Segmented Frame and Screen System with Friction Locking
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Solution Overview
Problem
The existing methods for assembling and shipping window and door frames are costly and require large vehicles, specialized tools, and time-consuming installation due to the size and fragility of the components, necessitating a more efficient and cost-effective solution for consumer assembly and transportation.
Innovation Solution
A component-based frame and screen system utilizing lineal, corner, splice, and cross-bar components that friction lock together, allowing for easy assembly and interlocking of a screen, with components made from polymeric or metal materials, and a screen locking insert for secure attachment, enabling compact packaging and minimal tool requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional window and door frames are shipped and installed as complete assemblies, then structural integrity and functionality are maintained, but shipping costs increase and require large vehicles and specialized handling
Solution Approach 1:
The frame assembly is divided into multiple discrete components including head pieces, jamb pieces, sill pieces, and corner pieces that can be separately packaged and shipped. These segmented components are designed with interlocking features that allow them to be assembled on-site to form the complete frame structure, thereby reducing shipping volume while maintaining structural integrity when assembled.
2Manufacturing precision
If complete frame assemblies are shipped to installation sites, then proper alignment and fit are ensured, but installation time increases and requires specialized tools
Solution Approach 1:
The frame components are pre-designed with integrated alignment features such as guide rails, positioning pins, and interlocking geometries that automatically ensure proper alignment during assembly. This preliminary design of alignment mechanisms eliminates the need for complex measurement and adjustment procedures during installation, thereby maintaining manufacturing precision while reducing installation time and tool requirements.
3Reliability
If screens are attached to complete frame assemblies, then screen stability is maintained, but packaging complexity and cost increase
Solution Approach 1:
The screen assembly is segmented from the frame structure, allowing the screen to be packaged separately in a flat, compact form. The frame components are designed with integrated screen attachment features such as channels, clips, or grooves that receive and secure the screen during assembly. This segmentation enables simple, flat packaging for both frames and screens while maintaining screen stability through the interlocking attachment mechanisms.
4Strength
If adhesive is used to bond frame components, then joint strength is improved, but assembly complexity and environmental impact increase
Solution Approach 1:
The patent replaces chemical bonding (adhesive) with mechanical interlocking systems including friction-fit interfaces, snap-fit features, and interlocking geometries between frame components. These mechanical connection methods provide sufficient joint strength while eliminating the need for adhesives, thereby reducing assembly complexity (no mixing, applying, or curing time required) and minimizing environmental impact associated with chemical substances.
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 reduces shipping and freight costs, allows consumers to assemble and install frames without specialized tools, and minimizes environmental impact by using compact, lightweight, and recyclable materials, facilitating rapid and cost-effective installation of frames and screens.
Implementation Method 1
lineal components with a hollow body, each lineal component capable of friction locking through the hollow body
Implementation Method 2
a screen locking insert that interlocks in the screen lock channel by compressing the screen into the screen lock channel
Data Source
AI summary
Disclosed is a multiple component frame and screen system and method which may include lineal components with a hollow body, each lineal component capable of friction locking through the hollow body. The system may further include corner components, each corner component capable of friction locking with the lineal components. The system may further include splice components, each splice component capable of friction locking with the lineal components. The system may further include cross-bar components, each cross bar component capable of friction locking with the lineal components. A multiple component frame and screen may include a screen that interlocks in a screen lock channel of the lineal components, the corner components, the splice components, and the cross-bar components. Further, configuration methods are disclosed wherein the system is configured through the connector components, lineal components, and screen components.