Frame Joint Connector for Tool-Free Lineal Alignment
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Solution Overview
Problem
The assembly of window and door frames using assembled lineals is tedious and time-consuming, often requiring factory assembly or specialized tools, and existing frames with solid filled profiles are costly and prone to inconsistent results due to variations in alignment and screw positioning, which can lead to splitting of the lineals.
Innovation Solution
A universal joint connection and tightening system that uses joint connectors with cylindrical or other shaped heads and corresponding cavities, allowing for reliable and simplified connection of joints without precise alignment or multiple fixtures, and eliminating the need for screws, thereby facilitating consistent assembly and reducing the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If angled screws are used to connect lineals, then the lineals can be joined together, but it is difficult to adequately tighten the joint and variations in alignment and screw positioning lead to inconsistent results and splitting of the lineals
Solution Approach 1:
The joint connector is designed to automatically tighten the joint between lineals without requiring external tools or specialized assembly equipment. The connector's internal mechanism self-adjusts to achieve proper tightness, eliminating the need for operators to use angled screws that require precise positioning and tool operation.
Solution Approach 2:
The joint connector acts as an intermediary component between lineals, replacing the direct screw-to-wood connection. This mediator component provides a standardized interface that ensures consistent joint tightening and distributes forces evenly, preventing the lineal splitting that occurs with direct screw fastening.
2Productivity
If factory assembly or specialized tools are used for field assembly, then the frame can be assembled, but the process becomes tedious and time-consuming
Solution Approach 1:
The frame assembly system is segmented into modular components: pre-fabricated lineals with integrated cavities and separate joint connectors. This segmentation allows for simple field assembly where components are joined by inserting connectors into cavities, eliminating the need for complex factory assembly equipment or specialized field tools.
Solution Approach 2:
The lineals are pre-fabricated with cavities during manufacturing, preparing them in advance for easy field assembly. This preliminary action eliminates the need for field workers to perform complex assembly operations or use specialized tools, thereby increasing productivity while maintaining simple assembly procedures.
3Strength
If lineals with solid filled profiles are used, then the frame structure is strong, but the cost and weight of the frame increase
Solution Approach 1:
The joint connector is nested within the cavity of each lineal, with the connector's heads receiving portions of adjacent lineals. This nesting arrangement allows the use of lineals with cavities instead of solid profiles, reducing weight and material cost while maintaining structural strength through the interlocking connector design.
4Manufacturing precision
If precise alignment and fastener positioning are required, then the joint connection can be consistent, but the assembly process becomes more difficult and time-consuming
Solution Approach 1:
The joint connector and lineal cavity are designed with specific geometric relationships that guide proper alignment during assembly. The connector's shape and the cavity's configuration work together to ensure correct positioning automatically, eliminating the need for operators to achieve precise alignment manually.
Data Source
AI summary
A frame the joint connector comprises a first head, a second head and a neck interconnecting the first head and the second head. The first head forms a first shoulder adjacent the neck facing the second head. The second head forms a second shoulder adjacent the neck facing the first head.