Trough Shade System Floating Roller Tube Support
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Solution Overview
Problem
Conventional shade systems face challenges in deploying larger areas of shade fabric without causing the support tube to bow or the fabric to wrinkle, leading to increased weight and cost due to the need for larger or stronger tubes or reduced fabric usage.
Innovation Solution
A trough shade system that includes a support cradle with a floating plate allowing the roller tube to move in a limited range along both vertical and horizontal axes, minimizing deflection and wrinkling through independent movement channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If larger diameter, thicker, and/or stronger support tubes are provided to avoid bowing, then the support tube strength is improved, but the weight and cost of the shading system increase
Solution Approach 1:
The patent introduces a dynamic support system where the roller tube can move vertically along the support tube through a floating mechanism with channels. This allows the support system to adapt dynamically to the changing weight distribution as shade fabric is deployed or retracted, preventing bowing without requiring a heavier static support structure
Solution Approach 2:
The patent changes the operational parameters of the support tube by allowing vertical movement of the roller tube within a controlled range. This parameter change enables the support tube to maintain optimal positioning and reduce deflection under varying loads, eliminating the need for oversizing the support tube
2Strength
If larger diameter, thicker, and/or stronger support tubes are provided to avoid bowing, then the support tube strength is improved, but the cost of the shading system increases
Solution Approach 1:
The dynamic floating support mechanism allows the roller tube to move vertically along the support tube, adapting to changing load conditions. This dynamic adjustment prevents bowing and fabric wrinkling without requiring expensive, oversized support tubes, thereby reducing manufacturing costs
Solution Approach 2:
By allowing the roller tube to move vertically within a controlled range along the support tube, the system changes its operational parameters to maintain optimal support conditions. This parameter change enables the use of standard-sized, cost-effective support tubes while still preventing bowing
3Stability of the object's composition
If the amount of shade fabric is reduced to avoid tube bowing, then the support tube deflection is reduced, but the shaded area decreases
Solution Approach 1:
The floating mechanism with vertical channels allows the roller tube to move dynamically as shade fabric is deployed or retracted. This maintains optimal alignment and tension distribution, enabling full deployment of large amounts of fabric without causing tube bowing or fabric wrinkling
Solution Approach 2:
The system changes the vertical position parameter of the roller tube along the support tube to accommodate varying fabric weights. This parameter adjustment maintains stable support conditions, allowing maximum fabric area to be deployed without compromising tube stability
4Stability of the object's composition
If the roller tube is constrained to prevent movement, then the support stability is improved, but the fabric wrinkling increases due to inability to accommodate weight changes
Solution Approach 1:
The floating mechanism with vertical channels provides controlled movement freedom, allowing the roller tube to adjust its vertical position dynamically. This maintains fabric tension and smoothness while preserving overall support stability, preventing both excessive constraint and uncontrolled movement
Solution Approach 2:
The system allows the vertical position parameter of the roller tube to change within a controlled range defined by the channel length. This parameter flexibility accommodates weight changes from deployed fabric, maintaining fabric smoothness while preserving support stability through the floating mechanism
Data Source
AI summary
A trough shade system and method of use provide improved support for a roller tube and shade material. The roller tube and wound shade material are located within a support cradle to minimize unwanted deflection by the roller tube and associated wrinkling and deformation of the shade material. Various mechanisms allow the roller tube a limited range of movement within the support cradle. The system is suitable for shading larger areas than other shading systems which rely on roller tubes with fixed supports at the ends.