Hinged Foldable Cornerlock for Reinforcing Notched Frame Corners
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Solution Overview
Problem
Existing frame assemblies with single frame members suffer from weakened corners due to notches, leading to reduced strength and rigidity, and aesthetically unpleasing appearances, as conventional cornerlocks cannot effectively reinforce these areas without adding cost and time to manufacturing.
Innovation Solution
A foldable cornerlock with movable body portions and a hinge portion is inserted into notches of the frame member, providing strength and rigidity while covering grooves to enhance aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If notches are formed in the frame member to enable bending at corners, then the frame member can be bent to form corners, but the strength and rigidity of the frame member are reduced at the notches
Solution Approach 1:
The cornerlock is divided into multiple body portions (first body portion, second body portion, third body portion, fourth body portion) that can be independently inserted into the notch from different directions, allowing the frame member to be bent while receiving reinforcement at the notch location
Solution Approach 2:
The cornerlock is inserted into the notch before the frame member is bent. This preliminary insertion ensures that the reinforcement is in place before the bending operation, preventing strength reduction during the forming process
2Ease of operation
If notches are formed in the frame member to enable bending at corners, then the frame member can be bent to form corners, but the aesthetic appearance is degraded due to groove formation
Solution Approach 1:
The cornerlock is segmented into multiple body portions that can be inserted from different directions, with the exterior surfaces of these portions forming a continuous cover over the groove, eliminating the aesthetic defect while maintaining bending capability
Solution Approach 2:
The cornerlock acts as an intermediary element that covers the groove formed by the notch. The exterior surfaces of the cornerlock's body portions conceal the unsightly groove while the interior surfaces provide reinforcement, simultaneously solving both aesthetic and structural problems
3Strength
If conventional coupling cornerlocks are used to reinforce corners, then corner reinforcement is provided, but the cornerlocks cannot be inserted into notches and do not fold
Solution Approach 1:
The cornerlock incorporates a hinge portion that allows the structure to flex and adapt during insertion. The hinge enables the cornerlock to navigate the insertion process into the notch and accommodate the bending of the frame member, providing both reinforcement and adaptability
Solution Approach 2:
The cornerlock is designed to nest within the notch of the frame member. The multiple body portions are arranged to fit within the confined space of the notch, with each portion inserted from a different direction, allowing the cornerlock to be embedded within the frame structure
4Strength
If brackets are mounted to the exterior of the frame member at corners for reinforcement, then strength and rigidity are improved, but manufacturing time and cost increase
Solution Approach 1:
The cornerlock combines multiple functions into a single component: it provides corner reinforcement, covers the groove for aesthetic purposes, and can be inserted into the notch before bending. This integration eliminates the need for separate brackets and additional manufacturing steps, improving productivity while maintaining strength
Data Source
AI summary
A foldable cornerlock is used in a frame assembly. The frame assembly includes first and second ends. The walls of the frame member define an interior of the frame member and also define at least one notch. The frame member is bendable at the notch to form a corner of the frame member. The foldable cornerlock is disposed in the notch and extends into the interior of the frame member. The foldable cornerlock comprises first and second body portions each configured to mate with the interior of the frame member. The body portions are movable relative to each other for inserting the foldable cornerlock into the notch of the frame member. The foldable cornerlock also comprises a hinge portion coupling the body portions together. The hinge portion defines an axis extending in a longitudinal direction through the hinge portion.