Roller Shutter Stress Limiting Layer Design

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Solution Overview

Problem

Vehicle interior roller shutters experience bending and stretching stresses that lead to marks and cracks on the decorative layer, affecting the perceived quality over time.

Innovation Solution

Incorporating a stress limiting layer, such as a compressible intermediate layer or a hard intermediate layer, between the carrier and the decorative lining to absorb and distribute stresses, along with a pre-compressed layer with pre-tensioned members to minimize tension on the decorative layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If the roller shutter is made flexible to close vehicle interior apertures, then the ease of operation is improved, but the decorative layer is subjected to bending and stretching stresses that cause marks and cracks over time

Engineering Contradiction:

Improveflexibility of roller shutterVSAvoidappearance quality of decorative layer

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

A stress-limiting intermediate layer is introduced between the flexible carrier and the decorative lining. This intermediary layer absorbs and distributes bending and stretching stresses, preventing them from reaching the decorative layer. The intermediate layer acts as a buffer that maintains flexibility while protecting the decorative surface from damage.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The roller shutter is constructed as a composite structure with multiple layers: a flexible carrier layer, a stress-limiting intermediate layer, and a decorative lining. Each layer serves a specific function, and their combination achieves both flexibility for operation and protection of the decorative appearance, resolving the contradiction between ease of use and reliability.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a decorative layer is applied to improve quality perception, then the appearance quality is improved, but the decorative layer becomes vulnerable to bending and stretching stresses during use

Engineering Contradiction:

Improveappearance qualityVSAvoidresistance to bending and stretching stresses

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The stress-limiting intermediate layer serves as a protective intermediary between the flexible carrier and the decorative lining. It absorbs mechanical stresses generated during bending and stretching operations, preventing these stresses from being transmitted to the decorative layer, thereby maintaining both appearance quality and stress resistance.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The intermediate layer is positioned beforehand between the carrier and decorative lining to provide preemptive protection. It is designed to cushion and distribute stresses before they can reach the decorative layer, preventing marks and cracks before they occur during normal operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of manufacture

If the roller shutter structure is simplified, then the ease of manufacture is improved, but the ability to limit stress on the decorative lining is reduced

Engineering Contradiction:

Improvestructural simplicityVSAvoidstress limitation capability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The roller shutter uses a composite structure with three functional layers, each contributing a specific property. This composite approach achieves stress limitation and appearance protection without requiring complex mechanisms, as each layer performs its function through material properties rather than complex structural arrangements.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The roller shutter is segmented into distinct functional layers: the flexible carrier, the stress-limiting intermediate layer, and the decorative lining. This segmentation allows each layer to be optimized for its specific function while maintaining overall structural simplicity and ease of manufacture through standardized layering.

Inventive Principle:

Principle #1Segmentation

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 solution effectively maintains the appearance of the roller shutter by reducing stress on the decorative layer, preventing marks and cracks, and ensuring durability even with repeated use.

Implementation Method 1

the stress limiting layer is formed of a compressible intermediate layer laminated between the carrier and the decorative lining

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

the roller shutter comprises pre-tensioned members embedded in the pre-compressed layer for imparting residual pre-compression to the pre-compressed layer

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10030441B2Roller shutter and storage compartment comprising said roller shutter

Publication Date: 2018.07.24 FAURECIA INNENRAUM SYSTEME GMBH

AI summary

A roller shutter that has a carrier and a decorative lining laminated over the carrier. The roller shutter includes at least one stress limiting layer configured to limit stress applied on the decorative lining when bending the roller shutter.