Modular Carport Frame Connectors for Fast Reconfiguration
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Solution Overview
Problem
Traditional carport structures lack versatility, are cumbersome to assemble, and inflexible in terms of cover materials and reconfiguration, limiting their adaptability for various uses and weather conditions.
Innovation Solution
A modular carport frame system featuring tubular components, 3-way and 4-way connectors with screw-in connections and snap-button joints, and a securing mechanism for various canopy materials, allowing easy assembly and disassembly without specialized tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional carport structures use permanent welding or complex mechanical fastenings, then structural strength is improved, but ease of assembly and disassembly deteriorates
Solution Approach 1:
The carport structure is divided into modular components (frame members, connectors, canopy sections) that can be independently assembled and disassembled. The frame members are segmented into standardized lengths that connect through interchangeable connectors, enabling tool-free assembly while maintaining structural integrity through multiple connection points.
Solution Approach 2:
The connection system transitions from static permanent welds to dynamic reversible connectors. The connectors feature movable locking mechanisms that allow quick attachment and detachment, enabling the structure to be reconfigured or relocated as needed while maintaining strength during use through engineered connection geometries.
2Ease of manufacture
If traditional carport structures use fixed design configurations, then manufacturing simplicity is improved, but adaptability for various uses deteriorates
Solution Approach 1:
The frame members are designed with universal connection interfaces that can accommodate multiple connector types and configurations. Standardized opening sizes, connector geometries, and attachment mechanisms allow the same basic frame structure to be adapted for different applications including vehicle shelters, equipment storage, recreational spaces, and seasonal covers without requiring custom manufacturing.
Solution Approach 2:
The structure allows modification of key parameters such as frame height, span width, and canopy shape by changing connector configurations and member arrangements rather than manufacturing entirely different structures. The standardized components enable parameter adjustments while maintaining manufacturing simplicity through repeated use of the same component library.
3Stability of the object's composition
If traditional carport structures use rigid connection methods, then structural stability is improved, but ease of reconfiguration deteriorates
Solution Approach 1:
The connectors are pre-engineered with built-in alignment features and self-centering geometries that guide frame members into proper positions during assembly. Pre-configured connector orientations and attachment sequences ensure stable structural formation without requiring complex alignment procedures or specialized tools, enabling both stability and ease of reconfiguration.
4Reliability
If traditional carport structures require specialized tools for assembly, then connection reliability is improved, but productivity deteriorates
Solution Approach 1:
The connection system is designed to be self-servicing through features such as self-aligning connector geometries, self-centering attachment mechanisms, and self-locking features that engage automatically when components are properly positioned. This eliminates the need for specialized tools or skilled operators while maintaining connection reliability through engineered tolerance stacks and redundant locking features.
Data Source
AI summary
Disclosed are example embodiments of a Modular Carport Frame System. The Modular Carport Frame System includes a plurality of tubular components forming the structural framework. The Modular Carport Frame System also includes connectors for joining said tubular components, wherein the connectors include at least one 3-way connector and at least one 4-way connector, wherein the connectors feature both screw-in connections and snap-button joints. Additionally, the Modular Carport Frame System includes a securing mechanism for attaching a canopy to the frame.