Window Covering Mounting Bracket With Rigid Housing and Spring Clip

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Solution Overview

Problem

Existing mounting brackets for window coverings are expensive to manufacture due to single-piece spring steel construction, which results in excessive flexibility and fatigue failure, and lack efficient disassembly mechanisms.

Innovation Solution

A two-piece or three-piece mounting bracket design, comprising a rigid molded plastic housing and a flexible spring steel clip, where the clip engages the housing to secure the head rail, allowing for easy assembly and secure locking, while the plastic housing provides structural support and the clip's flexibility enables easy disassembly without damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a single-piece spring steel bracket is used, then the bracket can provide both mounting and securing capabilities, but the manufacturing cost increases and the bracket experiences excessive flex and fatigue failure

Engineering Contradiction:

Improvebracket structureVSAvoidbracket durability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The bracket is divided into two separate components: a rigid plastic housing for mounting and a flexible metal clip for securing. This segmentation allows each component to be optimized for its specific function - the housing provides structural support while the clip provides flexible retention, eliminating the excessive flex and fatigue problems of single-piece spring steel brackets.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention combines two different materials - rigid plastic and flexible metal - into a composite bracket system. The rigid plastic housing provides dimensional stability and mounting strength, while the flexible metal clip provides elastic retention. This material combination resolves the contradiction by allowing each material to contribute its optimal properties rather than relying on a single material to perform all functions.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If a single-piece spring steel bracket is used, then the bracket can be manufactured as one component, but the manufacturing cost increases due to complex metalworking

Engineering Contradiction:

Improvebracket fabricationVSAvoidbracket design

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

By separating the bracket into a molded plastic housing and a stamped metal clip, the invention enables the use of simpler, more cost-effective manufacturing processes for each component. The plastic housing can be molded in high volumes, and the metal clip can be stamped from sheet metal, both of which are less expensive than machining or forming a complex single-piece spring steel bracket.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metal clip is designed as a simple, inexpensive component that can be easily manufactured and replaced if needed. Its simplicity allows for low-cost production through stamping or forming processes, making the overall bracket system more cost-effective despite the added complexity of having two components.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of operation

If a single-piece spring steel bracket is used, then the bracket can provide flexible retention, but the excessive flexibility causes fatigue failure

Engineering Contradiction:

Improveretention flexibilityVSAvoidbracket longevity

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The invention applies flexibility only where needed - in the metal clip that contacts the headrail - while maintaining rigidity in the plastic housing that provides mounting support. This localized flexibility allows the clip to accommodate installation variations and provide easy release, while the rigid housing prevents the excessive flexing that leads to fatigue failure in single-piece spring steel brackets.

Inventive Principle:

Principle #3Local quality

4Ease of manufacture

If a two-piece bracket design is used, then manufacturing costs are reduced and structural integrity is enhanced, but the assembly complexity increases

Engineering Contradiction:

Improveproduction costVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The metal clip is designed to snap onto the plastic housing in a simple, tool-free assembly process. The clip's elastic properties allow it to deform during assembly and then lock into place, creating a secure connection without requiring fasteners, welding, or complex joining operations. This merging of two simple components achieves the functionality of a complex single-piece bracket while maintaining ease of assembly.

Inventive Principle:

Principle #5Merging (Combining)

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 design reduces manufacturing costs, enhances structural integrity by minimizing 'give' in the bracket, and ensures secure mounting and easy removal of the head rail without damaging the bracket components, thus preventing accidental falls.

Implementation Method 1

The metal clip flexes momentarily during the head rail mounting process to allow the channel on top of the head rail to engage the rear projection on the plastic housing, and then the metal clip flexes back to lock the head rail in place

Methodology Applied

Scientific EffectElasticity: Elasticity