Roller Shutter Slat Coupling Tabs for Secure End Locking
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Solution Overview
Problem
Existing roller shutter slats face issues with unstable and insecure coupling between the coupling appendage and hollow seat, which can lead to slat disengagement and compromise functionality, and require additional components or modifications to the external face for securement, affecting both functionality and aesthetics.
Innovation Solution
The slat design incorporates a coupling cavity with transverse notches forming tabs that are bent to close the cavity ends, ensuring secure locking without altering the external face, using a manufacturing process that integrates these features into the production of the slat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the hollow seat is deformed to close the cavity ends and lock the coupling appendage, then the coupling stability is improved, but the external face of the slat is modified affecting aesthetics
Solution Approach 1:
The hollow seat is segmented into a body portion and separate end portions that are deformable. The end portions can be independently deformed to close the cavity ends without affecting the external face, while the body portion maintains its original aesthetic appearance. This segmentation allows the locking function to be separated from the visible surface.
Solution Approach 2:
The deformation is localized to specific end portions of the hollow seat rather than the entire structure. These end portions are specifically designed to be deformable while the main body and external face portions maintain their original shape and appearance. This local quality change enables secure locking without compromising overall aesthetics.
2Reliability
If end caps are used to retain the coupling appendage inside the hollow seat, then the coupling stability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The locking function previously requiring separate end cap components is merged into the hollow seat structure itself. The end portions of the hollow seat are designed to be deformable and can directly perform the retention function, eliminating the need for additional end cap components and simplifying the overall device structure.
Solution Approach 2:
The hollow seat structure provides its own locking and retention function through the deformability of its end portions, without requiring external end caps. The structure serves itself by incorporating the retention mechanism directly into the hollow seat body, reducing component count and manufacturing complexity.
3Reliability
If the hollow seat is deformed to close the cavity, then the coupling stability is improved, but the manufacturing process complexity increases
Solution Approach 1:
The hollow seat is pre-formed during the extrusion process with the end portions in an open state. The deformation to close the ends is performed as a preliminary action during the manufacturing process itself, rather than as a separate post-processing step. This integration of the closing action into the extrusion process maintains manufacturing simplicity while achieving secure locking.
Solution Approach 2:
The manufacturing process utilizes changes in the physical state and properties of the material during extrusion. The end portions are designed with specific material properties that allow them to be deformed and locked in place during the extrusion process itself, rather than requiring separate deformation steps after manufacturing. This parameter change approach simplifies the overall production process.
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 provides a stable and secure coupling without modifying the external appearance, enhancing the shutter's functionality and aesthetics while being cost-effective and simple to produce.
Implementation Method 1
two tabs (25, 26) obtained on said second appendage (22) near the two opposite longitudinal ends (10', 10'') of said elongated body (10)... Each tab (25, 26) is designed to be bent against the first appendage (21) so as to close the coupling cavity (20)
Data Source
Figure 1
Figure 2~3a
Figure 4~5
AI summary
The present invention concerns a slat (1) for roller shutters, comprising an internally hollow elongated body (10) which extends along a longitudinal direction (X) and comprises a first face (10e) and a second face (10i), opposite the first, which in use are designed to be turned respectively towards the outside and inside of the compartment closed by the shutter of which said slat is designed to be part. The elongated body comprises: - a coupling cavity (20) which is obtained along a first longitudinal edge (11) of said elongated body and is delimited by a first appendage (21) of the elongated body obtained on the first face (10e) and by a second appendage (22) of the elongated body obtained on the second face (10i); and - a coupling appendage (30) which extends from a second longitudinal edge (12) of said elongated body. The coupling appendage has a longitudinal extension (L1) that is smaller than the longitudinal extension (L2) of the elongated body so as to define two recesses (15, 16) at the ends of the second longitudinal edge (12). The slat comprises two notches (24', 24") which are obtained on said second appendage (22) near the two opposite longitudinal ends of said elongated body and extend transversely to said first longitudinal edge. The two notches define, on said second appendage (22), a first tab (25) and a second tab (26) which are respectively placed at the two opposite longitudinal ends of said elongated body. Each tab is in a transversely opposite position to one of said two recesses and has a longitudinal extension equal to or less than the respective recess. In use each tab is designed to be bent against said first appendage so as to close the coupling cavity at the two opposite longitudinal ends of the elongated body, once the coupling appendage (30) of an adjacent slat has been inserted into the coupling cavity with the respective recesses placed at the tabs. The first appendage (21) develops continuously from one end of the elongated body.