Corner Key Slot Enables Elastic Deformation
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Solution Overview
Problem
The existing corner key and frame assembly process faces challenges due to low precision in the aluminum extrusion process, leading to assembly difficulties, included-angle errors, and excessive force interference, which damages the tooth structure and reduces production capacity and increases maintenance costs.
Innovation Solution
The corner key design features a first body with a slot and an engaging portion having distinct sections, allowing for elastic deformation during assembly, preventing excessive interference and enabling self-tightening after assembly, thus improving assembly precision and reducing damage to components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If aluminum extrusion process is used to manufacture corner key, then manufacturing cost is reduced, but manufacturing precision deteriorates due to thermal expansion and contraction
Solution Approach 1:
The patent introduces a slot structure in the corner key that allows dimensional parameters to change during assembly. The slot enables the corner key to adapt to dimensional variations caused by thermal expansion and contraction, maintaining assembly feasibility despite low manufacturing precision from aluminum extrusion process
Solution Approach 2:
The corner key is segmented into multiple parts including the slot and engaging portions. This segmentation allows different sections to perform different functions - the slot accommodates dimensional changes while the engaging portions maintain connection functionality, resolving the contradiction between low-cost manufacturing and precision requirements
2Strength
If force interference assembly is used to assemble corner key and side frame, then connection strength is improved, but device complexity increases due to burrs and assembly difficulties
Solution Approach 1:
The slot structure serves as a cushioning mechanism that absorbs assembly errors and dimensional deviations before they propagate to the engaging portions. This beforehand cushioning allows force interference assembly to achieve strong connections without requiring excessively complex pre-processing of burrs and alignment procedures
Solution Approach 2:
The slot acts as an intermediary element between the corner key body and the engaging portions. It mediates the assembly process by accommodating dimensional variations and guiding the engaging portions into proper alignment, reducing assembly complexity while maintaining connection strength
3Productivity
If included-angle error and displacement difference occur during assembly, then assembly speed is maintained, but reliability deteriorates due to excessive force on corner key
Solution Approach 1:
The slot structure introduces dynamic adaptability to the corner key, allowing it to adjust to included-angle errors and displacement differences during assembly. This dynamic adjustment prevents excessive forces from being transmitted to the corner key, maintaining reliability while preserving assembly speed
Solution Approach 2:
The slot enables parameter changes in the corner key geometry during assembly, allowing it to accommodate angular and positional deviations. This parameter adaptability ensures that assembly can proceed at normal speed without compromising the reliability of the corner key through excessive loading
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
The design ensures precise assembly without damaging the corner key's tooth structure, enhances production efficiency, and eliminates the need for additional mounting processes, resulting in improved assembly quality and reduced maintenance costs.
Implementation Method 1
provides the engaging portion with sufficient space for elastic deformation during the assembly process of the side frame and the corner key
Data Source
AI summary
A corner key includes a first body and a first engaging portion. The first body has a first slot. The first engaging portion is disposed on a surface of the first body and a position of the first engaging portion is corresponding to the first slot. The first engaging portion has a first section, a second section and a third section, wherein the first and third sections are located at opposite sides of the first engaging portion, the second section is located between the first and third sections, and a height of the second section is greater than that of the first section or the third section.