Modular Frame Connector With Slot-and-Tab Reconfiguration
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Solution Overview
Problem
Existing connectors for building structures are bulky, costly to ship, require careful planning, and are not easily modifiable once assembled, limiting design flexibility and increasing construction costs and delays.
Innovation Solution
A modular connector system with sleeves and sockets that allow for easy assembly and reconfiguration, using slots, tabs, and end plates to couple frame members at predetermined angles without welding, enabling flexible structure modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If unitary connectors are welded as finished goods, then connection strength is improved, but shipping cost increases due to large volume and low weight-to-volume ratio
Solution Approach 1:
The connector is divided into separate components (first sleeve, second sleeve, end plate, tabs, slots) that can be shipped in a compact, nested configuration. The sleeves and connection elements are manufactured as separate parts that assemble into the complete connector, dramatically reducing shipping volume while maintaining connection strength through the assembled mechanical joint.
2Adaptability or versatility
If multiple connector variants are stocked to accommodate different connection types, then connection versatility is improved, but inventory complexity and storage cost increase
Solution Approach 1:
The connector system uses universal components (sleeves with standardized slots, tabs with standardized geometries, end plates with standardized attachment mechanisms) that can be combined in multiple configurations to create different connection types. A single set of standardized parts can accommodate various connection angles and orientations, eliminating the need to stock multiple specialized connector variants.
3Productivity
If pre-existing structures are built with fixed connectors, then construction speed is improved, but modification capability deteriorates requiring dismantling and rebuild
Solution Approach 1:
The connector system transitions from static, permanent welded connections to dynamic, reversible mechanical connections. The sleeve-and-tab design allows connectors to be easily assembled and disassembled without specialized tools or permanent modification to the structural members, enabling rapid reconfiguration and adaptation of the structure as needs change while maintaining the speed of initial construction.
4Manufacturing precision
If specialized delivery is used for large constructions, then delivery accuracy is improved, but cost and construction delay increase
Solution Approach 1:
By segmenting the connector into compact, lightweight components that can be nested within each other, the system can be shipped in standard boxes through regular delivery services. The modular components are small enough to be handled by standard logistics, eliminating the need for specialized delivery services while maintaining precision through standardized connection geometries that ensure accurate assembly at the construction site.
Data Source
AI summary
There is disclosed a modular connector for coupling a plurality of frame members to each other. Primary and secondary sleeves of the modular connector are elongated along their respective axes so as to be suitable to engageably receive therein corresponding frame members. A plurality of slots are defined on an axially extending outer face of the primary sleeve. A plurality of tabs extend outwardly from a terminal end of the secondary sleeve. The plurality of tabs are receivable in the plurality of slots to position the primary and secondary sleeves relative each other. An end plate extends inwardly from about the terminal end of the secondary sleeve to abut and fasten to the outer face of the primary sleeve when each of the plurality of tabs is engaged with the plurality of slots to allow removable coupling of the primary sleeve to the secondary sleeve.