Polymer Sleeve Corner Connector for Frame Misalignment
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Solution Overview
Problem
Existing support frames made of hollow profiles and corner connectors require precise coordination and adjustments to ensure proper bolt alignment, leading to material removal and torsion corrections during manufacturing, which complicates the assembly process.
Innovation Solution
The use of discrete polymer sleeves with recesses in the corner connectors allows for a flexible connection by accommodating offset between the hollow profiles and corner connectors, providing elasticity and preload, and adjustable spring properties to enhance connecting strength and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal corner connectors with bolt holes are used, then structural strength is improved, but manufacturing precision and assembly complexity worsen due to requiring perfect hole alignment
Solution Approach 1:
A polymer insert is introduced as an intermediary component between the metal corner connector and the bolt. This polymer insert contains the recesses that receive the bolts, while the corner connector itself retains its strong metal construction. The polymer insert absorbs misalignment tolerances and provides the necessary flexibility, allowing the robust metal connector to maintain its strength while the polymer component handles the alignment tolerance requirements.
Solution Approach 2:
The invention changes the material parameter from rigid metal to flexible polymer for the bolt-receiving component. This material parameter change allows the recesses in the polymer insert to be offset from the hole centers in the corner connector, creating a tolerance buffer that accommodates manufacturing variations without compromising the overall joint strength, since the metal corner connector maintains its structural integrity.
2Reliability
If precise hole alignment is required for bolt connection, then connection reliability is improved, but assembly time and corrective work increase
Solution Approach 1:
The polymer insert serves as a mediator that absorbs alignment tolerances between the corner connector holes and the bolt. This intermediary component allows assembly to proceed without requiring precise alignment, as the polymer can deform to accommodate offsets up to its elastic limit, thereby maintaining connection reliability while significantly reducing assembly time by eliminating the need for corrective adjustments.
Solution Approach 2:
By changing the material from rigid to elastic polymer, the system gains the ability to tolerate dimensional variations. The polymer's elastic properties allow it to deform and accommodate misalignment, maintaining connection reliability through its ability to return to its original shape after bolt insertion, while eliminating time-consuming alignment adjustments.
3Manufacturing precision
If material is removed from hollow profile ends for alignment, then fit precision is improved, but manufacturing complexity and material waste increase
Solution Approach 1:
The polymer insert acts as an intermediary that compensates for fit precision requirements without requiring material removal from the hollow profile ends. The polymer's elastic properties allow it to accommodate the natural tolerances of the metal components, eliminating the need for additional machining operations while maintaining precise fit through its ability to deform and conform to the assembled geometry.
4Manufacturing precision
If torsion corrections are made individually during production, then structural accuracy is improved, but production time and cost increase
Solution Approach 1:
By changing the material parameter from rigid metal to elastic polymer for the bolt-receiving component, the invention allows torsion and alignment variations to be absorbed through elastic deformation rather than requiring individual correction of each metal component. The polymer insert can accommodate these variations within its elastic limit, maintaining structural accuracy while eliminating time-consuming individual adjustments and significantly improving production efficiency.
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 eliminates the need for precise adjustments and material removal, enhances connecting strength through preload, and allows for flexible adaptation to manufacturing variances, decoupling tensile forces between hollow profiles and corner connectors.
Implementation Method 1
The polymer sleeves provide the necessary flexibility and elasticity to compensate for any misalignment between the holes in the hollow profiles and the receptacles on the corner connectors
Implementation Method 2
The polymer sleeve can also serve as a spring element between the corner connector and the hollow profile and be provided with a pre-adjustable spring constant/spring force
Implementation Method 3
an offset between the holes in the hollow profiles and the elastic receptacles can lead to prestressing between the bolts and the supporting frame parts in the assembled state
Implementation Method 4
The offset between the bore(s) in the hollow profile and the at least one recess in the polymer sleeve can preferably be 0.1 mm to 5 mm... can be supplemented by or replaced by a frictional connection
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to a part of a support frame with at least two mitered hollow profiles, each with at least one inner chamber, and at least one corner connector engaging the hollow profiles with its legs, wherein the corner connector has receptacles for insertable fasteners by means of which the hollow profiles and the corner connector can be connected, wherein the fasteners are designed as bolts that can be driven into bores in the hollow profiles and into receptacles in the legs of the corner connector, and wherein the bolts are positively locked in at least one of the receptacles through which the bolt extends, wherein the receptacles are designed as polymer sleeves inserted into the legs of the corner connector, in which at least one recess is provided for positively locking the bolts in the leg.