Frame Corner Joint Using Interlocking Flange Finger
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Solution Overview
Problem
Traditional frame construction methods require additional pieces or cumbersome steps, such as fasteners and bending tabs, to form corner joints, increasing manufacturing time and cost.
Innovation Solution
A frame design where a flange finger from one section is inserted into a retention opening of another section to form a retention corner, eliminating the need for fasteners and additional assembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fasteners (corner locks, corner keys, L-shaped brackets) are used to form corner joints, then the frame structure is secure and reliable, but the device complexity and manufacturing cost increase due to additional components
Solution Approach 1:
The flange and finger are merged into a single continuous frame section, eliminating the need for separate fastener components. The frame section is formed as one piece with the flange extending from it and the finger integrated into the flange structure, thereby reducing component count while maintaining joint security through the interlocking geometry of the finger and retention opening
Solution Approach 2:
The fastening function is extracted from separate fastener components and integrated directly into the frame section itself. The retention opening is formed in the frame section to receive the finger, making the frame section self-sufficient for both structural and fastening functions, eliminating the need for additional fasteners
2Reliability
If traditional fasteners and assembly steps (bending tabs, inserting hooks) are used to form corner joints, then the frame structure is secure, but the manufacturing time and assembly complexity increase
Solution Approach 1:
The flange and finger are pre-formed as integral parts of the continuous frame section during the initial forming process. The retention opening is also pre-formed in the frame section. This preliminary formation of all necessary features eliminates the need for subsequent bending, folding, or fastening operations, significantly reducing assembly time while ensuring secure corner joints
Solution Approach 2:
The frame section is designed to be self-assembling through the insertion of the pre-formed finger into the retention opening. The geometry of the finger and retention opening provides self-alignment and automatic engagement, eliminating the need for additional assembly steps such as bending tabs or inserting hooks, thereby reducing assembly time and complexity
Data Source
AI summary
A frame (20) for supporting an article includes a first frame section (36) and a first flange (62) extending to a first end (56). The frame (20) also includes a second frame section (38) and a second flange (64) extending to a second end (60). A notch (68) is formed in the first flange (62) and defines a flange finger (70) between the notch (68) and the first end (56). A retention opening (32) is formed in the second end (60) of the second frame section (38). A retention corner (94) for the frame (20) is formed between the first frame section (36) and the second frame section (38) by inserting the flange finger (70) of the first frame section (36) into the retention opening (32) of the second frame section (38).