Cellular Window Covering Segment Bonding
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Solution Overview
Problem
Existing window coverings made from cellular material often result in leftover segments that are difficult to combine seamlessly, leading to a noticeable bond thickness and aesthetic issues when trying to reuse them.
Innovation Solution
A method of preparing segments by removing excess fabric and glue from the top surface of cellular or tabbed material, applying a new glue line, and bonding them together to create a uniform appearance, using techniques like grinding, milling, or heating to achieve a thin, imperceptible bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If segments of cellular material are combined by trimming and gluing attachment surface strips, then the segments can be connected together, but the bond thickness becomes twice or three times the thickness of other bonds in the stack, creating a noticeable and aesthetically problematic bond
Solution Approach 1:
The patent removes the problematic attachment surface strip (composed of fabric and original glue) from the cellular material segment. By extracting this excess material, the bond line can be made thin and uniform. The strip is removed by grinding, milling, cutting, or sanding the cellular material to expose a thin bond line without the additional thickness of a full attachment surface strip.
Solution Approach 2:
The patent applies different treatment to different parts of the cellular material. The attachment surface strip is selectively removed only where needed for bonding, while the rest of the cellular material maintains its original structure. This localized modification allows the bond line to be thin and uniform in the bonding area while preserving the normal appearance and structure of the cellular material elsewhere.
2Ease of manufacture
If leftover fabric segments are discarded, then the manufacturing process is simple, but material is wasted and segments that could be reused are lost
Solution Approach 1:
Instead of discarding leftover fabric segments, the patent recovers them by removing the attachment surface strip and rebonding them to form complete window covering panels. The segments are prepared by trimming excess fabric and glue, then bonded together with new glue to create uniform, aesthetically acceptable bonds. This allows fabric segments that would otherwise be wasted to be recovered and reused effectively.
3Ease of manufacture
If the attachment surface strip is left intact, then the bonding process is simpler, but the resulting bond is noticeably thicker and creates aesthetic issues in the finished window covering
Solution Approach 1:
The attachment surface strip is extracted or removed from the cellular material segment before bonding. This extraction eliminates the excess thickness that would otherwise be present in the bond line. By removing this strip, the bond becomes thin and uniform, matching the appearance of other bonds in the stack, while still maintaining the structural integrity needed for effective bonding.
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
Enables the efficient reuse of leftover segments by creating a seamless and uniform window covering with a bond thickness comparable to standard segments, maintaining the appearance and functionality of the original material.
Implementation Method 1
One might heat the glue to soften it and then peel or scrape the fabric strip and glue away
Implementation Method 2
One could freeze the glue and then crack the frozen glue to remove the strip of fabric and at least some of the glue
Data Source
AI summary
In a method for making a window covering the user selects a first segment of cellular material in which there is a top cell having a top surface, at least one glue line on the top surface and a strip of fabric on the at least one glue line. The strip of fabric and at least a portion of the glue line are removed from the top surface of the top cell. and a second glue line is applied to that top surface. A second segment of cellular material is place over the second glue line on the top surface of the top cell of the first segment. The glue line cures and bonds the second segment of cellular material to the first segment of cellular material. If the cellular material has tabbed cells the processes can be used to join the tabs of the two segments together.