Extruded Corner Member with Grip Features for Modular Frame Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The construction of corner members for 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, featuring discrete surface features and holes for secure fastening of side and end members, providing a robust and modular corner structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If expensive wood joinery techniques are used to form solid and strong joints, then the frame remains rigid and square, but the construction cost and labor intensity increase
Solution Approach 1:
The patent changes the material parameter from wood to extruded metal (aluminum or aluminum alloy), which inherently provides superior strength-to-weight ratio and structural integrity. The extrusion process creates a consistent cross-sectional geometry with integrated reinforcement features that maintain rigidity and squareness without requiring complex joinery techniques.
Solution Approach 2:
The corner member functions as a composite structure integrating multiple functional elements: the extruded metal body provides structural strength, while embedded or attached components (such as reinforcement plates, mounting brackets, or damping elements) enhance specific properties like joint strength, corrosion resistance, or vibration damping without compromising the overall simplicity of the corner member design.
2Device complexity
If traditional wood corner members are used, then the frame structure is simple, but the construction cost and labor intensity increase due to expensive joinery techniques
Solution Approach 1:
The patent merges multiple previously separate components into a single integrated corner member. The extruded metal corner member combines the functions of structural support, joint reinforcement, and mounting integration that were previously achieved through separate wood pieces and complex joinery techniques. This consolidation maintains the simplicity of the frame structure while eliminating the need for expensive and labor-intensive woodworking operations.
Solution Approach 2:
The extruded metal corner member replicates and improves upon the traditional wood corner member design by maintaining the essential L-shaped geometry and structural function while using a superior material that requires simpler manufacturing processes. The extrusion process creates a consistent, repeatable component that can be mass-produced at lower cost and with less labor than custom wood joinery.
3Reliability
If metal extrusion with surface features is used, then assembly is secured and wear is mitigated, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies local quality by incorporating discrete surface features (such as ribs, grooves, or textured patterns) at specific locations on the extruded metal corner member where they are most needed for assembly stability and wear resistance. These features are strategically placed at contact surfaces, mounting areas, or high-stress regions rather than uniformly across the entire component, thereby enhancing reliability without requiring complex extrusion tooling throughout the entire part geometry.
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.