Polymorphic Metal Sections for Easy Frame and Truss Assembly
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Solution Overview
Problem
Existing methods for constructing metal frames and trusses require specialized equipment, skills, and detailed drawings, making them costly and time-consuming, and they often prevent proper contact between the screw head and covering materials.
Innovation Solution
A structural polymorphic system using two metal, thin wall, open sections with longitudinal channels, where one fits into the other vertically or inclined, joined with drill-screws, allowing for easy assembly without expensive equipment or special skills, and enabling full contact between covering materials and the metal sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If specialized digital guided roll-forming machines with perforating equipment are used, then manufacturing precision and structural strength are improved, but device complexity and production cost increase
Solution Approach 1:
The patent replaces expensive, complex digital guided roll-forming machines with simple, inexpensive roll-formers that produce basic C and U sections. The complexity is shifted from manufacturing equipment to the design of the section geometry itself, which enables polymorphic assembly without requiring precision perforating equipment.
Solution Approach 2:
The patent creates universal C and U sections that can serve multiple functions: they can be assembled in various configurations (flat frames, spatial structures, trusses), joined by different methods (drill-screws, welding, mechanical connections), and adapted to different construction needs without requiring different types of sections or specialized equipment.
2Manufacturing precision
If specialized equipment and detailed structural drawings are required, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent divides the construction system into standardized, modular C and U sections that can be independently manufactured and then easily assembled. The sections are segmented into basic geometric forms that can be combined in multiple configurations without requiring complex on-site fabrication or specialized skills.
Solution Approach 2:
The section geometry itself provides the assembly guidance through its inherent features (channels, protrusions, fitting surfaces), eliminating the need for detailed structural drawings and specialized assembly knowledge. The sections are designed to self-align and self-assemble using simple drill-screws or other basic joining methods.
3Productivity
If screw heads are placed on pre-perforated positions or externally on flat sides, then assembly speed is improved, but the contact of covering material is prevented
Solution Approach 1:
The patent nests the screw heads within the longitudinal channels of the C and U sections, similar to nesting one object inside another. This allows the screw heads to be concealed within the section geometry, enabling full contact between covering materials and the external surfaces while maintaining secure assembly connections.
Solution Approach 2:
The patent applies different functional qualities to different parts of the section: the external flat sides are designed for full covering material contact, while the longitudinal channels provide localized areas for screw head placement. This local differentiation allows both requirements to be satisfied simultaneously in different zones of the same component.
4Strength
If closed metal sections (tubes) are used, then structural strength is improved, but ease of manufacture and assembly deteriorates
Solution Approach 1:
The patent transitions from static, fixed configurations (closed tubes requiring cutting and welding) to dynamic, adaptable configurations (open C and U sections that can be assembled in multiple orientations and configurations). The open sections can be joined by simple mechanical connections rather than permanent welding, enabling easier modification and assembly.
Solution Approach 2:
Instead of using closed tubes and cutting/joining them, the patent inverts the approach by using open C and U sections that are designed to be assembled in their open state. The sections are configured to fit together and be joined by mechanical connections, eliminating the need for cutting and welding 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
This system achieves high mechanical strength, economical production, and versatility in construction, allowing for spatial structures without welding or painting, with easy cutting and screwing facilitated by metrical engraving and artificial embossment, making it suitable for both professionals and amateurs.
Implementation Method 1
joined with drill-screws, forming frames and trusses
Implementation Method 2
produced with the same technology of cold forming, ensuring dimensional precision
Data Source
Figure 1
Figure 2~3
Figure 4a~4f
AI summary
Structural, polymorphic system of metal, thin wall, open sections with three sides (FIG. 3), that everyone can construct from standardized section lengths, with simple means, fast and economically, without the need of expensive equipment and special skills, for the support of several covering materials (metal sheets, panels etc.) (FIGS. 1,2). It consists of two sections, a narrow and a wide one, which fit vertically or inclined, forming flat frames and trusses (FIGS. 6a,6b,7a,7b,8a,8b). The sections have trapezoidal channels (1,2,3) (where the drill-screw head is immersed) and projections (4,5,6,7,8,9,10,11) (FIGS. 8a,8b), that joint together with multiple ways (FIGS. 4a,4b,4c,4d,4e,4f, 5a,5b,5c,7a,7b,8a,8b) and safely connect frames and trusses at light spatial structures of high mechanical strength. The section forming is such that after rotating it by its longitudinal axis by 180°, it nests to an identical section that was not rotated, forming a "closed" section (FIGS. 7a,7b,10a,10b,13a,13b) and allowing the longitudinal continuation of the section with a "sleeve" of the same, and exploitation of all section waste (FIG. 3).