Lineal Connector Template for Accurate Field Assembly
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Solution Overview
Problem
Assembling window and door frames from lineals is tedious and time-consuming, particularly due to the difficulty in accurately locating holes for interconnection in the field.
Innovation Solution
A dual-purpose template and connector member that forms holes in lineals and aligns them for accurate joining, featuring legs with datum surfaces and connecting structures to guide the formation of assembly openings, allowing for precise alignment and connection of lineals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If holes are formed in lineals during field installation, then interconnection of lineals is enabled, but accurate location of holes becomes extremely difficult
Solution Approach 1:
The template includes pre-formed openings that are positioned at exact locations before field installation. These pre-positioned openings serve as guides for drilling holes in the lineals, ensuring accurate hole location without requiring complex measurements or calculations during installation.
Solution Approach 2:
The template acts as an intermediary tool between the installer and the lineals. It provides a physical guide structure with openings that directly indicate where holes should be drilled, eliminating the need for difficult field measurements and calculations while ensuring precise hole placement.
2Adaptability or versatility
If lineals are assembled to form frames in the field, then frame construction is enabled, but the process becomes tedious and time-consuming
Solution Approach 1:
The template is pre-configured with openings at exact locations and attached to the lineal before field installation. This preliminary preparation eliminates the need for time-consuming measurements, calculations, and trial-and-error hole drilling during frame assembly, significantly reducing installation time.
Solution Approach 2:
The template with its pre-positioned openings serves the dual function of both a fabrication tool and an alignment guide. It automatically provides the correct hole locations and alignment information, making the assembly process self-guiding and eliminating the need for external measurement tools or complex procedures.
3Adaptability or versatility
If fabrication of parts is performed after lineals leave the factory, then customization is enabled, but accurate hole location becomes extremely difficult
Solution Approach 1:
The template serves as a portable fabrication aid that brings factory-level precision to the field. Its pre-formed openings act as a physical reference system that guides hole drilling, eliminating the need for complex field measurements while enabling customization of frame assemblies.
Solution Approach 2:
The template replicates the precise geometric relationships and hole locations that would otherwise require complex calculations and measurements. By physically copying the required hole pattern onto the lineal through its pre-formed openings, it transfers precision from the factory design stage to the field fabrication stage.
Data Source
AI summary
A member is adapted to be used for forming at least one assembly opening in a first lineal, wherein the member provides a template for locating the at least one assembly opening. The members further adapted to be used to connect the first lineal to a second lineal using the member and the at least one assembly opening.