Adhesive-Bonded Polymer Connector Assembly for Lightweight Frames
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Solution Overview
Problem
Conventional metal brackets used in connector devices are heavy and expensive to manufacture, and polymer brackets lack the necessary strength and structural integrity to support loads and withstand repeated use, especially in applications like ladders and furniture.
Innovation Solution
A polymer bracket design featuring a base member with projections, channels, and ports for adhesive injection, allowing for secure coupling with frame members through a two-part phosphate ester elastomeric epoxy composition, enhancing structural integrity and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal brackets are used for connector devices, then strength and structural integrity are improved, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent uses polymer materials with reinforcing fibers (such as glass fibers, carbon fibers, or aramid fibers) embedded within the polymer matrix to create a composite bracket that combines the lightweight advantage of polymers with the strength characteristics of fiber reinforcements, thereby achieving both weight reduction and maintained structural integrity
Solution Approach 2:
The patent modifies the polymer material parameters by selecting high-strength, high-modulus polymers and adjusting the fiber reinforcement content, orientation, and distribution to optimize the strength-to-weight ratio, enabling the polymer bracket to withstand required loads while maintaining lightweight properties
2Strength
If metal brackets are used for connector devices, then strength and structural integrity are improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces traditional mechanical joining methods (such as welding or mechanical fastening) with chemical bonding using adhesives applied through channels and ports in the polymer bracket, simplifying the manufacturing process and reducing costs while maintaining joint strength
Solution Approach 2:
The patent optimizes polymer material parameters by selecting materials with appropriate viscosity, cure characteristics, and bonding properties that enable efficient adhesive application and curing processes, thereby reducing manufacturing complexity and cost
3Strength
If adhesive channels and ports are added to the polymer bracket, then coupling strength is improved, but device complexity increases
Solution Approach 1:
The patent integrates the adhesive delivery system (channels and ports) directly into the polymer bracket structure during the molding process, combining the structural function of the bracket with the adhesive application function, thereby avoiding separate components and reducing overall device complexity
Solution Approach 2:
The patent pre-forms the adhesive channels and ports within the polymer bracket during manufacturing, preparing the adhesive delivery pathways in advance before final assembly, which simplifies the bonding process and reduces the complexity of assembly operations
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
The solution provides a lightweight, cost-effective connector assembly that maintains structural integrity under compression, bending, and torsion forces, ensuring durability and ease of manufacturing.
Implementation Method 1
an adhesive, introduced via the port, situated within the end channel
Data Source
AI summary
The present teachings generally relate to a frame assembly comprising a connector device and a method for fabricating the same. The frame assembly comprises a member (12) and one or more connector devices (14A, 14B) coupled to and supporting opposing ends the member. Each of the one or more connector devices comprise a base member; a first projection extending from a first side of the base member, the projection defining a cavity; an end channel situated within the cavity and extending around a perimeter of the projection proximate the base member; a port extending from the end channel on the first side of the base member to a second side of the base member, the second side being in opposing relationship to the first side; and an adhesive, introduced via the port, situated within the end channel. Opposing ends of the member are situated within each of the cavities of two connector devices, respectively, and in contacting relationship with the adhesive.