Plastic Window Mullion Connector Screwless Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connection arrangements for mullions and frame profiles require significant assembly effort and time due to the need for multiple screws, leading to increased cycle times in automated production lines and material usage.
Innovation Solution
Incorporation of locking elements, such as elastically resilient spring hooks, on the plug-on and base parts allows for a form-fitting, screw-less attachment during assembly, reducing the need for screws and simplifying the assembly process by enabling automatic locking without additional production steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screws are used to fasten the base part to the frame profile and the plug-on part to the post, then a strong and reliable connection is achieved, but the assembly time and complexity increase significantly
Solution Approach 1:
The patent changes the connection mechanism from threaded fastening (screws) to form-fitting locking (interlocking geometry). The locking elements with corresponding locking receptacles create a secure connection through geometric interlocking rather than threaded engagement, eliminating the time-consuming screwing operation while maintaining connection strength
Solution Approach 2:
The patent extracts and eliminates the screws from the assembly process. By designing self-locking connection elements that are integrally formed with the base part and plug-on part, the separate fastening components (screws, bolts, etc.) are removed entirely, reducing assembly steps and time while maintaining structural integrity
2Reliability
If multiple screws are used for fastening, then a secure connection is achieved, but the device complexity and material usage increase
Solution Approach 1:
The patent merges the functions of multiple separate fastening elements into a single integrated locking mechanism. The locking elements and locking receptacles work together as a unified system, eliminating the need for multiple screws, washers, and nuts, thereby simplifying the overall device structure and reducing the number of components
Solution Approach 2:
The patent removes unnecessary fastening components (screws, bolts, washers, etc.) from the assembly. The connection is achieved through the intrinsic locking geometry of the base part and plug-on part themselves, eliminating the need for separate fastening hardware and reducing device complexity
3Reliability
If screws are used for fastening, then a strong connection is achieved, but material usage and production cost increase
Solution Approach 1:
The patent combines the connection function into the base material itself through integrally formed locking elements. These locking elements are molded as part of the base part and plug-on part during injection molding, eliminating the need for separate metal fasteners and reducing overall material usage and cost
Solution Approach 2:
The patent replaces expensive metal screws and fasteners with cost-effective plastic locking elements that are integrally formed during injection molding. This substitution significantly reduces material costs and eliminates the need for additional fastening hardware
4Productivity
If the cycle time is reduced in automated production lines, then productivity increases, but the assembly process becomes more difficult to implement
Solution Approach 1:
The locking elements are designed to automatically engage with their corresponding locking receptacles during the insertion process, without requiring additional fastening operations. This self-locking mechanism eliminates the need for complex automated screw-driving systems, making implementation in production lines straightforward while achieving rapid assembly
Solution Approach 2:
The locking elements are pre-formed as integral parts of the base part and plug-on part during injection molding. This preliminary formation of the locking geometry eliminates the need for subsequent fastening operations, enabling rapid assembly in automated lines without complex implementation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly reduces assembly time, eliminates the need for screws, and lowers material usage, accelerating the assembly process while maintaining a strong and detachable connection, with cycle times reduced from two minutes to less than one second in automated production lines.
Implementation Method 1
locking elements, by means of which the plug-on part on the post and the base part on the frame profile are positively-locking fastened during assembly
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
In a connection arrangement for joining a mullion (1) to a frame profile (2) of a plastic window or door, the mullion (1) has a hollow profile (3) and is attached to the frame profile (2) by means of a mullion connector (4). The connector comprises a base part (9) mounted on the frame profile (2) and a mounting part (5) arranged above it. The mounting part (5) is connected to the mullion (1) and is guided in a form-fitting manner when attached to the base part (9). In the assembled state, the mounting part (5) and the base part (9) are attached to each other. Locking elements (7, 11, 19, 21) are provided on both the mounting part (5) and the base part (9), by means of which the mounting part (5) can be attached to the mullion (1) and the base part (9) to the frame profile (2) in a form-fitting, interlocking manner during assembly.