Extruded Door Frame Assembly With Rounded Corners and Bracket Joining
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Solution Overview
Problem
Existing door frame subassemblies for electronic displays are typically manufactured by cutting and welding multiple pieces, resulting in potentially sharp corners and aesthetic defects, which are not addressed by current methods.
Innovation Solution
An extruded door frame subassembly is formed from a single piece of material, such as aluminum, which is bent with localized heating to create rounded corners and secured with brackets for strength, using a bending process that minimizes cracking and defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple pieces are cut and welded together to form a door frame subassembly, then the manufacturing process is simple and straightforward, but the corners become sharp and aesthetically defective
Solution Approach 1:
The patent merges multiple separate frame pieces into a single continuous extruded piece of material. This eliminates the need for cutting and welding multiple pieces together, thereby eliminating sharp corners at joints while maintaining manufacturing simplicity through a single extrusion process followed by bending.
Solution Approach 2:
The patent applies curvature to the corners of the door frame subassembly by bending the single extruded piece into a generally rectangular shape with rounded corners. This curvature eliminates the sharp corners that would result from cutting and welding multiple pieces, improving aesthetic appearance while maintaining structural integrity.
2Ease of manufacture
If multiple pieces are cut and welded together to form a door frame subassembly, then the manufacturing process is straightforward, but structural integrity and strength are reduced
Solution Approach 1:
The patent combines multiple frame segments into one continuous extruded piece, eliminating weak points at weld joints. This single-piece construction with integrated corners provides superior structural integrity and strength compared to assembled multiple-piece designs, while the bending process maintains material continuity.
3Manufacturing precision
If heat is applied during bending to reduce material strength, then tighter bend radius is achieved without cracking, but additional process steps are required
Solution Approach 1:
The patent changes the temperature parameter of the material during bending by applying localized heat. This thermal parameter change reduces material strength temporarily, allowing achievement of tighter bend radii without cracking or defects, while the heating is integrated into the bending process workflow.
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 extruded door frame subassembly provides rounded corners and improved structural integrity while reducing material defects, enabling efficient assembly and installation with enhanced aesthetic appeal.
Implementation Method 1
Heat may be applied during the bending process to reduce material strength in the localized area, thereby permitting a tighter bend radius without, or with reduced, cracking and/or aesthetic defects
Implementation Method 2
The heated metal may be (prior to, during, and/or subsequently) positioned adjacent to a fixed surface and the heated, outer portion of the frame where a bend is to be produced may be positioned against a bending die
Data Source
AI summary
Methods of manufacturing a door frame subassembly for an electronic display assembly and related systems and apparatuses are disclosed. A material is extruded to form a frame. The material is bent into a rectangular shape with rounded corners to define an opening. Notches may be formed in the frame to facilitate the bending. A remaining gap in the material is joined, such as by a bracket at a lower portion of the opening to secure the frame to itself.