Sunshade Outriggers with Integrated Mounting Notches

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Solution Overview

Problem

Existing sunshade installation methods face challenges such as misalignment, cumbersome bolt engagement, and difficulty in handling spacers, leading to inefficient and potentially unsafe installation processes, as well as issues with anodized aluminum outriggers not matching other sunshade components and the need for precise machining of pressure plates.

Innovation Solution

The design includes elongated outriggers with upper and lower legs, a spacer system for easy alignment and handling, and a connector mechanism to maintain sunshade alignment, along with extruded aluminum components for consistent anodizing and simplified installation, using a method that allows for secure fastening and alignment without requiring precise machining of pressure plates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If plate material outriggers are used with fasteners, then the sunshade units can be attached to anchor clips, but the fasteners become exposed and the alignment process becomes difficult due to slipping

Engineering Contradiction:

Improveattachment strengthVSAvoidalignment ease

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent uses extruded aluminum components for both the outriggers and the sunshade units, creating a homogeneous material system that provides consistent friction and grip characteristics throughout the assembly, eliminating the need for spacers and improving alignment

Inventive Principle:

Principle #33Homogeneity

Solution Approach 2:

The patent removes the spacer component entirely by designing the outriggers to interface directly with the anchor clips through integrated mounting features, eliminating the need for intermediate spacing elements and simplifying the assembly process

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If spacers are used between adjacent sunshade units, then the outriggers can be fastened to anchor clips, but the spacers are difficult to handle and maintain in proper position during installation

Engineering Contradiction:

Improvefastening capabilityVSAvoidhandling ease

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The patent combines the spacing function and the mounting function into a single integrated extruded aluminum outrigger component, eliminating the need for separate spacers and anchor clip assemblies, thereby simplifying handling and installation

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The extruded aluminum outrigger serves multiple functions simultaneously: it provides structural support, maintains spacing between units, enables fastening to anchor clips, and facilitates alignment, replacing multiple separate components with a single multi-functional element

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Shape

If extruded aluminum components are used, then consistent anodizing and visual appearance are achieved, but the components must be designed with specific extrusion geometries

Engineering Contradiction:

Improvevisual consistencyVSAvoidextrusion geometry complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent divides the sunshade system into modular extruded aluminum components (outriggers, sunshade units, anchor clips) that can be manufactured independently through extrusion processes, allowing for standardized production while maintaining visual consistency through uniform material and finish

Inventive Principle:

Principle #1Segmentation

4Measurement precision

If pressure plates are machined for precise mounting, then accurate positioning is achieved, but the machining process increases complexity and potential for error

Engineering Contradiction:

Improvepositioning accuracyVSAvoidmanufacturing simplicity

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical machining processes with extrusion manufacturing, where precise positioning features are created through the extrusion die set rather than post-manufacturing machining, simplifying the manufacturing process while maintaining positioning accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent incorporates positioning features directly into the extruded components during manufacturing, performing the positioning function in advance rather than requiring subsequent machining or adjustment operations, thereby eliminating potential sources of error

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS8490339B2Sunshades

Publication Date: 2013.07.23 YKK AP AMERICA INC

AI summary

A sunshade for mounting to a building structure has first and second extruded outriggers spaced apart from each other and louvers extending from the first outrigger to the second outrigger. The first and second outriggers have an elongated body, an upper leg extending from an upper portion of the elongated body, and a lower leg extending from a lower portion of the elongated body. The outriggers of adjacent sunshades face each other such that the upper legs face each other and the lower legs face each other. A pocket is formed between the adjacent outriggers. The outriggers also have a mounting notch at an end which is mounted to the building structure. The outrigger notch engages a hook on a sunshade anchor mounted to the building structure.