Mitered Corner Joint with Adhesive Injection for Mortise and Tenon Appearance
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Solution Overview
Problem
Thermally welded corner joints in structures like windows and doors face manufacturing difficulties while aiming for a visually pleasing mortise and tenon appearance on both sides, which is challenging to achieve and maintain structural integrity.
Innovation Solution
The corner joints incorporate mitered connections with flanges on both interior and exterior surfaces, using a corner key and adhesive material to create a mortise and tenon appearance, with an adhesive injection port system to secure the joint, ensuring structural soundness and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal welding is used to form corner joints, then structural integrity is achieved, but manufacturing complexity and difficulty increase
Solution Approach 1:
The corner joint is divided into multiple components: mitered frame members, flanges, and a corner key. This segmentation allows each component to be manufactured separately with standard machining operations, avoiding the complexity of thermal welding while maintaining structural integrity through mechanical assembly and adhesive bonding.
Solution Approach 2:
A corner key is introduced as an intermediary component that fits into recesses in both frame members. This corner key serves as a mechanical mediator that reinforces the joint and provides a positive mechanical connection, eliminating the need for thermal welding while maintaining strength.
2Shape
If flanges are added to create mortise and tenon appearance, then aesthetic quality improves, but manufacturing complexity increases
Solution Approach 1:
The flanges are segmented into inner and outer flanges that are integrated with the mitered frame members. This segmentation allows the aesthetic features to be built into the basic framing components during extrusion or molding, rather than being added as separate complex assemblies.
Solution Approach 2:
The flanges are merged with the mitered frame members as integrated components. The inner and outer flanges are formed as part of the frame member extrusion process, combining the aesthetic mortise and tenon appearance with the structural mitered connection in a single manufacturing step.
3Ease of manufacture
If mitered connection is used instead of thermal welding, then ease of manufacture improves, but structural integrity may be compromised
Solution Approach 1:
The joint uses a composite connection system combining mechanical elements (mitered surfaces, flanges, corner key) with chemical bonding (adhesive material). This composite approach provides both the ease of manufacture of mechanical assembly and the structural integrity of strong bonding, surpassing thermal welding in overall performance.
Solution Approach 2:
The mitered surfaces and flanges are pre-formed during the extrusion or molding of the frame members. This preliminary action prepares the components for simple assembly operations, making the manufacturing process easier while the subsequent adhesive bonding ensures structural integrity.
Data Source
AI summary
Corner joints and methods of forming corner joints are described herein. The corner joints may provide the appearance of a mortise and tenon joint on both the exterior and interior surfaces of the corner joint, but include a mitered connection within the joint. Structures including at least one of the corner joints are also described.