Injectable Corner Key for Fenestration Frame Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for joining frame members in fenestration systems, such as window frames, are costly and do not enhance the appearance of the finished product, particularly at corners where structural inserts are used with mechanical fasteners or adhesives.
Innovation Solution
A structural joint using an injectable corner key with dual injection ports and a distribution pathway that allows adhesive to be injected between the insert and frame members, forming adhesive-receiving cavities for bonding, which can be designed to include notches and protrusions for enhanced structural connection and flow control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fasteners or adhesives are used to join frame members with corner keys, then structural connection is achieved, but cost increases and appearance is compromised
Solution Approach 1:
The patent removes mechanical fasteners from the corner joint assembly, extracting only the corner key insert that is joined purely through adhesive bonding. This eliminates the need for costly mechanical fastening systems while maintaining structural integrity through the adhesive-receiving cavities that optimize adhesive distribution and bonding surface area.
Solution Approach 2:
The patent replaces the mechanical fastening system with an optimized adhesive bonding system. The corner key insert is designed with specific cavities and pathways that enable effective adhesive application and distribution, substituting mechanical connection methods with a chemically-bonded system that reduces cost and improves appearance.
2Strength
If mechanical fasteners or adhesives are used to join frame members with corner keys, then structural connection is achieved, but appearance of finished product is compromised
Solution Approach 1:
By removing mechanical fasteners from the corner joint, the patent eliminates visible hardware that would compromise the aesthetic appearance of the finished fenestration product. The corner key insert with its adhesive bonding system provides a clean, seamless appearance while maintaining structural connection.
Solution Approach 2:
The substitution of mechanical fasteners with an adhesive bonding system eliminates visible mechanical elements at the corner joint, providing a cleaner aesthetic appearance. The adhesive-receiving cavities ensure proper adhesive distribution for strong bonding without requiring visible fastening hardware.
3Device complexity
If adhesive is injected through a single injection port, then the process is simple, but adhesive distribution to multiple cavities is inefficient
Solution Approach 1:
The patent segments the adhesive injection system by providing multiple injection ports positioned to access different cavities of the corner key insert. This segmentation allows adhesive to be efficiently distributed to multiple adhesive-receiving cavities simultaneously or sequentially, improving productivity without excessive complexity.
Solution Approach 2:
The patent adds spatial dimensionality to the injection system by positioning multiple injection ports at different locations and orientations. This allows adhesive to be injected into multiple cavities from different directions, ensuring complete and efficient filling of the adhesive-receiving cavities while maintaining a manageable device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces costs and improves the appearance of fenestration systems by creating a secure, adhesively bonded joint with improved structural integrity and design flexibility, allowing for consistent and aesthetically pleasing corner connections.
Implementation Method 1
an adhesive material injected through the first injection port at least partially fills the distribution pathway, the first cavity, and the second cavity, wherein the adhesive material in the first and second cavities bonds the insert to the first and second frame members
Data Source
AI summary
A corner joint for fenestration frames and the like includes first and second frame members having hollow interiors and ends joined in abutment. A corner key insert has legs inserted into the ends of the frame members. End portions of the legs engage the hollow interiors of the frame members forming adhesive cavities within the frame members and along the end portions of the corner key legs. Adhesive is disposed within the cavities to bond the corner key legs to the frame members, thereby creating a structural joint between the frame members. The corner key insert may include multiple injection ports for delivering adhesive to the cavities from a selected side of the frame assembly. Legs of the corner key may have notches formed therein to receive an internal wall of the frame members, and distal ends of the legs may include a flow barrier that contours along the notches.