Modular Spring Unit for Roller Shades
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Solution Overview
Problem
Existing roller shades require custom springs for each width and material combination, leading to a large inventory of springs and difficulty in providing a consistent 'pre-wind' mechanism, as prior art systems lose 'pre-wind' when the roller tube is removed.
Innovation Solution
A modular spring unit that can be pre-assembled with any desired degree of 'pre-wind' and maintained independently, allowing for multiple units to be combined in a single roller shade assembly, with each unit's 'pre-wind' adjustable and retained throughout assembly and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom springs are supplied for each incremental change in shade width and material, then the roller shade can be finely counterbalanced, but the supplier must maintain a large inventory of springs
Solution Approach 1:
The spring is divided into multiple modular segments that can be assembled in different combinations. Each segment has standardized dimensions and spring constants, allowing suppliers to stock only the individual segments rather than complete springs for every possible shade configuration. These segments are connected via coupling mechanisms to form springs of varying total lengths and adjusted K values.
Solution Approach 2:
The spring constant K and length L are made adjustable through the modular segment design. By changing the number of segments, their arrangement, or the coupling configuration, the effective K and L values can be varied to match different shade weights and dimensions without requiring completely different spring designs.
2Reliability
If a pre-wind mechanism is added to booster assemblies, then the spring can provide assistance all the way to the fully retracted position, but it becomes extremely awkward and difficult to pre-wind each assembly, particularly if different degrees of pre-wind are desired
Solution Approach 1:
The pre-wind function is separated from the main spring assembly and implemented as independent pre-wind mechanisms on individual modular segments. This allows each segment to be pre-wound to a specific degree independently, and the pre-wind settings are maintained through the coupling mechanism when segments are assembled into the final spring configuration.
Solution Approach 2:
The spring segments are pre-wound to the desired degree before final assembly into the roller shade. This preliminary action ensures that the assistance force is available from the beginning of the retraction stroke, and the pre-wind settings are locked in during the modular assembly process rather than requiring adjustment after assembly.
3Ease of repair
If the roller tube is removed from the shaft, then the booster assemblies can be disassembled, but any pre-wind of the booster assemblies is lost
Solution Approach 1:
The spring is designed as modular segments with standardized coupling interfaces. When the roller tube is removed and the spring is disassembled into segments, each segment retains its pre-wind characteristics because the pre-wind is embedded in the segment structure itself rather than being dependent on the assembled configuration. The segments can be reassembled without losing the pre-wind properties.
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 efficient counterbalancing of roller shades with adjustable 'pre-wind' for various sizes and materials, reducing inventory needs and ensuring consistent assistance in raising and lowering the shade without losing pre-wind functionality.
Implementation Method 1
A spring is typically used to assist in raising (retracting) a roller shade
Implementation Method 2
A spring is typically used to assist in raising (retracting) a roller shade
Data Source
AI summary
A power assist module for use in roller tube driven products, such as roller shades. The module may be pre-wound prior to installation in a roller tube and retains its pre-wound condition, even after use, when removed from the roller tube.