Conical Grooved Roller Shade Tensioning for Skylight Motor Load
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Solution Overview
Problem
Existing motorized roller shade systems for skylights require larger, noisier motors due to fabric tension and are complex and unreliable to install, especially when dealing with non-vertical window orientations.
Innovation Solution
A self-contained tensioned roller shade system using parallel side channels, conical grooved spools, and pulley systems to distribute tension evenly, reducing motor stress and enabling easy installation by assembling the system before mounting it in a free-standing frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a dual-motor tensioning system is used to minimize fabric sagging in skylight windows, then fabric tension is improved, but motor size and noise increase
Solution Approach 1:
The tensioning function is extracted from the motor system and implemented separately through a spring mechanism and cable arrangement. The spring provides continuous tension to the fabric independently of the motor, allowing the motor to only control fabric movement without bearing the full tension load. This separation resolves the contradiction by maintaining fabric tension while reducing motor size and noise.
Solution Approach 2:
The spring mechanism acts as a counterweight system that continuously applies tension to the fabric through the cable and pulley arrangement. This counterbalances the fabric's tendency to sag, maintaining fabric stability without requiring the motor to continuously counteract gravity and tension forces, thus reducing motor power requirements.
2Stability of the object's composition
If a dual-motor tensioning system is used to maintain fabric tension, then fabric stability is improved, but system complexity increases
Solution Approach 1:
The tensioning control function is extracted from the dual-motor system and implemented through a passive spring mechanism. The spring automatically maintains constant tension on the fabric through the cable-pulley system, eliminating the need for complex coordinated control of two motors. This reduces system complexity while maintaining fabric stability.
Solution Approach 2:
The spring mechanism is a self-regulating tensioning system that automatically maintains fabric tension without requiring active control. The spring's mechanical properties provide continuous tension adjustment as the fabric moves, eliminating the need for complex control algorithms and coordination between multiple motors.
3Power
If a spring-biased roller tube is used to provide fabric tension, then motor size is reduced, but the length of shade fabric that may be tensioned is limited
Solution Approach 1:
The tensioning system uses a cable running through pulleys at both ends of the fabric, creating a distributed tensioning arrangement. This dimensional extension allows the spring mechanism to effectively tension much longer fabric lengths by distributing the tension force along the entire fabric span, rather than being limited to a single roller tube location.
4Stability of the object's composition
If prior art tensioning systems are used in skylight windows, then fabric tension is maintained, but installation difficulty increases
Solution Approach 1:
The roller tube, spool, and tensioning components are merged into a single integrated assembly that can be installed as one unit in the skylight opening. This consolidation eliminates the need for separate installation of multiple components and simplifies mounting, while the internal spring-cable mechanism maintains fabric tension throughout operation.
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
The system minimizes motor stress, reduces noise, and allows for easy installation and scalability to accommodate various roller tube sizes and shade fabric dimensions, providing efficient and reliable operation for non-vertical windows.
Implementation Method 1
a spring located in the first side channel and operatively coupled to the first tensioning cord, such that the spring biases the hembar toward the distal ends of the first and second side channels
Implementation Method 2
the spring biases the hembar toward the distal ends
Implementation Method 3
The first spool has a first spool end adjacent the first tube end, a second spool end, and a single groove that wraps around the spool from the first spool end to the second spool end. The groove receives the tensioning cord, such that the spool is adapted to rotate about the tube axis
Implementation Method 4
The roller tube is rotatably mounted between the proximal ends of the first and second side channels and is adapted to rotate about a tube axis
Data Source
AI summary
A tensioned roller shade system for installation in an opening, such as a window or a skylight, comprises a frame, a roller tube rotatably mounted between side channels of the frame adjacent a first end of the frame, a conical, grooved spool mounted adjacent the roller tube, and a shade fabric is windingly received around the roller tube. A tensioning cord is operatively coupled between the spool and a fabric end of the shade fabric. The spool has a single groove, which wraps around the spool and windingly receives about the tensioning cord. A pulley is operatively coupled to the frame adjacent a second frame end and windingly receives the tensioning cord. The tensioning cord is adapted to bias the second fabric end toward the second frame end, such that the second fabric end of the shade fabric is adapted to move between the first and second frame ends as the roller tube is rotated.