Angled End Cap Support Assembly to Prevent Rotation Under Load
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Solution Overview
Problem
Existing support assemblies for corner applications are prone to rotation and disengagement under significant force, and hollow wall mounting systems lack aesthetic appeal due to visible force-distributing elements, while sliding door mounting hardware is bulky and ineffective in controlling door momentum and sway.
Innovation Solution
A support assembly with end caps angled relative to each other to stabilize against rotational forces, a mounting system with a cover plate to conceal force-distributing elements, and a sliding door mounting system featuring a linear needle roller bearing and anti-sway bracket for smooth operation and reduced momentum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing support assemblies are mounted in corners between two converging walls, then they provide basic support functionality, but they rotate and become disengaged under significant force
Solution Approach 1:
The end caps are angled relative to each other rather than being parallel, creating an asymmetric configuration that stabilizes the support member against rotational forces. The first end cap has a first angle relative to the support member's longitudinal axis, while the second end cap has a second angle, preventing the assembly from rotating under load.
Solution Approach 2:
The patent introduces angular orientation as a new dimension of control by angling the end caps relative to the support member's longitudinal axis. This angular dimension creates moment forces that counteract rotational movement, adding a stabilizing mechanism that operates in a different dimensional space than simple parallel mounting.
2Reliability
If force-distributing elements are used in hollow wall mounting systems, then secure attachment is achieved, but aesthetic appeal is compromised due to visible elements
Solution Approach 1:
The visible force-distributing elements are extracted from the final aesthetic view by positioning them behind the cover plate. The cover plate serves as a visual barrier that conceals the functional but aesthetically undesirable mounting elements, separating the structural function from the aesthetic function.
Solution Approach 2:
The cover plate acts as an intermediary element that mediates between the functional mounting components and the aesthetic requirements. It provides a visually pleasing surface that hides the mechanical elements while allowing the mounting system to function effectively behind it.
3Strength
If traditional sliding door mounting hardware is used, then door support is provided, but the hardware is bulky and ineffective in controlling door momentum and sway
Solution Approach 1:
The patent changes the physical parameters of the mounting hardware by using thin, profiled brackets with precise geometric features rather than bulky traditional hardware. The angled slots and specific bracket configurations provide the necessary mechanical advantage and control without increasing overall hardware size.
Solution Approach 2:
The mounting system is segmented into distinct functional components: brackets with angled slots for positioning, rollers for movement, and anti-sway mechanisms. This segmentation allows each component to be optimized for its specific function while maintaining a compact overall structure.
4Ease of manufacture
If end caps are positioned parallel to each other in support assemblies, then simple mounting is achieved, but rotational stability is lost under force
Solution Approach 1:
The end caps are positioned at asymmetric angles relative to the support member's longitudinal axis rather than parallel to each other. This asymmetric angular positioning creates stabilizing moment forces that prevent rotation while maintaining relatively simple manufacturing processes.
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
The support assembly maintains stability under force without rotating, the mounting system provides secure and aesthetic attachment to hollow walls, and the sliding door system operates smoothly with reduced momentum and sway.
Implementation Method 1
linear needle roller bearing for smooth operation
Implementation Method 2
The rotational axes of the end caps contrast each other and in turn stabilize a structure extending between and from the end caps. Moment forces only exist in the area of the structure that exceeds the axes of the end caps.
Implementation Method 3
torsion forces are negated by opposing each other resulting in an assembly that is stable and does not rotate upon a force being applied thereto
Data Source
AI summary
A support assembly that includes a structural member that is delimited by a first end and a second end with a first end cap configured to be at least partially disposed within the first end of the structural member and a second end cap configured to be at least partially disposed within the second end of the structural member to mount the structural member to a structure. The support assembly allows for forces to be applied in all directions without causing rotation or disengagement of the support assembly from a mounting structure.