Modular Corner Connector Using Overlapping Projections for Rigidity
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Solution Overview
Problem
Existing connectors for building structures are bulky, costly to ship, require careful planning, and lack flexibility for modification or expansion, with modular connectors often compromising structural rigidity and aesthetics.
Innovation Solution
A modular connector system comprising angle brackets and a sheath that allows easy assembly and reconfiguration into different configurations, providing rigidity through overlapping projections and weld-free connections, enabling expansion without dismantling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If unitary connectors are welded as finished goods, then structural strength and rigidity are improved, but shipping costs increase and device complexity increases
Solution Approach 1:
The connector is divided into separate modular components (angle brackets, sleeves, connection pieces) that can be assembled on-site to form various connector configurations. This segmentation allows a single standardized kit to produce multiple connector types, reducing the variety of items that need to be shipped and managed while maintaining structural integrity through proper assembly.
Solution Approach 2:
A universal connector kit containing standardized components can be configured to create different connector types (corner connectors, gable connectors, hip connectors, etc.) through various assembly arrangements. This multi-functionality eliminates the need to ship and manage separate inventory for each connector variant, reducing both shipping costs and device complexity while preserving structural strength through designed assembly configurations.
2Device complexity
If modular connectors are used to reduce shipping costs, then shipping costs decrease, but structural rigidity and manufacturing precision worsen
Solution Approach 1:
The modular connector components are pre-engineered with predetermined geometries, hole patterns, and attachment features that guide their assembly into rigid structures. The angle brackets, sleeves, and connection pieces are designed with specific dimensional relationships that ensure proper alignment and stable configurations when assembled, maintaining manufacturing precision without requiring complex welding processes.
Solution Approach 2:
Multiple modular components are combined through standardized connection interfaces to form unified connector assemblies. The design incorporates overlapping elements, interlocking features, and distributed fastening points that create rigid composite structures from modular parts, achieving structural rigidity equivalent to welded unitary connectors while preserving the shipping and assembly benefits of modularity.
3Ease of manufacture
If fully modular connectors are assembled without welding, then ease of manufacture and assembly are improved, but structural performance and rigidity worsen
Solution Approach 1:
Specialized connection pieces and fastening mechanisms serve as intermediaries between the modular components, creating reliable mechanical joints that transfer loads effectively. These intermediary elements (such as bolted connection pieces, friction-fit interfaces, or interlocking brackets) provide the structural performance of welded joints while maintaining the ease of assembly characteristic of modular construction, eliminating the need for welding equipment and expertise.
Solution Approach 2:
The connector system utilizes composite construction combining different materials and structural elements (metal angle brackets, plastic or metal sleeves, fastening hardware) to achieve both ease of assembly and structural performance. The composite nature allows each component to be optimized for its specific function while the combination creates a rigid, reliable overall structure that meets or exceeds the performance of traditional welded connectors.
4Productivity
If pre-existing structures are built with fixed connectors, then construction speed is improved, but adaptability for modification worsens
Solution Approach 1:
The connector system transitions from static, permanent welded connections to dynamic, reconfigurable modular assemblies that can be easily adjusted, expanded, or repositioned. The standardized modular components can be disassembled and reconfigured to accommodate structural modifications, adding or changing elements without requiring dismantling of the entire structure, thereby providing both rapid initial construction and future adaptability.
Solution Approach 2:
By segmenting the connector into standardized modular components with universal attachment interfaces, the structure can be efficiently assembled initially and then easily modified by replacing or reconfiguring individual modules. This segmentation allows selective modification of specific areas without affecting the rest of the structure, providing adaptability while maintaining construction speed through standardized assembly procedures.
Data Source
AI summary
There is disclosed a corner connector to connect three separate frame members to form a tubular corner of a structure. Two angle brackets are provided, each of which includes a corresponding projection and bottom slot formed on respective opposite arms thereof, to attach to two of the frame members. One of the angle brackets includes a side slot dimensioned to securably receive a projection of the other angle bracket therethrough into an interior of the tubular corner to couple the angle brackets to each other. A third angle bracket is attached to the third frame member and comprises a plurality of projections dimensioned according to the bottom slots so as to be securably received therethrough into the interior to overlap the projections to improve rigidity by obstructing the projections to mitigate movement. A rigid sheath is then attached to the angle brackets to form three sleeves.