Modular Roll-Up Wall System With Differential Travel Correction
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Solution Overview
Problem
There is a need for retractable wall systems that can effectively divide larger rooms and public spaces while providing acoustic barriers, as existing solutions are inadequate for these applications.
Innovation Solution
A modular roll-up wall system comprising a vertical track, frame, roller assembly, tube, and flexible barrier, which includes a fabric panel with a reinforced mass loaded vinyl core and felt backing, supported by rollers and a tube motor, and a control unit for monitoring and correcting differential rotational travel, achieving a Sound Transmission Class rating of 46 STC to 53 STC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a modular roll-up wall system is designed to divide larger rooms and public spaces, then the coverage area and partitioning capability are improved, but the device complexity and structural requirements increase
Solution Approach 1:
The wall system is divided into multiple modular panels that can be independently configured and assembled. Each panel contains its own frame, roller assembly, and flexible barrier components, allowing the system to scale to cover larger areas while maintaining manageable complexity through standardized modular units
Solution Approach 2:
The modular panels are designed with universal connection interfaces and standardized components that can be used across different configurations. The same basic panel design serves multiple functions including acoustic partitioning, space division, and potential integration with various mounting systems, reducing overall device complexity through component reuse
2Object-affected harmful factors
If the flexible barrier includes acoustic barrier materials with high Sound Transmission Class rating, then the acoustic barrier performance is improved, but the weight and material complexity increase
Solution Approach 1:
The flexible barrier incorporates composite material construction with a mass-loaded vinyl core layer providing acoustic blocking, sandwiched between fabric panels and felt backing layers. This composite structure achieves high Sound Transmission Class ratings (46-53 STC) while distributing weight across multiple functional layers rather than relying on a single heavy material
Solution Approach 2:
The acoustic barrier properties are concentrated in the mass-loaded vinyl core layer where they are most needed, while the outer fabric and felt layers provide structural support and aesthetic functions with minimal acoustic mass. This localized placement of acoustic materials optimizes the weight-to-acoustic-performance ratio
3Stability of the object's composition
If the tube assembly is supported by multiple rollers spaced along the longitudinal axis, then the stability and support are improved, but the device complexity increases
Solution Approach 1:
The support system is segmented into discrete roller units spaced at intervals along the longitudinal axis of the tube assembly. Each roller independently supports a portion of the tube, distributing the load and providing stability without requiring a continuous complex support structure
Solution Approach 2:
The rollers are designed to self-align and self-support the tube assembly through their positioning in the frame members. The frame structure provides inherent guidance and support, reducing the need for additional active control mechanisms or complex adjustment systems
4Manufacturing precision
If a control unit monitors and corrects differential tube assembly travel, then the operational precision and synchronization are improved, but the device complexity and control system requirements increase
Solution Approach 1:
The control unit continuously monitors the position and travel of each tube assembly through encoder feedback signals. When differential travel is detected between multiple tube assemblies, the control unit automatically adjusts motor operation to correct the misalignment, maintaining synchronized operation without requiring manual intervention or complex mechanical linkages
Data Source
AI summary
A modular roll-up wall system (10) is disclosed. The modular roll-up wall system (10) may include a frame (20), a first tube motor assembly (366A), a second tube motor assembly (366B), and a control unit (264) operatively associated with the first tube motor assembly (366A) and the second tube motor assembly (366B). The control unit (264) may monitor and correct differential rotational travel between the first tube motor assembly (366A) and the second tube motor assembly (366B). A first screen (16A) may be connected to the first tube motor assembly (366A). A second screen (16B) may be connected to the second tube motor assembly (366B). The modular roll-up wall system (10) may form an acoustic barrier which achieves a Sound Transmission Class rating of approximately 46 STC.