Modular Window Connector Set Reduces Part Variety
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Solution Overview
Problem
Current connector systems for window frames and door thresholds require a large variety of parts to accommodate different profile widths and configurations, leading to increased manufacturing complexity and inventory needs, as at least 18 individual parts are necessary for three face widths, including left and right connector elements and setting post connectors.
Innovation Solution
A modular connector set comprising six to eight individual parts, including mirror-image right-hand and left-hand sub-connector sets, with widening elements that allow for adaptation to different profile widths, enabling the formation of setting post connectors from existing parts, reducing the need for specialized elements and simplifying production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate connector elements are manufactured for each ground sill form and profile width, then the connection can be precisely adapted to specific requirements, but the variety of parts increases significantly (at least 18 individual parts)
Solution Approach 1:
The connector element is designed with a universal base structure that can serve multiple functions: it can connect both window frames and setting posts, and it can accommodate different profile widths through the addition of widening elements. This single universal connector design replaces the need for multiple specialized connector types.
Solution Approach 2:
The connector element is divided into modular components: a base connector element and separate widening elements. These segments can be combined in different configurations to create connectors for various profile widths, reducing the need to manufacture completely different connector types for each width.
2Adaptability or versatility
If multiple specialized connector elements are manufactured and kept in stock, then all connection situations can be covered, but manufacturing complexity and inventory requirements increase
Solution Approach 1:
A single universal connector element design serves all connection situations (window frame connections and setting post connections) across all profile widths when combined with appropriate widening elements, eliminating the need to manufacture and stock multiple specialized connector types.
Solution Approach 2:
The function of multiple specialized connector elements is merged into a single universal connector element that can be configured for different applications through the addition of widening elements, consolidating inventory requirements.
3Reliability
If connector elements are designed as two-component production (metal core with injection-moulded elastomeric sealing parts), then sealing functionality is integrated, but the number of parts and production steps increases
Solution Approach 1:
The metal connector core and elastomeric sealing parts are combined into a single integrated connector element through injection molding, eliminating the need for separate sealing components and reducing the total part count while maintaining sealing reliability.
Data Source
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AI summary
A connector set for connecting a threshold to the frame of a window or door comprises two partial connector sets (100, 100') for the left and right connection sides of the threshold, each comprising at least: - a rebate corner connector element (10, 10'); - an elastomeric sealing element (20, 20'); and - a tab connector element (30, 30'). The elements (10, 20, 30) of the partial connector set (100) for the right connection side are mirror images of the elements (10', 20', 30') of the partial connector set (100') for the left connection side. The elements (10, 20, 30; 10', 20', 30') of each partial connector set (100; 100') can be combined to form a frame connector (210). Furthermore, the folding corner connector elements (10, 10') and sealing elements (20, 20') from both partial connector sets (100; 100') can be combined to form a post connector.