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Class A Opening Roof (Benefits (Technically (Better seal/ overlapping/ no…
Class A Opening Roof
Benefits
Improved acoustic insulation performance + 4Db (estimated)
Cleaner aesthetic
Slightly increased reverb time over felt roof +0.1 sec but better quality flutter
Relatively low total capex especially straight variants
Class A Fire Solution ASTM E84
Improved Quality
Straighter blades/ less or no bow
Improved supply chain using established and proven supplier
Extruded design makes it easier to translate to other pods being simple cut lengths
Less or no light gaps increases perceived quality
More consistent finish quality using textured paint
Improved blade costs and scale of economy utilising single extrusion
Potential to tighten up tolerances
Quality
Full ownership at ABL
Complete finished unit to Hengoed (less damage and handling)
Aesthetics
Crisper
Design freedom in terms of texture and finish
Lighter colour roof
Cleaner end detail
Technically
Better seal/ overlapping/ no gaps or minimal gaps
Rigid structure
Improved insulation
Potential to fill with rockwool to control cavity resonance
Potential to retro fit/ add absorbent pads- fine tune acoustics
Class A US
EU/ BS fire ratings
Easier to clean
Higher percentage open area
Seal needs to be super easily to fit (snap fit face fit not slide fit)
Better insulator
Round Roof
Tooling
10 or12 dedicated end mouldings
High Cappex £60k
New round pivot sweet (6 mouldings)
Longer development time
Does it compromise linear roof variants?
Cutting round extrusions is difficult or expensive
Laser cutting and waterjet cutting are not options due to multi-walled extrusion profile
Faceted Saw cuts are the most economical over machining radii
Does this compromise the aesthetics
No machining on round sections!
Blade 6 always problematic
Can blade 6 be fixed and still achieve 70% open area?
Will it look good
New Roof Frame
2 New Extrusions
3K Cappex
Hollow sections for increased load strength and torsional support
Mechanically fixed (screwed) mitred corners
Requires machining but lower investment in cast corner
Machine operations provide opportunity to mechanically fixed spindles (current spindles can twist from grub screw friction)
New internal extrusion to have interlocking detail instead of relying on bubble seal
Improves quality and acoustics in the corners
Provides opportunity to retool pivots to improve assemble and fit
Required to Support additional 10kg (30kg per quadrant)
Do we still use existing Bubble seal or tool something new?
Current bubble is a little stiff in UL tested material would a flipper for instance be better?
New Transmission mechanism
Rack and Pinion
Tooth poly belt
Chain and Sprocket
Worm gear drive
Is it necessary or stick with existing linkage?
Existing mechanism works well and is robust
Drive arms raise above roof frames and are potential susceptible to damage
Would increase lead time and complexity
Current mechanism could be more refined and drive arms are very visible which could be negative
New mechanism would look far sweeter and may not protrude above roof for a cleaner aesthetic
Linear Roofs
Relatively low Capex £20k
New end cap mouldings
LH/RH drive arms
LH/RH follower arms
Extruded Roof Blade
Simple straight profile
£20 Target per blade
4.5 kg per blade
5 cavity
2mm wall thickness
Cons
Physical
Heavier
Optomise wall thickness vs. Insulation (2mm wall?)
Frame could be too flimsy
May require 2 x new roof dies
Corner joint could be susceptible to failure due to additional weight
Aesthetics
Harsh finish but minimised by colour/ texture/ paint surface shape