Prefabricated Wall Frame Structure with Shape Coupling
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Solution Overview
Problem
Traditional prefabricated wall frame structures experience instability and material weakening due to single fixing points and through holes, leading to undesired movement and reduced mechanical strength under stress.
Innovation Solution
A frame structure with 'C' or 'U' section profiles featuring raised portions and longitudinal recesses for secure connection, allowing for multiple connection points and stress distribution, enhancing stability and strength through shape coupling and riveted connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single fixing points are used to connect uprights and cross-members, then the structure is easier to manufacture, but the structure experiences undesired relative movement and instability under high stresses
Solution Approach 1:
The connection system is segmented into multiple fixing points (at least two per side) instead of a single fixing point. This segmentation distributes the mechanical loads and prevents relative movement between uprights and cross-members, thereby improving stability while maintaining ease of manufacture through modular connection elements.
Solution Approach 2:
The connection is enhanced by adding multiple fixing points in different spatial locations (different dimensions) along the overlapping sides. This multi-dimensional distribution of connection points prevents rotation and translation under stress, transforming a single-point hinge connection into a multi-point rigid connection.
2Ease of manufacture
If through holes are formed for riveted connection, then the connection is simpler, but the material is weakened at the connection zones
Solution Approach 1:
Instead of forming through holes that weaken the entire connection zone, the invention uses raised portions with localized through openings. The connection strength is concentrated in the raised portions which have increased material thickness, while the through openings are minimized to only where necessary for rivet passage. This local quality approach maintains overall material strength while enabling simple riveted connection.
Solution Approach 2:
Raised portions are formed in advance on the uprights and cross-members before the actual connection process. These raised portions pre-position the connection zones and provide reinforced areas that can accommodate riveted connections without significantly weakening the parent material, as the raised portions themselves are designed to be the connection interface.
3Reliability
If multiple connection points are provided at raised portions, then the resistance and stability are improved, but the device complexity increases
Solution Approach 1:
Multiple connection points are merged into an integrated raised portion structure. The raised portions on both the upright and cross-member are designed to interengage as a unified connection system, providing multiple fixing points simultaneously. This merging approach improves resistance and stability while avoiding the complexity of separate connection mechanisms for each fixing point.
Solution Approach 2:
The raised portions serve multiple functions: they provide structural reinforcement, define the connection interface, locate multiple fixing points, and facilitate the riveting process. This multi-functionality reduces the need for additional specialized components, thereby improving resistance without proportionally increasing device complexity.
Data Source
Figure 1
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AI summary
The frame structure comprises at least one first element (2) and at least one second element (3) operably associable with each other, in which each of the at least one first element (2) and the second element (3) comprise at least one longitudinal recess (6, 9), the at least one second element (3) having at least one end (10) engageable along the at least one longitudinal recess (6) of a first element (2), in which the frame structure comprises connection means (12) for the reciprocal connection between overlapping portions of the first element (2) and of the second element (3) in correspondence at least of the end (10), wherein the first element (2) comprises at least one raised portion (13, 13') and the second element (3) comprises at least one further raised portion (14, 14') engageable by the raised portion (13, 13') by shape coupling and in which the raised portion (13, 13') and the further raised portion (14, 14') each respectively contain at least one or more through openings (15) or further through openings (15') that may be reciprocally overlapped and engageable by the connection means.