Universal Frame Assembly with Dovetail Keys and Keying Channels
Solution Overview
Problem
Existing door and window frames are limited to standard sizes, leading to delays and additional costs when non-standard sizes are required, as they often necessitate customization or waiting for specific manufacturer products.
Innovation Solution
A method and kit for assembling frames that includes forming a sill and lintel with keying channels and attaching dovetail keys to jambs, allowing for customizable frame sizes without excessive waste or specialized tools, enabling quick assembly and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If standard-sized frames are used, then manufacturing and assembly are simplified, but adaptability to non-standard dimensions is reduced
Solution Approach 1:
The frame is divided into separate modular components (sill, lintel, jambs) that can be independently manufactured in standard sizes and then assembled into custom configurations. The keying channel and key mechanism enable these segmented parts to connect flexibly, allowing the same standardized components to create frames of various dimensions without requiring custom-manufactured frames for each size.
Solution Approach 2:
The keying channel design with tapered sections creates a universal connection mechanism that works across different frame sizes and configurations. The same keying channel and key design can accommodate various jamb widths and frame dimensions, making the joining mechanism multi-functional and adaptable to diverse structural requirements while maintaining assembly simplicity.
2Adaptability or versatility
If custom-sized frames are manufactured, then adaptability to specific dimensions is improved, but production time and cost increase
Solution Approach 1:
The sill, lintel, and jambs are pre-manufactured in standard sizes with the keying channels and keys already formed as integral parts. This preliminary preparation of standardized components eliminates the need for time-consuming custom manufacturing and fitting processes, allowing rapid assembly into custom configurations by simply connecting the pre-formed modular sections.
3Stability of the object's composition
If traditional frame joining methods are used, then structural stability is achieved, but assembly complexity and material waste increase
Solution Approach 1:
The keying channel and key mechanism is designed to be self-aligning and self-locking through its tapered geometry. The taper automatically guides the key into the correct position within the keying channel and creates friction-based retention without requiring additional fasteners, alignment tools, or complex assembly procedures, thereby maintaining structural stability while simplifying the assembly process.
Data Source
AI summary
The invention is a method, an apparatus and a kit of parts for assembling a universal frame with at least two jambs, a lintel and a sill. The resulting frame is suitable for any size of opening and any size of door, with the option to include single doors or double doors as well as side screens and/or side lights. The frame is typically assembled by cutting the jambs (and optionally the sill and/or lintel) to a selected size, attaching keys to each end of each jamb and inserting the keys into keying channels in the sill and lintel.