Hidden Extrusion Connector for Perpendicular Frame Joints
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Solution Overview
Problem
Existing extrusion connectors do not provide a hidden solution to securely attach perpendicular extrusions, lacking the ability to retain multiple vertical fastening members within a base.
Innovation Solution
A hidden extrusion connector comprising a base bar with vertically formed threaded holes and vertical bars with threaded posts and set-screws, allowing secure attachment of perpendicular extrusions by threading the vertical bars into the base bar and extrusions, with optional pre-threading for parallel axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional inside corner connector is used to connect perpendicular extrusions, then the connection is visible and structurally functional, but the aesthetic appearance is compromised due to visible connectors
Solution Approach 1:
The connector design extracts the visible portion from the final assembly by using a two-part system where the base bar receives the first extrusion and the vertical bar receives the second extrusion, with the connection hidden within the extrusion profiles themselves rather than visible externally
Solution Approach 2:
The connector components are nested within the extrusion profiles - the base bar is received by the inner channel of the first extrusion, and the vertical bar is received by the inner channel of the second extrusion, creating a hidden connection that appears as part of the extrusion structure
2Adaptability or versatility
If a hidden connector design is implemented with multiple threaded holes, then multiple vertical fastening members can be retained in the base, but the manufacturing complexity increases
Solution Approach 1:
The base bar is designed with multiple threaded holes that can accommodate various vertical fastening members, making it a universal component that can retain different types and numbers of fastening members depending on the application requirements
Solution Approach 2:
The connection system is segmented into distinct functional components - the base bar with vertically formed threaded holes for vertical fastening members, and the vertical bar with horizontally formed threaded holes for additional fastening members, allowing flexible configuration
3Strength
If threaded connections are used to secure perpendicular extrusions, then strong structural attachment is achieved, but the connection becomes visible rather than hidden
Solution Approach 1:
The vertical bar acts as an intermediary component that provides the threaded connection strength while being received within the inner channel of the second extrusion, mediating between the structural requirement for threaded fastening and the aesthetic requirement for hidden connections
Data Source
AI summary
A hidden extrusion connector preferably includes a base bar and at least one vertical bar. The base bar includes a rectangular cross section, which is sized to be received by an inner channel of a first extrusion. A plurality of base threaded holes are formed vertically through the base bar. Each vertical bar includes a rectangular section, which is sized to be received by an inner channel of a second extrusion. A plurality of threaded holes are formed horizontally through the vertical bar. A threaded post extends from a bottom of the vertical bar. The threaded post is sized to be threadably received by one of the plurality of threaded holes in the base bar. The plurality of threaded holes in the base bar and the vertical bar are sized to threadably receive a threaded fastener, such as a set-screw.