Connector With Radiused Edge Lips For Frame Assembly
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Solution Overview
Problem
Conventional connector systems for aluminium profile machine framing are difficult and time-consuming to assemble due to the need for precise drilling, specialized tools, and complex mechanisms, which also lead to the formation of dirt traps between frame elements.
Innovation Solution
A connector comprising a single-piece block with a flat inner engagement face and a parallel outer engagement face, featuring outwardly projecting lips with curved inner faces for smooth engagement with radiused edges, along with a locking element and a fastener system including retaining washers and screws for secure assembly without dirt traps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional connector systems are used, then frame elements can be joined, but assembly becomes difficult and time consuming due to precise drilling requirements, specialized tools, and complex mechanisms
Solution Approach 1:
The connector is divided into distinct functional components: a body portion with engagement faces, lips for radiused edge engagement, locking elements for rotation prevention, and a separate fastener system. This segmentation allows each component to perform its specific function independently, simplifying the overall assembly process and reducing the need for complex mechanisms.
Solution Approach 2:
The connector body is pre-configured with engagement faces, lips, and locking elements during manufacturing. The retaining washers are pre-positioned on the connector body at the outer engagement face before assembly. This preliminary preparation eliminates the need for precise drilling and specialized tools during field assembly, significantly reducing assembly time and complexity.
2Reliability
If conventional connector systems with precise drilling are used, then frame elements can be connected, but the process becomes complex and requires specialized tools and jigs
Solution Approach 1:
The connector integrates multiple functions into a single unified component: the body provides structural connection, lips provide radiused edge engagement, locking elements prevent rotation, and the fastener system secures the connection. This merging of functions into one component eliminates the need for separate drilling operations, specialized tools, and complex jigs, reducing overall system complexity while maintaining reliable connections.
Solution Approach 2:
The connector design allows the components to self-align and self-secure during assembly. The lips automatically engage with radiused edges, the locking elements prevent rotation without additional mechanisms, and the retaining washers with interference fit holes automatically grip the retaining screws during insertion. This self-service capability eliminates the need for complex adjustment mechanisms and specialized installation tools.
3Ease of manufacture
If frame elements with radiused edges are abutted, then connection is achieved, but grooves forming dirt traps are formed at opposite side edges
Solution Approach 1:
The lips of the connector act as intermediary elements between the radiused edges of adjacent frame elements. These lips provide a transition surface that bridges the gap created by radiused edges, preventing the formation of grooves and dirt traps while maintaining the structural integrity and ease of manufacture of the frame elements themselves.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A connector (20) for attachment of two frame elements (2, 3) in a framing system has a connector body (21) of similar rectangular section to the frame elements (2, 3). A flat inner engagement face (22) of the connector body (21) engages with a flat end face (23) of a first frame element (2), and essentially forms an extension of the first frame element (2). An outer engagement face (24) of the connector body (21) is substantially parallel to the inner engagement face (22) and in use abuts against a flat side wall (25) of a second frame element (3). The outer engagement face (24) has two outwardly projecting lips (27) along opposite side edges of the connector body (21) at the outer face (24). Each lip (27) has a curved inner face (28) for engagement with opposed radiused edges (4, 7) at opposite sides of the flat side wall face (25) of the second frame element (3). A flat outer face (29) of the lip (27) forms an extension of a side wall (30) of the connector body (21) and provides a smooth transition between adjacent side walls (31, 32) of the two frame elements (2, 3). Thus, advantageously, there is no groove forming a dirt trap between the two frame elements (2, 3) when they are interconnected.