Shutter Kit Segmentation for Custom Fit Assembly
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Solution Overview
Problem
The window shutter industry lacks a cut-down program similar to those for blinds, making it difficult for homeowners to obtain custom-sized shutters efficiently, as shutters are typically custom-made and require professional measurement and installation, taking several days to weeks to receive and install.
Innovation Solution
Providing retailers with sets of standard-sized shutter components that can be cut and assembled by customers to create custom-sized shutter panels, including a jig for easy alignment and attachment of components, allowing for same-day purchase, assembly, and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom-made shutter panels are manufactured to fit exact window openings, then the shutter fit and appearance are improved, but the manufacturing time and customer waiting period increase to several days or weeks
Solution Approach 1:
The shutter is divided into multiple separable components including panels, frames, and shims that can be manufactured independently in standard sizes and then assembled on-site to achieve custom-fit without lengthy manufacturing processes
Solution Approach 2:
Standard-sized shutter components are pre-manufactured and prepared in advance, allowing for rapid assembly and installation to fit specific window openings without requiring custom manufacturing time
2Productivity
If standard size shutter panels are sold with frames and shims to achieve custom fit, then the manufacturing speed is improved, but the installation appearance deteriorates due to visible shims and spacers
Solution Approach 1:
Adjustable shims are designed to be concealed within the frame structure or between the frame and window opening, making them locally adapted to be invisible from the exterior while still enabling standard-sized panels to fit custom openings
Solution Approach 2:
Concealed shim components act as intermediaries between standard-sized shutter panels and custom window openings, providing the necessary adjustment while remaining hidden to maintain professional appearance
3Manufacturing precision
If professional measurement and custom manufacturing are used for shutters, then the shutter precision is improved, but the process complexity and time requirement increase compared to blinds
Solution Approach 1:
The shutter system is segmented into modular components that can be independently sized and assembled, simplifying the measurement and manufacturing process while maintaining precision through standardized connection mechanisms
Solution Approach 2:
Standard-sized shutter components are designed with universal connection features that allow them to be adapted to various window opening sizes through simple assembly variations, reducing the need for completely custom manufacturing
Data Source
AI summary
A kit containing components which can be assembled into a shutter panel includes a header, a footer, a plurality of brackets, a first stile, a second stile, a plurality of louvers. One embodiment also contains a jig to align the bracket with the header or footer for attachment. Each bracket is sized and configured to be connected to an end of the header or footer. The stiles each have a longitudinal channel which enables the stiles to be fitted over at least one of the brackets. The jig has a mouth sized to receive an end of the footer or header and a cavity adjacent the mouth such that a user of the jig can place one end of a bracket in the cavity and the other end of the header or footer in the mouth. The kit may be packaged in two packs. One pack contains a header, a footer and a plurality of brackets. The second pack contains mounting frame pieces, at least one first stile, at least one second stile, a plurality of louvers, louver strips, a tilt rod, screws and other hardware which can be assembled into a shutter panel having the desired dimensions. The header, footer, stiles and brackets are provided to a retailer in standard sizes. The retailer may then trim these components as required to create a shutter having the desired dimensions.