Self-Backing Corner Joint Clip for Faster Metal Door Assembly
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Solution Overview
Problem
Conventional commercial metal doors face challenges with labor-intensive assembly processes due to the need for blind support and alignment of discrete backing plates in corner joints, which increases component count and assembly time.
Innovation Solution
A simplified clip assembly design where the backing plate is integrally formed with the clip, reducing the need for separate backing plates and allowing for easier alignment and secure fastening within the frame member slots, using a projection to secure the clip to the adjacent frame member, and employing mechanical fasteners or welds for stabilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If discrete backing plates are used in conventional clip assemblies, then the corner joint can be stabilized and frame members can be interconnected, but the assembly process becomes labor-intensive and time-consuming due to the need for blind support and alignment of separate backing plates
Solution Approach 1:
The backing plate and clip are merged into a single integrally formed component. The clip includes a body with a back side that provides an integrated backing plate, eliminating the need for separate discrete backing plates. This integration allows the clip to be self-backed and simplifies the assembly process by reducing the number of parts that need to be aligned and fastened.
2Reliability
If discrete backing plates are used in conventional clip assemblies, then the corner joint can be stabilized, but the number of component parts increases making the assembly process more complex
Solution Approach 1:
The backing plate and clip are merged into a single integrally formed component. The clip includes a body with a back side that provides an integrated backing plate, eliminating the need for separate discrete backing plates. This integration reduces the component count from multiple separate parts to a single unified clip assembly.
3Ease of operation
If discrete backing plates are used in conventional clip assemblies, then the frame members can be interconnected, but the alignment of holes in separate backing plates with holes in the clip is difficult and labor-intensive
Solution Approach 1:
The backing plate and clip are merged into a single integrally formed component. The clip includes a body with a back side that provides an integrated backing plate, eliminating the need for separate discrete backing plates. This integration reduces the component count from multiple separate parts to a single unified clip assembly.
Solution Approach 2:
The clip is designed to be self-backed, meaning the backing plate is automatically positioned as part of the clip structure itself. The integral design ensures proper alignment of fastener holes without requiring separate alignment operations for discrete backing plates, making the assembly process self-aligning and reducing labor requirements.
Data Source
AI summary
A framed assembly includes a first frame member providing an inner vertical wall extending between opposing front and back surfaces and defining a slot, and a second frame member positioned adjacent the first frame member at a corner joint and providing a horizontal wall extending between opposing front and back surfaces of the second frame member. A clip having opposing front and back sides provides a backing plate extending from the back side and a projection extending from the front side. The backing plate is received within an interior of the first frame member via the slot, and the projection is received within an interior of the second frame member adjacent the horizontal wall.