Patent Application
20240301686
This application relates generally to the field of roll-drop curtain assemblies, and, more particularly, to a roll-drop curtain assembly having enhanced stability for supporting curtains of a variety of materials while maintaining structural integrity, shape, and form of the overall assembly.
Roll-drop curtain assemblies are commonly used in the field of theater and performance venues in order to provide a visual barrier between the stage and audience that can be deployed or retracted as desired. Additionally, roll-drop curtain assemblies may have applications for use as temporary privacy dividers for large event spaces, such as ballrooms, gymnasiums, or the like. Roll-drop assemblies may also be used to support vinyl, plastic, or fabric materials which can be deployed for use as projection screens, advertising graphics, or the like. Typically, a roll-drop assembly consists of a roll of fabric, vinyl, or other rollable, pliable, or foldable material, which can be rolled around, or unrolled from, a drum assembly, thereby allowing a user to either raise or lower (retract or deploy) the material at their convenience. In some cases, roll-drop assemblies may include a power source and a motor which actuate the drum attached to a fabric or curtain material, whereby the rotating movement of the drum acts to wrap or unwrap the fabric or curtain material in order to raise or lower a rolled material relative to a floor surface. In either a retracted or deployed state, it is known that heavy fabrics or other pliable materials may place concentrated strain on portions of the roll-drop assembly, drum, outer housing, end point connections, or various other supporting means or components of the assembly. In addition, the weight of the housing, internal components, or the like, of the roll-drop assembly may cause the assembly to sag or bend over time if it can only be mounted at two distal end points.
In order to maintain a pleasant visual appearance of the rolled and unrolled material, reduce concentrated wear on specific portions of the roll-drop assembly, and ensure structural stability overall, there is a need for an improved system and method for ensuring the structural integrity of roll-drop assemblies such that the assembly maintains a flat, parallel disposition with respect to the floor, ground, ceiling, or the like, across the entire length and width of the roll-drop assembly. An ideal solution would not substantially increase the weight or size footprint of the roll-drop assembly by nature of this reinforcement.
In light of the needs described above, according to a broad aspect of an embodiment of the present invention, described herein is an improved system and method for structurally enhanced roll-drop stability assembly. The structurally enhanced roll-drop stability assembly, or “assembly,” as referred to throughout this disclosure, includes a reinforced drum and housing structure comprised of a series of concentric pipes, tubes, bars, tension cables, and other components used to support the structural integrity of the assembly in order to ensure that it remains substantially rigid, and in ideal embodiments, completely rigid, under heavy loads. It is noted that while “cables” are referred to throughout this disclosure, one of ordinary skill in the art will appreciate that other means of providing tension to the assembly are contemplated, including wires, ropes, or the like.
Conventional solutions take multiple approaches to designing a roll-drop assembly that retains structural integrity and shape under heavy loads; however, each of these approaches has been shown to have significant drawbacks. For instance, conventional systems may include using thicker, heavier materials for the drum assembly, which adds complexity and risk to the installation of the assembly and requires additional support above or around the assembly in order to ensure safety. Additionally, the increased cost of obtaining drum housings with thickness and material specifications required to achieve complete rigidity may be prohibitive, as these components may involve custom specifications which are not produced on a mass scale or are not otherwise widely available. In other embodiments, conventional drum assemblies may include additional external supports, external clamps, or the like, or various stiffeners, hanger attachments, or protrusions which attempt to keep the drum assembly from sagging under heavy loads. Again, these components frustrate the installation process and cause undue complexity to the operation and maintenance of the assemblies, in addition to the obvious drawback of added cost due to additional material. As such, the majority of conventional solutions introduce added material cost, weight, and size to the overall assembly structure. There is a need for a solution that acts to reinforce the drum assembly of a roll-drop structure in such a way that is contained within the footprint of a conventional roll-drop assembly, utilizes readily available and relatively low-cost materials, and does not require the use of many additional external components, fasteners, supports, or the like, which add weight to the assembly and/or increase its overall footprint to an extent that would make it incompatible with some venues or otherwise draw attention in an unseemly fashion.
The improved roll-drop assembly of the present invention offers multiple benefits with respect to conventional roll-drop assemblies and solutions. For instance, the reinforced system described herein substantially reduces, or completely eliminates, the amount that the roll-drop assembly bends, sags, or bows due to a heavy weight of material raised or lowered by the roll-drop assembly, effectively ensures that the assembly remains safe to use for a longer period of time by reducing premature wear on specific portions of the assembly due to repeatedly bending and relaxing metal components, results in a more even power demand for motorized components, and also ensures that the material of the curtain (or other raised or lowered material) is not wrinkled or damaged during rolling or unrolling due to bunching or sagging around the drum. This also results in a more pleasing appearance of a deployed curtain or fabric material on a consistent basis. As described throughout the disclosure, the primary means for achieving the improved stability of the roll-drop assembly of the invention is the use of specifically selected cables connected to either end of the roll-drop assembly within the interior of the assembly itself. The cables are placed in a specific manner and tensioned to a specific degree of force, thereby providing an even tension across an inner tube of the roll-drop assembly and preventing the assembly from sagging, bending, or bowing across its length. Additionally, due to the nature of the reinforcing components being placed within the housing of the assembly, the overall footprint of the assembly remains unchanged in ideal embodiments. By utilizing cables with a high degree of tensile strength relative to their weight and size, the overall weight of the assembly is also not significantly increased relative to conventional assemblies. Thus, the present invention can be retrofitted in locations where existing roll-drop assemblies may already be in place, provides the benefit of increased structural integrity and capacity for heavier loads, and achieves both goals while remaining price-competitive to conventional systems.
As such embodiments of the invention relate to a system and method for a structurally enhanced roll-drop stability assembly, the invention generally comprising: a housing structure extending longitudinally and having opposing distal ends comprising end plates; a rotatable drum located within the housing structure for winding and unwinding the flexible sheet material; anchoring means located at or near each of the distal ends of the housing structure; one or more stabilizing members within the housing structure arranged to maintain the structural integrity of the roll-drop assembly; and a plurality of tensile members connected to the anchoring means and configured to provide tension across the housing structure, wherein the tensile members interact with the stabilizing members to prevent sagging and deformation.
In some embodiments, the tensile members comprise adjustable cables, wherein adjusting the adjustable cables varies tension across the housing structure of the roll-drop assembly system.
In some embodiments, the invention further comprises a tension adjustment mechanism operably connected to the tensile members for selectively increasing or decreasing tension force.
In some embodiments, the guide assemblies further include openings through which the tensile members are threaded.
In some embodiments, the anchoring means include plates with apertures configured for securing ends of the tensile members.
In some embodiments, the housing structure is cylindrical and the guide ring assembly is configured to provide concentric support within the housing structure.
In some embodiments, the flexible sheet material is selected from the group consisting of: fabric, vinyl, plastic, and composite materials.
In some embodiments, the guide ring assembly further comprises additional supporting material attached to a circular edge via one or more spokes, the one or more spokes.
In some embodiments, the end plate is positioned on the interior recesses of the assembly and constructed from a material selected from the group consisting of steel, titanium alloys, and anodized aluminum, with a surface treatment for corrosion resistance.
In some embodiments, the guide ring assembly is operatively coupled to the interior wall of the housing structure at a midpoint with respect to the longitudinal axis.
To the accomplishment of the foregoing and the related ends, the one or more embodiments of the invention comprise the features hereinafter fully described and particularly pointed out in the claims. The following description and the annexed drawings set forth certain illustrative features of the one or more embodiments. These features are indicative, however, of but a few of the various ways in which the principles of various embodiments may be employed, and this description is intended to include all such embodiments and their equivalents.
The foregoing and other advantages and features of the invention, and the manner in which the same are accomplished, will become more readily apparent upon consideration of the following detailed description of the invention taken in conjunction with the accompanying drawings, which illustrate embodiments of the invention and which are not necessarily drawn to scale, wherein:
Embodiments of the present invention may now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure may satisfy applicable legal requirements. Like numbers refer to like elements throughout.
Also, it will be understood that, where possible, any of the advantages, features, functions, devices, and/or operational aspects of any of the embodiments of the present invention described and/or contemplated herein may be included in any of the other embodiments of the present invention described and/or contemplated herein, and/or vice versa. In addition, where possible, any terms expressed in the singular form herein are meant to also include the plural form and/or vice versa, unless explicitly stated otherwise. Accordingly, the terms “a” and/or “an” shall mean “one or more.”
It should be understood that “operatively coupled,” or “operatively connected” when used herein, means that the components may be formed integrally with each other, or may be formed separately and coupled or connected together. Furthermore, “operatively coupled” or “operatively connected” means that the components may be formed directly to each other, or to each other with one or more components located between the components that are operatively coupled or connected together. Furthermore, “operatively coupled” or “operatively connected” may mean that the components are detachable from each other (e.g., via a lock and pin arrangement, a bolt-on arrangement, or the like), or that they are permanently or semi-permanently coupled together (e.g., welded, bonded, riveted, bolted, screwed-on, or the like).
It should be understood that “tension force” when used herein, refers to the mechanical force applied along the length of the tension cables, which is measured in pounds or newtons, and is used to maintain the structural integrity of the roll-drop assembly by preventing sagging and bending under the weight of the deployed material.
It should be understood that “load bearing capacity” when used herein, describes the maximum weight or force that the roll-drop assembly can support. In some embodiments, “load bearing capacity” specifically refers to the maximum weight or force that the roll-drop assembly can support without experiencing deformation, failure, or loss of structural integrity, as determined by the materials used, design of the assembly, and the configuration of its components, or the like.
It should be understood that “guide ring assembly” when used herein, refers to the component or series of components within the roll-drop assembly that serves to direct, position, and maintain one or more tension cables in a manner that promotes even distribution of tension forces throughout the system.
It should be understood that “structural rigidity” when used herein, refers to the ability of the roll-drop assembly to maintain its shape and resist deformation under stress, which is achieved through the use of materials, design considerations, and the application of tension forces that prevent bending and flexing.
It should be understood that “anchoring point” when used herein, denotes a specific location or component on the roll-drop assembly where tension cables are securely fastened in order to apply and maintain tension force, which is critical for the assembly's stability and operation, or the like.
It should be understood that “friction interaction” when used herein, relates to the contact forces that resist the relative motion between components of the roll-drop assembly, such as between the tension cables and the guide ring assembly, which are engineered to be minimal to reduce wear and prolong the lifespan of the assembly.
It should be understood that “corrosion resistance” when used herein, refers to the property of materials used in the roll-drop assembly to withstand degradation caused by environmental factors such as humidity, temperature fluctuations, and exposure to chemicals, which is essential for maintaining the assembly's durability and functionality over time.
It should be understood that “adjustment mechanism” when used herein, pertains to the system or method implemented within the roll-drop assembly that allows for the precise setting and alteration of the tension force applied by the tension cables, which is key for customizing the assembly's performance based on specific load requirements.
It should be understood that “wear and corrosion” when used herein, are terms that describe the deterioration and degradation processes affecting the roll-drop assembly components, where “wear” refers to the mechanical erosion from regular use, and “corrosion” pertains to the chemical breakdown of materials, both of which are mitigated through material choice and design to ensure long-term reliability of the assembly.
As further shown in
It is understood that the guide ring assembly 108 may be one or more “puck-like” ring components that are operatively coupled to the interior wall at the midpoint of the outer housing 102 with respect to axis 1-1. The selection of materials for the guide ring assembly 108, be it polymer or metal, is based on a comprehensive analysis of tension dynamics, ensuring long-term resilience of the assembly under cyclic loading conditions. It is understood that the guide ring assembly 108 may be constructed of any suitable material required to withstand the tension force strength of tension cables 106. In some embodiments, the guide ring assembly may be constructed from a polymer material. In other embodiments, the guide ring assembly 108 may be constructed from a metal material, depending on the specifications and requirements of the location where the assembly 100 will be installed. In some embodiments, the metal material of the guide ring assembly 108 undergoes a surface treatment process such as galvanization, anodizing, or powder coating, to enhance its corrosion resistance, ensuring longevity even in environments with high humidity or corrosive elements. Additionally, to facilitate minimal friction interaction with the tension cables 106, the metal surfaces that come into contact with the cables may be machined to a smooth finish and treated with a low-friction coating such as Teflon (PTFE) or a suitable lubricant-infused material, which preserves the integrity of the cables and contributes to the overall smooth operation of the assembly. The one or more metal rings of the guide ring assembly 108 contain multiple circular openings which allow for the one or more tension cables 106 to be fed through the guide ring assembly 108. In the embodiment depicted in assembly 100, there are two tension cables 106: (1) a first tension cable 106 which is attached to the bottom left-hand distal end portion of the assembly 100, feeds up through the top of the guide ring assembly with respect to vertical axis 2-1, and transverses down from the midpoint section, where the guide ring assembly 108 is located to terminate at the bottom right-hand distal end portion of the assembly 100; and (2) a second tension cable 106 which is attached to the upper left-hand distal end portion of the assembly 100, feeds down through the bottom of the guide ring assembly 108 with respect to vertical axis 2-1, and transverses up from the midpoint section, where the guide ring assembly 108 is located, in order to terminate at the upper right-hand distal end portion of the assembly 100. This strategic placement and orientation of the tension cables 106 create a balanced, symmetrical tension system that enhances the structural rigidity and stability of the assembly. In order to achieve a tension force outward on the inner surface of the assembly 100, the tension cables are tightened from either end of the assembly 100 in order to achieve a desired tension force that acts on the guide ring assembly 108. The tensioning process involves precise force measurements to ensure uniform tension distribution and optimal structural integrity. It is understood that the number of tension cables 106 may vary according to each embodiment. For instance, in some embodiments, there may exist four or more separate cables terminating equidistant from one another around the concentric circular portion of either distal end of the assembly 100. It is understood that these additional tension cables 106 can be added to accommodate larger assemblies or those intended to support heavier materials without compromising stability.
As further indicated in
In some embodiments, the operator may use the hydraulic pull testing assembly 201 to apply tension force by means of twisting a turning handle with integrated nut on the hydraulic pull testing assembly 201. The turning handle is ergonomically designed for ease of use, allowing for precise adjustment of the tension force without requiring excessive physical effort from the operator. The tension force applied to the tension cable 106 is measured using a digital gauge of the hydraulic pull testing assembly 201. This gauge provides an accurate and easily readable tension measurement, facilitating precise calibration of the tension cables. In some embodiments, each tension cable 106 is tensioned to at least 2,500 pounds of tension force; however, it is noted that, depending on the size of the assembly 100, the materials used for the assembly 100, or the curtain material supported by the assembly 100, a different tension force may be desired in other embodiments. The capacity to adjust the tension force is a critical feature, allowing the system to be tailored to a wide range of materials and environmental conditions. As noted, in other embodiments, the end plate 206 may be positioned inside the assembly 100. In such cases, one or more of the tension cables 106 may first be securely attached to the end plate 206, and the end plate 206 may then be pulled back toward the end of the hydraulic pull testing assembly 201 in order to increase the tension on the tension cables 106 to a desired force. This internal positioning of the end plate 206 also serves to protect the tensioning mechanism from external environmental factors that could impact performance. A slightly wider orthographic perspective view is shown in
The isometric perspective of
While certain exemplary embodiments have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that this invention not be limited to the specific constructions and arrangements shown and described, since various other changes, combinations, omissions, modifications and substitutions, in addition to those set forth in the above paragraphs, are possible. Those skilled in the art will appreciate that various adaptations, modifications, and combinations of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
This application is a non-provisional application of and claims priority to U.S. Provisional Application No. 63/451,130, filed on Mar. 9, 2023, the contents of which are also incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63451130 | Mar 2023 | US |
