Stacked Corner Connector Discs for Automated Frame Assembly
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Solution Overview
Problem
Existing frame assembly technologies require numerous corner connector variants to accommodate varying frame profile heights, complicating automated assembly and limiting the use of identical parts.
Innovation Solution
A modular corner connector system composed of stacked corner connector discs, each with a uniform or slightly varying height, connected through positive locking and/or adhesive mechanisms, allowing flexible adaptation to different frame profile dimensions and enabling automated assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If different corner connectors are used for each corner connector chamber height, then the frame profiles can be accurately assembled, but the number of different corner connector variants increases severely
Solution Approach 1:
The corner connector is divided into multiple individual corner connector discs that can be stacked in different quantities. Each disc has a standardized height, and by varying the number of discs stacked (1, 2, 3, or more), corner connectors of different total heights are created. This segmentation allows a single disc design to replace numerous variant designs.
Solution Approach 2:
A single corner connector disc design serves multiple functions by being stackable in different quantities. The same disc type can create corner connectors of various heights to match different corner connector chamber heights in frame profiles, eliminating the need for multiple specialized disc designs.
2Adaptability or versatility
If a large number of corner connector variants are used, then different frame profile heights can be accommodated, but automated frame assembly is complicated
Solution Approach 1:
The corner connector is segmented into standardized discs that can be automatically stacked in different quantities. Automated assembly systems can easily control the number of discs stacked to match the required corner connector chamber height, simplifying automation compared to handling numerous pre-configured variant types.
Solution Approach 2:
Instead of changing the design parameters of the corner connector disc itself, adaptability is achieved by changing the quantity parameter - the number of identical discs stacked. This single parameter change (stack height) provides versatility for different frame profile dimensions while maintaining identical disc geometry for automated manufacturing.
3Adaptability or versatility
If identical parts are limited in use, then customization for different chambers is possible, but the use of identical parts is severely limited
Solution Approach 1:
The corner connector is segmented into identical, reusable disc units. These identical discs can be stacked in different quantities (1, 2, 3, or more) to create customized corner connectors for different chamber heights, maximizing the use of identical parts while achieving customization.
Solution Approach 2:
A single identical corner connector disc design performs multiple functions by being used in different stack configurations. The same disc type can be used alone or stacked with others to match various chamber heights, greatly increasing the quantity of identical parts that can be utilized across different applications.
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
Facilitates easy and automated assembly of frame corners by providing a versatile connector system that adapts to various profile dimensions, reducing the need for multiple connector types and simplifying the assembly process.
Implementation Method 1
corner connector discs stacked one above the other in a stacking direction in the area of their main outer surfaces and connected to each other, in particular by positive locking and/or adhesive connection
Implementation Method 2
corner connector discs stacked one above the other in a stacking direction in the area of their main outer surfaces and connected to each other, in particular by positive locking and/or adhesive connection
Data Source
Figure 1a~1d
Figure 1c
Figure 2a
AI summary
A corner connector (1) for connecting mitered frame profiles (11, 12) for doors, windows or facade elements, wherein the corner connector (1) has an angular basic geometry with a first leg (2a) and a second leg (2b), wherein the frame profiles (11, 12) are made from a profile (10), wherein the profile (10) has at least one corner connector hollow chamber (8, 9), each having a height dimension B, into which the legs (2a, 2b) of the corner connector (1) are inserted when assembling the frame profiles (11, 12) to form a frame or sash, wherein the corner connector (1) is composed of several, for example three or more, corner connector discs (2), such that a stack (3) of corner connector discs (2) is formed.