Frame Beam Cup-Shaped Recess Concealed Fastening
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Solution Overview
Problem
Existing frame spars for doors and gates face challenges in achieving strong attachment to masonry and drywall while maintaining a visually appealing appearance, with visible screw fasteners and the need for early mortar work in construction phases.
Innovation Solution
A frame spar with an integral cup-shaped recess in the metal profile for complete accommodation of fastener heads, along with a tab and angle for inclined fastening, allowing for concealed fasteners and late-stage assembly without mortar, ensuring stability and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw fasteners are used to attach the frame spar to masonry or drywall, then strong attachment is achieved, but the fasteners become visible and detract from visual appeal
Solution Approach 1:
The fastener head is extracted from the visible surface by providing a cup-shaped recess that receives and conceals the fastener head below the surface level of the frame spar, eliminating the visual defect while maintaining the fastening function
Solution Approach 2:
The fastener head is nested within the cup-shaped recess of the frame spar, creating a concealed fastening system where the fastener is housed inside the recess rather than protruding outward, achieving both strong attachment and aesthetic appearance
2Productivity
If the frame spar is mounted early in construction phase, then mortar work can be performed, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The cup-shaped recess and inclined mounting surface are prepared in advance during frame spar manufacturing, enabling simplified on-site assembly where only the fastener needs to be inserted at an angle without requiring preliminary mortar work or complex alignment procedures
Solution Approach 2:
Instead of requiring mortar work to be performed before frame installation, the design allows the frame to be installed first using the inclined fastening mechanism, and mortar work can then be performed afterward, reversing the traditional construction sequence
3Strength
If the fastening element is positioned close to the door stop area, then stronger fastening is achieved, but the mounting becomes more difficult
Solution Approach 1:
The cup-shaped recess is positioned asymmetrically close to the door stop area to maximize fastening strength, while the inclined mounting surface provides asymmetric guidance that simplifies the insertion process despite the unconventional positioning
Data Source
Figure 1~2
Figure 3~6
Figure 7~9
AI summary
The beam (10) has a cup-shaped recess (26) formed for complete diagonal admission of a head (34) of a fastening part (32) at a folding region (16) of a frame connector (1). The recess is integrally formed in a metal profile, where the beam is fastened with a mounting device by a fastening part at brickwork (12). The recess comprises a diagonally running passage, and is formed for retaining a cover cap. Two bracket regions (20, 22) are bent at ends that are turned toward the brickwork, where the beam is turned away from the brick-work.