Extruded Corner Member with Grip Features for Frame Assembly
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Solution Overview
Problem
The construction of corner joints in physical exercise apparatus frames, such as reformers, requires expensive and labor-intensive wood joinery techniques to maintain structural rigidity and squareness, necessitating a more cost-effective approach.
Innovation Solution
An elongated hollow, tubular metal or rigid plastic extrusion with an L-shaped cross section is used to form corner members, featuring discrete surface features and holes for secure fastening of side and end members, providing structural support and facilitating assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional wood joinery techniques are used to form corner joints, then structural rigidity and squareness are maintained, but construction cost and labor intensity increase significantly
Solution Approach 1:
The patent changes the material parameter from wood to aluminum extrusion, and the joining method parameter from traditional wood joinery to riveted connections. The aluminum extrusion is designed with specific geometric parameters including an L-shaped cross-section with flanges that accommodate rivets, transforming the corner joint from a complex wood joinery operation to a standardized metal fabrication process that reduces labor and cost while maintaining structural integrity
Solution Approach 2:
The corner member is segmented into distinct functional zones: the L-shaped extrusion body providing structural support, the flanges providing attachment surfaces, and the rivet holes providing connection points. This segmentation allows each element to be optimized independently and assembled through standardized riveting operations rather than complex integrated wood joinery
2Reliability
If traditional wood joinery techniques are used to form corner joints, then structural integrity is maintained, but labor intensity and assembly time increase
Solution Approach 1:
The corner member is pre-fabricated as an aluminum extrusion with flanges and rivet holes already formed during the extrusion process. This preliminary action eliminates the need for on-site cutting, shaping, and joining operations required by traditional wood joinery, allowing rapid assembly through simple riveting operations while ensuring consistent structural integrity
Solution Approach 2:
The extrusion design incorporates self-aligning features where the flanges and rivet holes are automatically positioned during the extrusion process. The geometry of the extrusion itself provides the alignment and positioning functions that would otherwise require additional manual operations, enabling faster assembly without sacrificing structural reliability
Data Source
AI summary
A frame corner member includes an elongated hollow extrusion having a central corner portion and two leg portions extending from the central portion. Each leg portion includes an inner side wall spaced from and parallel to an outer side wall, and merging with the central portion. An outer end wall joins the inner and outer side walls, which each include an inner surface facing the inner surface of the other side wall. An opening through the outer end wall defines a space between the inner and outer side walls adjacent one end of the extrusion for receiving one end of one of frame side members and end members. At least one of the inner surfaces in the space has discrete surface features adapted to grip and retain the one end of one of the side members and end members in the space when received through the opening.