cells to stack compactly in a single direction, reducing the contracted profile depth and mounting space requirements.
Solution Approach 2:
The cellular structure is designed so that when contracted, the cells nest within each other in a compact stack. The front and back faces collapse together rather than apart, allowing the cells to occupy minimal space when retracted, similar to nested dolls.
3Illumination intensity
If heavy back face material is used for structural support, then the cell structure is stronger, but it prevents light from passing through and illuminating the front face
Solution Approach 1:
The invention applies different material properties to different parts of the cellular structure. The back face is made from lightweight, sheer material optimized for light transmission, while the front face uses heavier material optimized for appearance and opacity. This local differentiation of material qualities allows light to pass through the back face to illuminate the front face while maintaining structural integrity.
Solution Approach 2:
The cellular shade combines different materials with complementary properties - a lightweight sheer back face material for light transmission and a heavier front face material for aesthetic appearance and opacity. This composite material approach allows the structure to simultaneously achieve light transmission and structural support functions.
Data Source
AI summary
An expandable and contractable cellular shade assembly (10) includes a plurality of closed D-shaped cell structures (12) aligned vertically one above another with juncture lines (16) defined between adjacent structures. Each closed cell structure (12) includes a front face (22) and a separate back face (26) that are attached to one another at top and bottom tabs (17). The front face (22) of one cell structure (12) is attached but non-continuous to the front face (22) of an adjacent cell structure (12). Accordingly the horizontal width of the shade assembly (10) is not limited by the width of the materials forming the individual cell structures (12). Upon collapse, the back face (26) folds toward the front (14) of the shade such that the back face (26) and the front face (22) are nested within one another, leading to a narrow depth profile for the collapsed shade.