Awning Frame Assembly Using Modular Connectors

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Solution Overview

Problem

Existing awning frames made from tubular materials are expensive, heavy, difficult to manufacture, assemble, and ship due to their bulk, and require specialized welding skills, making them impractical for mass production and on-site assembly with varying dimensions.

Innovation Solution

The use of open-ended square tubing members connected with internally fitted right-angle connectors by friction or adhesives, allowing for angular cuts to create a smooth exterior surface and enabling assembly of awning frames with adjustable run-off angles without welding, facilitating kit form packaging and simplified on-site assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welded construction is used for tubular awning frames, then structural strength and stiffness are improved, but manufacturing cost and complexity increase, and the frames become heavy and difficult to assemble on-site

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The awning frame is divided into separate modular components (side members, transverse members, mounting brackets) that can be manufactured independently and assembled on-site using simple connectors instead of welding, resolving the contradiction between structural strength and manufacturing ease

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Orthogonal connectors serve as intermediary elements that join the tubular members without requiring welding, providing a simple mechanical connection that maintains structural integrity while eliminating complex welding operations

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If welded tubular frames are manufactured in advance, then structural integrity is improved, but shipping cost and storage space increase due to bulk and weight

Engineering Contradiction:

Improvestructural integrityVSAvoidshipping volume

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The frame is segmented into collapsible modular components that can be compacted for shipping and expanded at installation, dramatically reducing shipping volume and storage requirements while maintaining structural integrity when assembled

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The frame components are designed to be dynamically collapsible and expandable, allowing them to occupy minimal space during transport and storage while forming a rigid structure when installed, resolving the contradiction between structural integrity and shipping volume

Inventive Principle:

Principle #15Dynamics

3Weight of moving object

If aluminum tubing is used instead of steel, then weight is reduced, but welding skill requirements and cost increase

Engineering Contradiction:

Improveframe weightVSAvoidwelding skill requirement

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The welding process is replaced with a mechanical connection system using orthogonal connectors that join tubular members through simple insertion and friction fit, eliminating the need for specialized welding skills while maintaining structural integrity and enabling the use of lightweight aluminum tubing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This solution reduces manufacturing and inventory costs, simplifies handling and shipping, and allows for customizable awning structures to be assembled efficiently on-site, overcoming the limitations of traditional welded tubular frames.

Implementation Method 1

orthogonal, vertical, horizontal and transverse member connections are made with internally fitted right angle connectors by friction or adhesives

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

orthogonal, vertical, horizontal and transverse member connections are made with internally fitted right angle connectors by friction or adhesives

Methodology Applied

Scientific EffectAdhesive: Adhesive

Implementation Method 3

The inclined members are angularly cut for a flush fit to the orthogonal members at the awning sides

Methodology Applied

Scientific EffectGeometry: Geometry

Data Source

PatentUS8104527B1Method and apparatus for making an awning structure

Publication Date: 2012.01.31 KONDA SRINIVAS

AI summary

A method and apparatus for joining angularly oriented side planar members into an otherwise orthogonal awning frame of open ended side plane and transverse members joined by fitted right angle connectors has the angularly oriented member cut to length at end angles that provide a flush fit to the side plane members at transverse member connections and lengths of formed right angle section material, cut at the same flush fitting angles as the tubing end angle cuts, for fastening to inwardly facing surfaces of the planar and transverse members, so as to present a smooth exterior surface for supporting an awning cover.