Plastic Window Frame Corner Joint Using Connector Elements
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Solution Overview
Problem
The challenge in producing window frame corner connections for 'Dutch windows' using hollow plastic profiles is that complex three-dimensional preparations are required, which are difficult to achieve with simple milling machines, making it inaccessible to smaller window construction companies.
Innovation Solution
A method involving post milling on the vertical frame section and using a specially designed connector set, including an angle connector element and an external connecting element, to create a corner connection without the need for miter cuts or welding, allowing for a simple and cost-effective assembly with standard tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complex three-dimensional preparation of frame section ends is performed to achieve tight welding, then joint strength and sealability are improved, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The corner joint is divided into multiple components: two angle connector elements (each forming a right angle with arms) and two profile sections. Each component is simpler to manufacture individually, but together they form the complete corner joint assembly, replacing the need for complex monolithic three-dimensional preparations.
Solution Approach 2:
The angle connector elements serve as intermediary components between the profile sections. Instead of directly joining profile sections requiring complex three-dimensional preparations, the angle connectors mediate the connection through simple right-angle geometries that are easier to manufacture and assemble.
2Manufacturing precision
If multi-axis milling machine is used to create three-dimensional contours, then manufacturing precision is improved, but equipment cost and availability worsen
Solution Approach 1:
Instead of using complex multi-axis milling machines to create three-dimensional contours on the profile ends, the invention inverts the approach by using simple right-angle connector elements that require only basic cutting operations. The complexity is transferred from the machining process to the design of the connector geometry.
Solution Approach 2:
The angle connector elements are simple, inexpensive components that can be manufactured with basic equipment. Rather than investing in expensive multi-axis milling machines, smaller companies can produce these connectors using affordable tools, making the manufacturing process accessible and cost-effective.
3Stability of the object's composition
If miter cuts are made to join profile ends, then joint tightness is improved, but visibility of cuts on exterior surface worsens
Solution Approach 1:
The angle connector elements are designed with different geometries for different locations: the external surfaces maintain smooth, clean lines suitable for visible exterior surfaces, while the internal connection areas provide the necessary right-angle geometry for tight joints. This local differentiation of qualities resolves the conflict between joint tightness and aesthetic appearance.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
Method for producing a frame corner joint (100): a) Providing a first plastic hollow profile with a first angle of inclination α of the visible surface (13) for a lower horizontal frame section (10); b) Providing a second plastic hollow profile with a second angle of inclination of the visible surface (23) for the vertical frame section (20); c) Producing a mullion milling (52) at each end of the vertical frame section (20), wherein the angle α' between the cut edge (27) and the outer visible surface (21) corresponds in each case to the opposite angle of the first angle of inclination α; d) Producing a contour milling (51) at each end of the horizontal frame section (10), wherein at least the outer outer visible surface (11) is in each case in a projection section (11).1) remains and the subsequent profile body is removed; e) attaching an external connector element (40) with a projecting profile tongue (41, 42) to the end face of the horizontal frame section (10); f) placing the vertical section (20) onto the horizontal section (10), wherein the profile tongue (41, 42) of the external connector element (40) is inserted between locking lugs on the outer circumferential surfaces of the vertical frame section (20); and g) connecting the sections (10, 20) via an angle connector element (30) each, which is placed on the inner rebate surfaces (14, 24) and screwed to them.