Metal Extrusion Corner Member for Modular Frame Assembly
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Solution Overview
Problem
The existing construction methods for reformer exercise apparatus frames require expensive and labor-intensive wood joinery techniques to form solid and strong joints, making them costly and inefficient.
Innovation Solution
A reformer exercise apparatus frame with corner members made from elongated hollow metal extrusions, featuring a central corner portion and leg portions extending at a right angle, with inner and outer side walls and discrete surface features to securely join side and end members, facilitating a cost-effective and modular assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional wood joinery techniques are used to form frame corners, then strong and rigid joints are achieved, but manufacturing cost and labor intensity increase significantly
Solution Approach 1:
The patent changes the material parameter from wood to metal extrusion, and the connection method from traditional joinery to extrusion-based mechanical interlocking. The corner member is formed as a single extruded piece with integrated connection features, eliminating complex multi-step wood joinery processes while maintaining joint strength through precise geometric fitting and metal fastener engagement.
Solution Approach 2:
The patent extracts the corner joint functionality from traditional wood-frame construction and implements it through a separate, pre-fabricated metal corner member. This corner member is inserted into the frame assembly, separating the corner joint function from the main frame members and enabling standardized, repeatable connections that are both strong and easy to manufacture.
2Reliability
If traditional wood joinery techniques are used for frame construction, then structural integrity is maintained, but production time and labor costs increase
Solution Approach 1:
The patent segments the frame construction into separate components: main frame members and pre-fabricated corner members. Each corner member is independently manufactured as a complete assembly unit with all connection features already formed. This segmentation allows for parallel production of components and simplifies final assembly, significantly improving productivity while maintaining structural integrity through the engineered corner member design.
Solution Approach 2:
The corner members are pre-fabricated with all connection features, fastener holes, and structural geometry formed during the extrusion process. This preliminary action of pre-forming the corner joints eliminates the need for on-site carving, drilling, and assembly operations that would otherwise be required for traditional wood joinery, thereby accelerating production while ensuring consistent quality.
3Duration of action of stationary object
If expensive wood joinery techniques are used, then durable and long-lasting frame joints are achieved, but manufacturing cost increases
Solution Approach 1:
The patent employs a composite construction approach, combining metal extrusion for the corner members with wood or other materials for the main frame members. The metal corner members provide durable, corrosion-resistant connection points that extend the frame's service life, while the overall structure can be manufactured more economically than traditional all-wood joinery, achieving both longevity and cost-effectiveness.
Data Source
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AI summary
A frame corner member includes an elongated hollow extrusion having a central corner portion and two leg portions extending from the central portion. Each leg portion includes an inner side wall spaced from and parallel to an outer side wall, and merging with the central portion. An outer end wall joins the inner and outer side walls, which each include an inner surface facing the inner surface of the other side wall. An opening through the outer end wall defines a space between the inner and outer side walls adjacent one end of the extrusion for receiving one end of one of frame side members and end members. At least one of the inner surfaces in the space has discrete surface features adapted to grip and retain the one end of one of the side members and end members in the space when received through the opening.