Tool-Free Accessory Kit for Curb-Mounted Skylight Shades
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Solution Overview
Problem
Existing skylight installations face challenges in controlling daylight, particularly due to difficulties in selecting and installing mounting hardware for screening devices like blinds or shades, especially in tight skylight frames and at elevated heights, where there is a lack of suitable interior surfaces for attachment and complex assembly processes.
Innovation Solution
An accessory kit comprising interlocking accessory frame members, corner keys, brackets, and flexible gaskets that can be assembled tool-free on-site, allowing for easy installation of various accessories such as blinds or shades, with components designed to fit exact skylight dimensions and shipped in separate pieces for cost-effective handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting hardware and assembly methods are used for screening devices in skylights, then secure mounting can be achieved, but installation becomes complex and requires tools, especially in tight frames and at elevated heights
Solution Approach 1:
The accessory frame is divided into multiple separate members that can be shipped individually and assembled on-site. This segmentation allows for easier handling and installation without requiring complex pre-assembled structures, directly addressing the issue of installation complexity while maintaining secure mounting through the interlocking corner keys
Solution Approach 2:
Corner keys are introduced as intermediary components that facilitate the connection between frame members. These corner keys with detents provide a simple, tool-free interlocking mechanism that replaces complex traditional mounting hardware, enabling secure assembly without requiring tools or specialized installation procedures
2Ease of operation
If accessory frame components are shipped assembled, then installation is simpler, but shipping costs increase and handling becomes more difficult
Solution Approach 1:
The accessory frame components are shipped in a segmented, disassembled state rather than pre-assembled. This reduces the volume required for shipping and makes handling more efficient, while the components are designed to be easily assembled on-site using the corner keys with detents, maintaining installation simplicity without the penalties of shipped assembly
3Object-affected harmful factors
If screening devices are installed in tight skylight frames, then daylight control is effective, but access for installation becomes difficult
Solution Approach 1:
The corner keys are designed with self-locking detents that automatically engage when frame members are brought together. This self-service mechanism eliminates the need for complex fastening operations that would be difficult to perform in tight spaces, allowing installers to easily assemble the frame even when access is limited, while still achieving effective daylight control through the fitted screening device
Data Source
AI summary
Provided herein is an accessory kit for a curb-mounted skylight, including accessory frame members, corner keys, brackets, and an accessory. The frame members, which may have mitered ends, are sized to the dimensions of the skylight opening and are configured to interlock with a corner key element to form an accessory frame. The corner keys are configured to join the frame members at their respective mitered ends and include at least one detent for interlocking with a portion of the accessory frame member. Brackets are also provided for holding an accessory within the accessory frame, and an accessory (for example, blinds or a shade) having end portions complementary to the brackets is also included herein. The accessory kit may further comprise a flexible gasket. The kit may be shipped in an unassembled form and be assembled on-site without the need for tools.