Roll-up Screen Panel Hook Assembly and Segmented Shipping
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Solution Overview
Problem
Conventional screen panels require specialized tools and skills for assembly and shipping, leading to high costs and damage due to their large size and complex assembly processes.
Innovation Solution
A screen panel design featuring a screen frame with a screen mesh attached using hooks, allowing for partial assembly at a manufacturing facility and easy reassembly at a job site without specialized tools or skills, with the screen mesh rolled around frame members for compact shipping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If screen panels are fully assembled in a manufacturing facility, then assembly quality is improved, but shipping costs increase and damage risk increases due to large size
Solution Approach 1:
The screen panel is divided into frame members that can be separately shipped and assembled at the job site. The screen mesh is attached to only two opposite frame members during manufacturing, while the other two frame members are shipped separately and attached on-site, enabling compact packaging and reduced shipping costs while maintaining assembly quality through controlled manufacturing processes.
Solution Approach 2:
The screen mesh is preliminarily attached to two opposite frame members at the manufacturing facility before shipping. This preliminary assembly allows quality control measures to be applied during manufacturing while keeping the overall panel compact for shipping. The remaining frame members are prepared in advance and shipped separately for final assembly at the job site.
2Manufacturing precision
If screen panels are fully assembled in a manufacturing facility, then assembly quality is improved, but handling complexity increases due to wide rectangular boxes
Solution Approach 1:
The screen panel is segmented into multiple frame members that can be shipped in a compact configuration. By attaching the screen mesh to only two opposite frame members during manufacturing and shipping the other two frame members separately, the overall handling complexity is reduced while maintaining assembly quality through standardized connection mechanisms.
3Loss of energy
If screen panels are rolled in on the jobsite, then shipping costs are reduced, but assembly time increases and specialized skills are required
Solution Approach 1:
The screen mesh is preliminarily attached to two opposite frame members at the manufacturing facility with pre-positioned hooks. This preliminary assembly reduces the complexity and time required for on-site assembly, as the screen mesh is already secured to the frame and only needs to be connected to the remaining two frame members at the job site, eliminating the need for specialized rolling skills.
Solution Approach 2:
The hooks are designed to enable easy self-service assembly by the end user without requiring specialized tools or skills. The hooks can be simply inserted into slots or channels on the frame members, allowing non-specialized workers to complete the assembly quickly and efficiently at the job site.
4Strength
If conventional spline attachment is used, then screen mesh is securely attached, but specialized tools and skills are required for assembly
Solution Approach 1:
The conventional spline attachment mechanism is replaced with a hook-based system. Instead of requiring specialized spline rolling tools and skills, the hooks can be simply inserted into slots or channels on the frame members, providing secure attachment through mechanical interlocking while enabling easy assembly by non-specialized workers without requiring specialized tools or skills.
Data Source
AI summary
A screen panel is provided. The screen panel can have a screen frame and a screen mesh positioned over the frame. The screen mesh can be attached to the frame with hooks that can be selectively insertable and removable from the frame. The screen mesh can be attached to a portion of the frame and rolled around itself for shipping, and unrolled and attached to the remainder of the frame for use.