Corner Connector Distribution Channel Extraction
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Solution Overview
Problem
The production of existing corner connectors for mitred hollow profiles is complex and expensive due to the need for separate work steps to introduce the distribution and supply channels, which complicates the manufacturing process.
Innovation Solution
A corner connector design where the recesses are connected by a single distribution channel, allowing for simplified manufacturing and assembly, with the distribution channel being introduced separately, such as through milling, and a sealant introduced into one recess to form a reliable connection with the hollow profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If both distribution channel and supply channel are integrated into the corner connector, then adhesive bond strength is improved, but manufacturing complexity increases due to requiring separate work steps
Solution Approach 1:
The distribution channel is extracted as a separate component from the corner connector body. Instead of being integrated during extrusion, it is introduced afterward as a separate element that fits into a corresponding recess in the corner connector, thereby simplifying the manufacturing process while maintaining the dual-channel adhesive delivery function
Solution Approach 2:
The recess for receiving the distribution channel is pre-formed during the extrusion process of the corner connector body. This preliminary preparation allows the distribution channel to be easily inserted in a subsequent step without requiring complex re-milling or additional processing of the main connector structure
2Ease of manufacture
If distribution channel is introduced separately through milling, then manufacturing flexibility is improved, but production time increases
Solution Approach 1:
The recess accommodating the distribution channel is pre-formed during the extrusion process before the distribution channel is inserted. This preliminary preparation enables rapid insertion of the distribution channel without requiring time-consuming re-milling operations, thus maintaining high production speed while preserving manufacturing flexibility
Solution Approach 2:
The corner connector manufacturing process is segmented into distinct stages: extrusion of the main body with pre-formed recess, separate production of the distribution channel component, and final assembly by inserting the channel into the recess. This segmentation allows each component to be optimized independently and assembled quickly
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 approach reduces manufacturing complexity and cost by eliminating the need for a second processing step, ensuring a reliable and stable connection between the corner connector and hollow profiles through a single distribution channel, facilitating easier production and assembly.
Implementation Method 1
the sealant can be introduced into one of the recesses 108, so that the sealant reaches both the distribution channel 110 and the other recess 108
Data Source
Figure 1
Figure 2
AI summary
The single or multi-portion corner connector (100) has two sections (102,104) which are arranged adjacent to each-other in a corner area (106), where the corner area is arranged in the connection of hollow sections in the region of a miter joint. Each of the two sections has a recess (108), where the recesses are connected together by a distribution channel (110). An independent claim is included for a method for manufacturing a corner connector.