Extruded Member Bracket with Fin Deformation for Rigid Connection
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Solution Overview
Problem
Traditional methods for connecting extruded metal members in structures like pocket-door frames often result in loose connections over time, are labor-intensive, and require specialized tools and features like slots, which are costly to create and time-consuming.
Innovation Solution
A bracket design featuring a base plate with a longitudinal wedge element and constraining bracket flange that forms a rigid connection by deforming extrusion fins when fasteners are inserted, eliminating the need for specialized slots and reducing assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional joining techniques are used to connect extruded members, then the connection can be made, but the connection may loosen over time and lack rigidity
Solution Approach 1:
The bracket is pre-formed with a deformation cavity and positioned between extrusion fins before fastening. The fastener insertion process then deforms the extrusion fin into the cavity, creating a rigid mechanical interlock that prevents loosening over time.
Solution Approach 2:
The extrusion fin undergoes a change in shape and physical state during assembly, being deformed from its original form into the deformation cavity. This parameter change creates a permanent, rigid mechanical connection that resists loosening.
2Ease of manufacture
If fasteners are driven directly through extruded members, then connections can be made, but specialized slots must be created which is time-consuming and expensive
Solution Approach 1:
The connection system is divided into separate components: the bracket with deformation cavity and the extrusion fin. This segmentation allows the bracket to be a standard component while the extrusion fin requires no special features, simplifying manufacturing.
Solution Approach 2:
The bracket acts as an intermediary component between extruded members. It provides the deformation cavity that enables fastener-based connection without requiring slots or special features in the extruded members themselves, simplifying their manufacturing.
3Adaptability or versatility
If many extruded members are connected together to form structures like pocket-doors, then the desired structure is achieved, but the process becomes labor-intensive and costly
Solution Approach 1:
The bracket design with deformation cavity serves multiple functions: it provides rigid connection, eliminates the need for specialized slots, and works with standard extrusion fins. This universal design can be applied to all connections in structures like pocket-doors, improving overall assembly efficiency.
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 solution provides a quick, cost-effective, and robust connection between extruded members, reducing the risk of loosening and simplifying the assembly process, making it suitable for structures subject to movement like sliding doors.
Implementation Method 1
a deformation cavity adjacent the fastener receiving aperture configured to receive a deformed extrusion portion of the first extrusion fin
Data Source
AI summary
A bracket for connecting a first extruded member having spaced and generally parallel extrusion fins to a second member. The bracket comprising a base plate, a longitudinal wedge element configured to be inserted in between the extrusion fins, an extrusion fin receiving channel to receive a first extrusion fin of the first extruded member, fastener receiving apertures through the base plate to receive a fastener to rigidly couple the bracket to the first extruded member, and a deformation cavity adjacent the fastener receiving aperture configured to receive a deformed extrusion portion of the first extrusion fin. The fastener receiving aperture is located on the base plate such that the deformed extrusion portion is forced into the deformation cavity and at least partially out of the extrusion fin receiving channel to form a rigid connection in a deformed condition when a fastener is located in the fastener receiving aperture.