Interlocking Tube Framing Joints Without Welding or Connectors

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Solution Overview

Problem

Traditional methods of joining tubes for framed structures, such as welding and using connectors, require significant expertise, can deform the material, and increase costs and complexity, while also compromising aesthetic appeal and dimensional accuracy.

Innovation Solution

A framing system where tubular members are pre-cut with interlocking shapes and fastening features, allowing for secure and accurate assembly without welding or additional connectors, using CNC machines to precision-cut hooks, slots, and other shapes for efficient and strong joint formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to join tubes, then the joint strength is improved, but the manufacturing complexity and expertise required increase significantly

Engineering Contradiction:

Improvejoint strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces the welding process (thermal/chemical joining) with a mechanical interlocking system using integrated hooks and slots. The hooks are formed as integral parts of the tube ends through forming processes, eliminating the need for welding equipment and expertise while maintaining joint strength through mechanical engagement.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The hooks and slots are pre-formed into the tube ends during manufacturing before assembly. This preliminary action of shaping the joining features eliminates the need for on-site welding or complex assembly procedures, reducing manufacturing complexity while ensuring consistent joint strength.

Inventive Principle:

Principle #10Preliminary action

2Strength

If welding is used to join tubes, then the joint strength is improved, but the dimensional accuracy deteriorates due to material deformation

Engineering Contradiction:

Improvejoint strengthVSAvoiddimensional accuracy

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent replaces welding (which causes thermal deformation) with cold-forming processes to create the hooks and slots. This mechanical forming method does not generate the intense heat that causes material distortion, thereby maintaining dimensional accuracy and true-square geometry while still achieving strong mechanical joints.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If connectors or brackets are used to join tubes, then the ease of assembly is improved, but the device complexity and cost increase due to additional elements

Engineering Contradiction:

Improveease of assemblyVSAvoidnumber of components

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent merges the tube body and the joining features (hooks and slots) into a single integrated component. Instead of using separate connectors or brackets, the joining functionality is built directly into the tube ends through forming processes, reducing the total number of parts while maintaining ease of assembly through simple interlocking.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The tubes serve dual functions: they provide structural support and simultaneously serve as their own connectors through the integrated hooks and slots. This multi-functionality eliminates the need for separate joining elements, reducing component count and overall system complexity while maintaining ease of assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of operation

If connectors or brackets are used to join tubes, then the ease of assembly is improved, but the aesthetic appeal deteriorates due to obstructions on the frame surface

Engineering Contradiction:

Improveease of assemblyVSAvoidaesthetic appeal

Core Design Contradiction:

Ease of operationVSShape

Solution Approach 1:

The patent merges the joining features with the tube body, creating a seamless appearance. The hooks and slots are formed as integral parts of the tube ends, eliminating protruding connectors or brackets that would obstruct the frame surface and compromise aesthetic appeal.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The joining features (hooks and slots) are localized to the end regions of the tubes where they are functionally required. The main body of the tubes remains smooth and unobstructed, maintaining aesthetic appeal while providing functional joining capability at the specific locations where connections are needed.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20240229479A1Framing system including tubes joined with slots, hooks and wedges integrated into the tubes

Publication Date: 2024.07.11 HRYNIEWICZ GREG HYDE

AI summary

A framing system and method of mechanically joining tubular elements to form frames without the need for welding technologies or connectors. The frames are two dimensional or, e.g., horizontal or vertical planes, or three-dimensional frames, e.g., cubes or rectangles. These joints between tubes are formed by fastening features cut into the tubes. The fastening features include hooks, slots, wedges and other shapes. The fastening features engage with each other to form joints between tubes that form a frame. The tubes can be metal or plastic or other material, and have cross sectional shapes of square, rectangular, rounded or other.