1

ALUMINUM BLINDS

ALCOA DESIGN PROJECT

EDSGN 100 | Section 10 | Group 5

Submitted By:

Michael Kontra mrk5397@psu.edu

Lachlan Blubaughlzb5227@psu.edu

Drew Buzzell deb5317@psu.edu

Mack Burgess mbb5177@psu.edu

Submitted To: Xinli Wu

4 December 2013

2

TABLE OF CONTENTS

1) Cover Page…………..………………………………………………………………………1

Author: Michael Kontra; mrk5397@psu.edu

2) Table of Contents…...…………………………………………………….………………..2

Author: Lachlan Blubaugh; lzb5227@psu.edu

3) Abstract……...…….…………………………………………………………………………3

Author: Michael Kontra; mrk5397@psu.edu

4) Introduction…………………………….……………………………………………………3

Author: Lachlan Blubaugh; lzb5227@psu.edu

5) Description of the Design Task…………………………………………………..……...4

A. problem statement

B. mission statement

C. design specifications

Author: Michael Kontra; mrk5397@psu.edu

6) Design Approach…………………………………………………………………………4-5

A. customer needs assessment

B. project management (Gantt Chart)

C. concept generation

D. design selection matrices

Author: Lachlan Blubaugh; lzb5227@psu.edu

7) The Final Design and Its Prototype…………………………….……….…..………5-12

A. prototype scale and digital images

B. design features

C. operation instructions

Author: Mack Burgess; mbb5177@psu.edu

8) Engineering Analysis…………………………………………………………………….12

A. Working mechanism

B. cost analysis

Author: Drew Buzzell; deb5317@psu.edu

9) Conclusion and Suggestions………………...………………………………………...13

Author: Drew Buzzell; deb5317@psu.edu

10) Acknowledgements……………………………………………………...………….13-14

Author: Drew Buzzell; deb5317@psu.edu

3

ABSTRACT

In this project, a comprehensive report of the given assignment may be found. Imbedded

in this report are descriptions of the task, design approach, final design of the prototype,

engineering analysis, and conclusion of the project. Additional acknowledgements and

references to outside sources may also be found after the conclusion.

INTRODUCTION

The students of Xinli Wu’s Engineering Design 100 class were given a problem in

society and asked to design the best solution to the problem. Throughout this project

each group went through the full design process from brainstorming to building and

presenting a prototype.

Once the problem was defined, research was conducted on the materials. With this

information, several design concepts were brought up in each group. Then a design

matrix was set up in order to eliminate four of the five designs considered. Upon arrival

of the strongest design, any last changes were made and detailed drawings of the most

crucial parts and a rough sketch of the assembly were drafted via solidworks. Using

these drawings, a working prototype was built . Once this prototype proved to be an

accurate showcase of the design, the solution was presented to the class.

DESCRIPTION OF THE DESIGN TASK

1) Problem Statement

The problem was that there existed multiple opportunities across the campus to take

advantage of aluminum’s intrinsic properties for the purpose of increasing the efficiency

or sustainability of Alcoa’s products and product systems that had not yet been

implemented into the campus; Alcoa sent students out to find these opportunities, and

create a product abiding by the aforementioned process.

2) Mission Statement

The objective of the project was to either create or modify a product that will encourage

and contribute to sustainability across campus; it was decided that a modification of a

certain product - namely blinds - would prove to be more beneficial, seeing as many of

the most effective ideas have already been implemented across campus. It was also

decided that a couple of aluminum’s properties - namely low cost and heat transferring -

would be taken advantage of as well.

3) Design Specifications

a) Must either improve efficiency of an existing product on campus, or exist as a

separate, unique product.

b) Must take advantage of aluminum’s intrinsic properties

c) Must show originality, creativity, and innovation inherent in the creators

d) Must be able to be easily implemented on campus

4

DESIGN APPROACH

A)Project Management

At the start of this project, the team outlined a schedule for when certain parts of this

process should be completed. A Gantt chart was used to lay out the schedule.

Smaller objectives were handed out to individual team members in order to make things

run smoothly and efficiently. This allowed people to work on the project outside of class

and around their respective work schedules. Taking time to do this saved hours in the

long run.

B) Concept Generation

Because this project addresses such a broad issue that has been dealt with by many

engineers and scientists, the team took a lot of time trying to come up with something

that hasn’t already been created or designed. In fair time, a concept involving the

integration of aluminum in common blinds came about.

C) Design Selection

The main selection process was for what shape of blinds to use with this concept. The

group experimented with straight, venetian, and honeycomb blinds. In the end, venetian

blinds were the most efficient and versatile.

5

Working Drawings and Digital Images

FIG. 1. working drawing

6

FIG. 2. Blind slat, aluminum up

FIG. 3. Blind slat, black up

7

FIG. 4. Aluminum side facing window

FIG. 5. Black side facing window

FIG. 6. Horizontal configuration

8

FIG. 7. Prototype CAD model

Prototype

9

FIG. 8.

The prototype (Fig. 8.) was designed for

ease of use in showing the design concept

as well the ability to effectively gather data.

The blind leaves (FIG. 8.1) where

constructed with aluminum foil on the

concave side, and the convex side was

painted black.

Fig. 8.1

10

Fig 9.

FIG 9.1

When the idea of multi material blinds was

first considered, a preliminary prototype

(FIG. 9. and FIG. 9.1) was created to

ensure the idea was practical.

FIG. 10. Internal temperature

measurement

One of the main features of our prototype is

the ability to measuring the internal

temperature with an infrared thermometer

(Fig. 10.)

FIG. 11. Aluminum side out

FIG. 12. Black side out

The prototype can be locked in two different

configurations: aluminum facing out (FIG.

11.), or black facing out (FIG. 12.).

FIG. 13. Horizontal

The blinds rest horizontally when not in one

of the other configurations (FIG. 13.).

11

FIG. 14. Blinds drawn up.

FIG. 15. Top of Prototype

Final Design

Our final design is a variant of venetian blinds with aluminum on the concave side and a

black surface on the convex side. The blinds are able to improve the efficiently of both heating

and cooling a building. When the aluminum side is facing the window the blinds help to keep the

room cool. This is achieved by reflecting the thermal energy from the sun out the window. This

helps to reduce the cost of cooling a building in the summer. When the aluminum side is facing

the interior radiant thermal energy is reflected back into the room, and the black side of the

12

blinds form a insulating layer with the window. Unlike traditional venetian blinds, our design has

the concave side of the leaves facing upwards. This improves the efficiently with witch thermal

energy is reflected out the window. By utilizing the reflective properties of aluminum, energy will

be saved year round.

Operation Instructions

To decrease heat lost during the winter position the blinds with the aluminum facing in.

To reduce heat absorbed in the summer position the aluminum side facing the window

Engineering Analysis

A) Working Mechanism The two sides of the blinds are made to either cool or insulate a room. The aluminum side is used to cool. It does this by reflecting light and heat from the sun. When the black side of the blind is facing outward it absorbs light and heat as well as act as an insulating layer between the blinds and the room.

B) Cost Analysis

The cost of the blinds comes from its three components; a black coating, an aluminum coating, and the venetian blinds. A set of venetian blinds can cost as little as $11 for a reasonably sized window. In order to cover a set of venetian blinds about 12 oz of paint was used which can cost $5. Aluminum is $.80 per pound and would be applied by chemical vapour deposition, which is a cheap process. In all the blinds could cost as little as $20 to manufacture. Use of the design saves money by reducing the energy spent controlling the temperature of a room. If installed in all the dorms on campus it is thought to save almost $2,000,000 in energy cost.

Table 1. Wattage Saved

13

Conclusion

The prompt given by Alcoa was solved through the design of aluminum blinds. These blinds are

coated in aluminum on one side and black paint on the other. It creates a more sustainable

campus by reducing energy consumption by passively altering the temperature of an

environment. The design is cheap while saving a lot of money overtime.

References

"Aluminium alloy." Wikipedia: The Free Encyclopedia. 10 Dec. 2013, Invalid Date. . Wikimedia

Foundation, Inc. 10 Dec. 2013. http://en.wikipedia.org/wiki/Aluminium_alloy\

"Aluminum metal property & uses: production, transformation & recycling." 10 Dec. 2013

http://www.constellium.com/aluminium-company/aluminium-properties-and-uses

"SEDTAPP - Engineering Design Program - Client-Centered Design." 10 Dec. 2013

http://sedtapp.psu.edu/design/design_projects/edsgn100/fa13/materials.html

eFunda, Inc., "eFunda: The Ultimate Online Reference for Engineers." 10 Dec. 2013

http://www.efunda.com/home.cfm

"What Penn State Can Do." 10 Dec. 2013 http://sustainability.psu.edu/live/penn-state

"Our Energy Future." 10 Dec. 2013 http://sustainability.psu.edu/our-energy-future

"Alcoa Sustainability Report, Corporate Social Responsibility." 10 Dec. 2013

http://www.alcoa.com/sustainability/en/home.asp#

"Aluminum >> Conductivity." 10 Dec. 2013

http://sam.davyson.com/as/physics/aluminium/siteus/conductivity.html

"Top Three Energy Efficient Blinds | Treatment Window." 10 Dec. 2013

http://treatmentwindow.com/top-three-energy-efficient-blinds/

"Energy Savings Window Blinds - Energy Efficient Shades from Blinds Chalet." 10 Dec. 2013

http://www.blindschalet.com/energy.aspx

"High Performance Verosol | North Solar Screen." 10 Dec. 2013

http://northsolarscreen.com/indoor-shades/high-performance-verosol/

"Measuring for thermal blinds for sash windows." Times Online. 10 Dec. 2013. Times Online. 10

Dec. 2013 http://thermalblind.co.uk/business/sash-windows/

14

"Readily customizable blind set - Lee, Han-sen." 10 Dec. 2013

http://www.freepatentsonline.com/6758257.html

"QIAKON." 10 Dec. 2013 http://www.qiakon.com/en/ProductShow.asp?ID=141

"How to Cut Energy Costs with Window Coverings - For Dummies." 10 Dec. 2013

http://www.dummies.com/how-to/content/how-to-cut-energy-costs-with-window-coverings.html

"Never paint again - Liquid Vinyl Siding - The ultimate exterriorcoating !" 10 Dec. 2013

http://www.lifetimecoating.com/

"PVC Vertical Blinds - PVC Blinds." 10 Dec. 2013 http://www.pvcblinds.info/pvc-vertical-

blinds.html