RV Flange Corner Piece Squared Extrusion Assembly
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Solution Overview
Problem
The existing flange systems for slide-out rooms in RVs require precise measurement and attachment of mitered corners, which is skill-intensive and prone to errors, leading to poor fitment, leaks, and aesthetic issues due to the need for external fasteners that can damage the seal or prevent proper closure.
Innovation Solution
A flange system using corner pieces that receive extrusions, allowing for squared cuts with a wide tolerance band, eliminating the need for external fasteners and ensuring proper alignment and sealing without the risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If mitered corners are used for the extrusion, then the aesthetic appearance is improved, but the manufacturing precision and skill requirement increase significantly
Solution Approach 1:
The corner assembly is segmented into three separate components: the extrusion (cut squarely), the corner cover (pre-formed at 45-degree angles), and the mounting bracket. This segmentation allows the extrusion to be cut with standard square cuts using common tools, while the aesthetic mitered appearance is achieved through the pre-formed corner cover that is attached separately.
Solution Approach 2:
The corner cover acts as an intermediary element between the squarely-cut extrusion and the final aesthetic requirement. It provides the mitered appearance without requiring the extrusion itself to be mitered, thereby simplifying the manufacturing process while maintaining the desired visual outcome.
2Strength
If external fasteners are used to attach trim pieces, then the attachment strength is improved, but the risk of damage to seal and side wall increases
Solution Approach 1:
The mounting bracket serves as an intermediary that distributes the attachment forces across a broader area of the extrusion and corner cover assembly. This intermediate structure allows for secure attachment while preventing concentrated fastener forces from directly damaging the seal or side wall, as the bracket absorbs and distributes these loads.
Solution Approach 2:
The mounting bracket extends the attachment system into a third dimension by providing a structural framework that connects the extrusion to the corner cover. This dimensional addition allows fasteners to attach to the bracket rather than directly to the seal or side wall, thereby maintaining attachment strength while eliminating the harmful direct contact between fasteners and sensitive components.
3Manufacturing precision
If precise measurement and attachment are required for mitered corners, then the fitment quality is improved, but the manufacturing time and productivity decrease
Solution Approach 1:
By segmenting the corner assembly into separately manufactured components (extrusion, corner cover, mounting bracket), each piece can be produced using standard, faster manufacturing processes. The extrusion is cut squarely with common tools, the corner cover is pre-formed with mitered angles in advance, and assembly is simplified to basic attachment steps, thereby eliminating the need for time-consuming on-site mitering and precision measurement during installation.
Solution Approach 2:
The corner cover is prepared in advance with pre-formed 45-degree angles and attachment features during manufacturing. This preliminary action transfers the complex machining operations to the factory setting where they can be performed efficiently, allowing the field installation to proceed quickly with simple assembly steps rather than requiring precise measurement and mitering at the installation site.
Data Source
AI summary
A flange corner piece is provided that is used to provide decoration and sealing to the perimeter of a slide-out room. The slide-out room has an outside wall with a perimeter edge. Elongate extrusions are attached to the perimeter. The extrusions have terminal ends that are located proximate corners on the outside wall. Terminal ends of the extrusions are received by first and second receiving pockets in the flange corner piece. The receiving pockets are made up of walls that overlay portions of the extrusions and constrain it. The first and second receiving pockets affix neighboring extrusions and conceal the corners of the slide-out room.