Input Output Device Frame Profile Corner Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current manufacturing processes for input and output devices for industrial use are inefficient and costly due to high material losses and complex production methods, particularly when producing frames with one-piece designs that require significant investment in injection molds for small batch sizes, and often result in frames with gaps or grooves that are not suitable for harsh industrial environments.
Innovation Solution
A one-piece frame profile with a band and groove design is used, where free spaces are milled to form corners, allowing for overbending to prevent material stress and the insertion of corner elements for stability, and additional seals are integrated for IP65 standard compliance, eliminating the need for complex die-casting and separate tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a one-piece frame is produced using injection molding or solid material milling, then the frame achieves high mechanical robustness and tightness, but material losses increase and production costs rise
Solution Approach 1:
The frame is segmented into a frame profile and separate corner elements that are assembled together. The frame profile contains grooves that receive the corner elements, allowing the frame to be constructed from multiple parts rather than requiring a single-piece injection molded or milled component. This segmentation dramatically reduces material waste while maintaining structural integrity.
2Reliability
If a one-piece frame is produced using injection molding, then the frame achieves high mechanical robustness, but production complexity and initial costs increase due to expensive molds
Solution Approach 1:
The frame production is segmented into simpler steps: extruding the frame profile and separately manufacturing corner elements, then assembling them. This eliminates the need for expensive injection molds while maintaining frame strength through the groove-corner element connection system.
Solution Approach 2:
The invention replaces expensive, complex injection molds with simpler, more economical extrusion dies and corner element manufacturing processes. The extrusion process requires significantly less initial tooling investment compared to injection molding, making frame production more accessible for smaller production volumes.
3Shape
If corners are bent to form a one-piece frame, then residual stress causes springing back, but additional reinforcement increases complexity
Solution Approach 1:
Free spaces are milled into the frame profile at the corner locations before assembly, creating predetermined receptacles for the corner elements. This preliminary preparation ensures that when corner elements are inserted, they immediately provide the necessary structural support and prevent springing back without requiring additional reinforcement measures.
Solution Approach 2:
Corner elements act as intermediary components between the frame profile sides. These elements fit into the milled free spaces and serve as mediators that absorb and distribute stresses, preventing the frame corners from springing back while maintaining a clean, integrated appearance.
4Ease of manufacture
If grooves and gaps are present in the frame, then assembly is facilitated, but dirt deposits increase and hygienic requirements are compromised
Solution Approach 1:
The frame design uses localized grooves that are precisely positioned and sized to accommodate corner elements while minimizing exposed gap surfaces. The grooves are configured to allow easy insertion of corner elements during assembly, while the overall design reduces the surface area where dirt could accumulate, balancing assembly ease with hygienic requirements.
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to a frame (1) for an input and output device (100) with four corners (A, B, C, D), wherein a one-piece formed frame profile (10) is used, which has a first leg (S1) and a second leg (S2), wherein a strip (20) is arranged on the first leg (S1), and wherein recesses (11, 12, 13, 14) are arranged in the frame profile (10) to form the four corners (A, B, C, D) such that the strip (20) remains in the area of the recesses (11, 12, 13, 14), and a groove (21) is arranged on the second leg (S2), wherein a corner element (31, 32, 33, 34) is arranged in each of the corners (A, B, C, D), and the corner element (31, 32, 33, 34) comprises an element body (40) with a first element leg (41) and a second element leg (42), wherein the element legs (41,42) are arranged substantially at right angles to each other on the element body (40) and the corner elements (31,32,33,34) are arranged in the free spaces (11,12,13,14)that the first element leg (41) and the second element leg (42) are each arranged in the groove (21) of the frame profile (10).