Roller Shutter Slat Clip Mounting via Pre-Drilled Foam Holes
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Solution Overview
Problem
The existing roller shutter slat manufacturing processes are complex and laborious due to the need for cavity creation, milling, and the use of screws or rivets for clip fixation, which generates dust and requires multiple operations.
Innovation Solution
The roller shutter slat design includes end holes for easy drilling, allowing for automatic insertion of a sleeve-based clip system with locking pins or screws that create a positive connection without external fasteners, ensuring secure alignment and locking without protruding screws or rivets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional milling operations are used to create recesses for clip mounting, then the clip can be securely mounted, but the manufacturing process becomes laborious and generates significant dust
Solution Approach 1:
The patent pre-drills holes through the foam insulation material during the manufacturing process, so that when the metal strip with clips is later installed, the clips can be directly inserted and secured with fasteners through the pre-existing holes without requiring additional milling or cavity creation operations
Solution Approach 2:
The patent separates the hole creation function from the clip mounting function, with holes being pre-drilled through the foam insulation in a first manufacturing step, and clips being installed in a subsequent step, thereby simplifying both operations and eliminating the need for complex milling to create recesses
2Reliability
If multiple fastening operations are used to secure the clip, then the clip is firmly fixed, but the manufacturing complexity increases with multiple separate operations
Solution Approach 1:
The patent combines the hole creation, clip insertion, and fastening operations into a single integrated manufacturing step where pre-drilled holes in the foam insulation receive metal strip clips that are secured with fasteners in one continuous operation, eliminating the need for separate cavity preparation and clip installation steps
3Reliability
If screws or rivets are used for clip fixation, then the clip is securely attached, but external fasteners protrude and require additional mounting operations
Solution Approach 1:
The patent nests the fastening mechanism within the existing structure by having fasteners pass through pre-drilled holes in the foam insulation and secure the metal strip clips from the interior side, so that the fastening elements are concealed within the roller shutter assembly rather than protruding externally, simplifying the mounting 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
This design simplifies the mounting and locking of the clip, reducing manufacturing complexity and dust generation, while ensuring secure alignment and locking without the need for external fasteners, enhancing the overall efficiency and reliability of the roller shutter slat assembly.
Implementation Method 1
the ends of the sleeves are spread open and a positive connection is thus produced between the sleeve and the plastic foam
Data Source
Figure 1~3
Figure 4~8
Figure 9~12
AI summary
The slat (1) has a hollow section (2) that is filled with plastic foam (3). A clip (6) is attached at an end of the slat, and includes a sleeve (7) that is inserted into a set of bores (10). The sleeve is arranged with longitudinally extending slots, and a set of protrusions is presented at ends (7') of the sleeve. A longitudinally movable body is provided between the protrusions, and the ends of the sleeve are positively engaged into the plastic foam.