Folded Sheet Picture Frame Profiles to Reduce Material Waste
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Solution Overview
Problem
Conventional picture frame manufacturing processes result in significant material wastage and increased costs due to the need for cutting timber to specific sizes, creating off-cuts that are often discarded as waste, and the additional processing step required to form rebates in timber profiles.
Innovation Solution
A method of forming a picture frame assembly using individual profile members made from sheet material, where grooves are milled to facilitate folding into a three-dimensional configuration, eliminating the need for additional material removal to create rebates and reducing waste, with reinforcement members added for structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional timber processing methods are used to form picture frame profiles, then the frame structure is achieved, but significant material wastage occurs due to cutting timber to specific sizes and removing regions to form rebates
Solution Approach 1:
The invention changes the physical state and form of the material from solid timber requiring cutting and removal to sheet material that can be folded. By transforming the manufacturing approach from subtractive (cutting and removing) to formative (folding and assembling), the patent eliminates material wastage while simplifying the manufacturing process. The sheet material is processed into profile members with creases that allow folding into the final frame configuration without requiring rebate removal.
2Manufacturing precision
If timber is cut to specific sizes for picture frame profiles, then the required dimensions are achieved, but off-cuts of random lengths and sizes are created that have little commercial value and are disposed of as waste
Solution Approach 1:
The invention divides the frame into separate profile members that can be independently formed from sheet material. Each profile member is created with precise dimensions through folding along predetermined creases, ensuring dimensional accuracy. The segmented approach allows each component to be optimized independently, eliminating the need to cut from larger timber pieces and thereby preventing off-cut waste.
3Shape
If rebates are formed by removing timber regions from rectangular profiles, then the recess structure is created, but additional processing steps are required that increase manufacturing costs
Solution Approach 1:
The invention extracts the rebate formation step from the traditional timber processing sequence. Instead of removing material to create rebates, the design uses folded sheet material where the rebate structure is formed by the folding action itself. This extraction eliminates the costly and time-consuming material removal process while achieving the same functional result of creating a recess for the picture and backing member.
4Strength
If conventional timber processing methods are used, then traditional frame construction is achieved, but multiple processing steps increase manufacturing costs and reduce efficiency
Solution Approach 1:
The invention uses composite construction by assembling multiple profile members formed from sheet material. The profile members are joined together to create the complete frame assembly, with reinforcement members added at corners and joints to ensure structural integrity. This composite approach maintains the strength of traditional timber frames while reducing manufacturing costs and improving efficiency through simplified processing steps.
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
This approach reduces material wastage and manufacturing costs by eliminating the need for further processing steps, allowing for efficient assembly and application of finishes with minimal waste, while enhancing the structural integrity of the frame.
Implementation Method 1
the profile member is folded to form a three dimensional profile member having an outer side portion and an inner side portion
Data Source
Figure 1~2
Figure 3a~3c
Figure 4~5
AI summary
A frame assembly (11) comprising a plurality of profile members (12) connectable to form the frame assembly (11). Each profile member (12) being formed from a substantially planar sheet of material folded to form a rebate (13) at a rear surface thereof. A backing member (16) is mountable to the frame assembly so as to be supported within a recess formed at a rear surface thereof, said recess being defined by the rebate (13) of each profile member (12).