Fenestration Frame Corner Key With Crumple Zone Connectors

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Solution Overview

Problem

Existing fenestration assemblies with multiple lineal members face challenges in securely connecting these members at corners, particularly in maintaining a strong and adjustable joint.

Innovation Solution

The use of a corner key with a base and extension members connected via crumple zone connectors allows for adjustable and secure connections between lineal members, enabling the assembly of fenestration frames.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional corner keys are used to connect lineal members, then the connection is simple, but the joint strength and adjustability are insufficient

Engineering Contradiction:

Improvejoint strengthVSAvoidcorner key structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The corner key is divided into separate functional components: a base portion, first and second extension members, and first and second connectors. Each component performs a specific function, allowing the assembly to achieve strong joint connection through coordinated action of multiple parts rather than a single complex structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The connectors are designed with crumple zones that allow controlled deformation during assembly. The extension members can move relative to the base portion through these flexible connectors, enabling adjustment of the joint position and orientation while maintaining strong connection strength.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If rigid connectors are used to secure extension members, then the connection is stable, but assembly adjustability is limited

Engineering Contradiction:

Improveassembly adjustabilityVSAvoidconnection stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The connectors are designed with crumple zones that change their structural parameters (shape, volume) during the assembly process. Initially in an expanded state allowing movement and adjustment, they collapse to a compact state that provides stable, rigid connection, thus transitioning from adaptability to stability as needed.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The crumple zones are pre-designed with controlled deformation characteristics that allow the extension members to move and adjust during assembly. This predetermined flexibility cushions the assembly process, enabling position adjustment while the collapse of crumple zones subsequently provides the necessary stability for the finished assembly.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Ease of operation

If extension members are fixed to the base, then the structure is rigid, but positioning flexibility is reduced

Engineering Contradiction:

Improvepositioning flexibilityVSAvoidconnector design

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The connectors transition from a dynamic, flexible state during assembly (allowing extension members to move and position themselves) to a static, rigid state in the finished assembly (providing stable connection). The crumple zones enable this dynamic behavior without requiring complex mechanical joints or fasteners.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The crumple zones act as intermediary elements between the extension members and the base portion. They mediate the connection by allowing controlled movement and adjustment during assembly, then collapsing to provide a stable, rigid connection in the finished product, thus simplifying the overall connector design while achieving both flexibility and stability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 provides a strong, adjustable, and secure connection between fenestration frame lineal members, enhancing the structural integrity and assembly efficiency of fenestration assemblies.

Implementation Method 1

a first connector having a first crumple zone and a second extension member operatively coupled to the base; and a first lineal having a first hollow interior receiving the first extension member

Methodology Applied

Scientific EffectCrumple zone deformation: Deformation

Implementation Method 2

a first extension member movably connected to the first portion with a first connector integrally formed with the first extension member and the first portion

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20250172036A1Frame corner key

Publication Date: 2025.05.29 MI WINDOWS & DOORS LLC

AI summary

A corner key having a base with a first portion and a second portion; a first extension member movably connected to the first portion with a first connector integrally formed with the first extension member and the first portion; and a second extension member movably connected to the second portion with a second connector integrally formed with the second extension member and the second portion; wherein a portion of the first connector is movable as the first extension member is moved toward the first portion.