Roof Corner Connector With Plug-In Legs to Replace Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The complex and labor-intensive process of welding aluminum roof edging profiles to form 90° outside and inside corners for roof edges is inefficient and requires a more straightforward connection method.
Innovation Solution
A corner connector system comprising a post and plug-in legs that connect two roof edging profiles without welding, using plug-in legs that fit into receiving grooves and contact surfaces to align with the roof corner angle, allowing for easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect roof edging profiles, then the connection strength is improved, but the manufacturing complexity and labor intensity increase
Solution Approach 1:
The corner connector is divided into separate modular components: a post element and plug-in leg elements that can be manufactured independently and assembled through simple plug-in connection, eliminating the need for complex welding processes while maintaining structural integrity
Solution Approach 2:
The post element acts as an intermediary component that connects the two roof edging profiles through plug-in legs, providing a simplified connection mechanism that replaces direct welding between profiles while ensuring stable structural connection
2Reliability
If welding is used to form 90° corners, then the structural integrity is improved, but the production time and labor effort increase
Solution Approach 1:
The plug-in legs are pre-formed as integral parts of the post element during manufacturing, with receiving grooves and connection features already prepared. This preliminary preparation allows for rapid on-site assembly without time-consuming welding operations, significantly improving production efficiency while maintaining structural integrity through the pre-engineered connection geometry
3Ease of operation
If plug-in connection is used instead of welding, then the ease of assembly is improved, but the connection strength may be reduced
Solution Approach 1:
The plug-in legs are inserted into receiving grooves of the post element, creating a nested connection structure where the roof edging profiles connect through the post element. This nested arrangement provides mechanical interlocking that ensures strong connections while maintaining simple plug-in assembly operations
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
In order to simplify the manufacture of a system (10) for covering a roof corner, comprising two roof edging profiles (14, 16), a corner connector (12) comprises a post (18) extending along a vertical axis (H), and two plug-in legs (20, 22) connected to the post and extending along a first and a second leg axes (S1, S2), respectively, which are arranged perpendicular to the vertical axis and at a first angle to one another with respect to the vertical axis, which is between 30° and 150° for an external roof corner and between 210° and 330° for an internal roof corner, wherein the roof edging profiles each have a first and a second end and extend along the first and second profile axes, respectively, which are arranged perpendicular to the vertical axis and at a first angle to one another with respect to the vertical axis.A system for covering a roof corner comprises the corner connector and the roof finishing profiles, the first being connected to the second roof finishing profile via the first plug-in leg, the post, and the second plug-in leg. The invention proposes a method for manufacturing the system, wherein the corner connector and the roof finishing profiles are provided, the profile axes are arranged perpendicular to the vertical axis and at a first angle to each other with respect thereto, and the first is connected to the second roof finishing profile via the first plug-in leg, the post, and the second plug-in leg.