Corner Connector for Perpendicular Frame Profiles
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Solution Overview
Problem
Existing corner connectors require manual alignment of frame profiles, which is labor-intensive, and are not easily producible through simple forming processes.
Innovation Solution
A corner connector design featuring a first shaped sheet metal part with perpendicular limbs and a second part with a reference surface, where the threaded sleeve is pressed or welded into corresponding openings, allowing for precise alignment and connection of mutually perpendicular frame profiles without manual effort, and incorporating legs for secure engagement with vertical profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alignment of frame profiles is used, then connection of perpendicular frame profiles is achieved, but labor intensity increases and alignment precision decreases
Solution Approach 1:
The corner connector is pre-formed with receiving openings, threaded sleeves, and legs positioned at precise locations and orientations. This preliminary preparation eliminates the need for manual alignment during assembly, as the frame profiles simply need to be inserted into the pre-configured connector components.
Solution Approach 2:
The corner connector acts as an intermediary component between frame profiles, providing a pre-fabricated interface that includes receiving openings, threaded sleeves, and positioning legs. This intermediary element transfers the alignment function from the assembly process to the manufacturing process, where precision can be achieved through forming operations.
2Manufacturing precision
If complex corner connector designs are used to achieve precise alignment, then alignment precision improves, but manufacturing complexity increases
Solution Approach 1:
The corner connector is divided into distinct functional segments: a central body with receiving openings, threaded sleeves for fastening, and legs for positioning. Each segment can be formed and positioned independently through simple forming operations, avoiding the need for complex multi-step manufacturing processes while achieving precise overall alignment.
Solution Approach 2:
The invention uses geometric parameters (angles, distances, orientations) that are inherently achievable through standard sheet metal forming processes. The perpendicular legs and receiving openings are configured at parameters that can be directly produced by forming operations, eliminating the need for complex machining or assembly steps.
3Strength
If additional components are added to improve connection stability, then connection strength improves, but device complexity increases
Solution Approach 1:
The corner connector merges multiple functions into a single integrated component: the central body provides the connection interface, threaded sleeves provide fastening capability, and legs provide positioning and support. This consolidation achieves strong connections without requiring separate alignment fixtures, positioning devices, or fastening mechanisms.
Solution Approach 2:
The corner connector is designed as a multi-functional component that simultaneously provides frame profile reception, precise positioning through legs, structural support, and fastening capability. This universal design eliminates the need for multiple specialized components while achieving comprehensive connection functionality.
Data Source
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AI summary
A corner connector for connecting at least two frame profiles of a frame which are arranged perpendicularly relative each other, said corner connector consisting of a plurality of parts at least one of which is designed to come to rest against one or more of the frame profiles is characterized in that the part which is designed to come to rest against one or more of the frame profiles is a first molded sheet metal part having a receiving opening in or on which a threaded sleeve is situated.