Cellular Shades Using Segmented Fabric Stacks
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Solution Overview
Problem
Conventional methods for manufacturing cellular shades require substantial capital investment, are unsuitable for custom fabricators using woven and knitted fabrics, and face challenges with storage, handling, and inventory management due to the need for large rolls of fabric, limiting the variety of fabrics that can be used and the width of shades that can be produced.
Innovation Solution
A method of manufacturing cellular shades using folded fabric segments with P-shaped cells, where alternate folds on a second panel are attached to a first panel to create curved cell walls, allowing for more flexible and space-efficient production, enabling the use of woven fabrics and various fabric types, and allowing for the creation of asymmetrical shapes that maintain their form over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods use large rolls of fabric for manufacturing cellular shades, then production can be scaled, but storage space requirements increase and handling becomes difficult
Solution Approach 1:
The fabric is divided into pre-cut segments that can be stored in compact stacks rather than large rolls. Each segment is a discrete unit that can be easily handled and stored, eliminating the need for extensive rack space while maintaining production capability through assembly of multiple segments.
2Productivity
If fabric is stored in large rolls, then continuous material is available for production, but the fabric width is limited by the roll width
Solution Approach 1:
Multiple fabric segments can be joined together to create cellular shades wider than any single roll width. The segmentation allows flexibility in combining multiple narrower segments to achieve the desired final width, overcoming the limitation of individual roll dimensions.
3Area of stationary object
If rolls of fabric are stored horizontally on flat surfaces, then space is utilized, but the material flattens and distorts over time
Solution Approach 1:
Pre-cut segments maintain their shape stability better than continuous rolls when stored. The segmented structure allows for compact vertical stacking without the flattening and distortion issues that occur with horizontal roll storage, as each segment is a self-contained unit with defined edges.
4Productivity
If conventional manufacturing methods are used, then large scale production is efficient, but capital equipment investment is substantial
Solution Approach 1:
The manufacturing process is simplified by working with pre-cut segments rather than requiring complex continuous feed equipment for large rolls. This segmentation approach reduces the need for substantial capital equipment investment while maintaining production efficiency through modular assembly processes.
Data Source
AI summary
In a cellular material a first panel having a series of lengthwise accordion folds across the width of the panel, alternate folds projecting toward the front of the panel and the back of the panel is attached to a second panel of material in a manner to create a series of P-shaped cells having a back, an upper cell wall and a lower cell wall in which the upper cell wall and the lower cell wall are curved in a same direction.