Tubular Frame Connectors for Weld-Free Modular Assembly

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Solution Overview

Problem

The challenge of constructing high-quality awning frames efficiently and transporting them to customer locations is hindered by the need for welding and the resulting large, heavy structures, which require significant equipment and time.

Innovation Solution

The System of Tubular Connections (STC) uses lightweight, portable connection pieces that allow for on-site framework assembly, utilizing elements like threaded rods, tubing fasteners, and building blocks to securely join symmetrical tubing without welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to connect framework pieces, then structural strength is improved, but fabrication time and complexity increase

Engineering Contradiction:

Improvestructural strengthVSAvoidfabrication time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The framework is divided into separate tubular elements that can be connected through telescoping joints rather than welded, allowing for modular assembly and disassembly while maintaining structural integrity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Telescoping joint mechanisms serve as intermediary components between tubular elements, providing a non-welded connection method that maintains structural strength while enabling easier assembly and disassembly

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If welding is used to connect framework pieces, then structural strength is improved, but device complexity increases

Engineering Contradiction:

Improvestructural strengthVSAvoidfabrication complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The welding process is replaced with a mechanical telescoping joint system that achieves structural strength through interlocking mechanisms rather than thermal joining

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If framework structures are made large and heavy for strength, then structural strength is improved, but ease of transportation deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoidease of transportation

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The framework transitions from a static, fixed structure to a dynamic, modular system that can be assembled and disassembled, enabling easy transportation without compromising structural strength when assembled

Inventive Principle:

Principle #15Dynamics

4Strength

If framework structures are made large and heavy for strength, then structural strength is improved, but productivity deteriorates

Engineering Contradiction:

Improvestructural strengthVSAvoidassembly speed

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Framework elements are pre-fabricated as separate tubular components with standardized telescoping joints, allowing for rapid on-site assembly without requiring complex welding operations

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS12398743B1System of tubular connections

Publication Date: 2025.08.26 WINTERS JR DOUGLAS E

AI summary

The System of Tubular Connections (STC) is a building method for constructing and fastening together any elongated symmetrical frameworks such as awning or fences, eliminating the need for other fastening methods such as welding. The STC consists of 4 basic physical elements. Element 1 is any elongated symmetrical shape, for example tubing or 2×4 wooden boards. Element 2 is any threaded product. Element 3 is a tubing fastener used when Element 1 is symmetrical hollow tubing. Element 4 is the building block that the elongated symmetrical shape is screwed into or through.