Ball-and-Cavity Coupler System to Reduce Wear in Rod Connections
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Solution Overview
Problem
Conventional hook-and-slot systems for hanging horizontal rods require precise 90-degree engagement, leading to wear and enlargement of slots, resulting in excessive play and reduced effectiveness over time.
Innovation Solution
A coupler system featuring a top-cap component with beveled cavities and ball-cap components that allow for secure attachment and rotation of horizontal rods at various angles (75-150 degrees) using reinforced plastic or metal materials, reducing wear and maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional hook-and-slot systems are used, then the connection structure is simple, but the slots become enlarged over time causing excessive play and reduced effectiveness
Solution Approach 1:
The patent replaces the conventional slot geometry with a spherical ball element that fits into a corresponding cavity. The ball's curved surface allows for point contact rather than linear contact, eliminating the wear and enlargement issues associated with slots. The spherical geometry enables the connection to maintain stability while accommodating angular adjustments without causing slot deformation.
2Strength
If hook components engage slot components at 90 degrees, then the connection is secure, but the metal hook edge causes wear against the slots
Solution Approach 1:
The ball component with its spherical surface replaces the metal hook edge, distributing contact forces over a curved surface rather than concentrating them at a sharp edge. This curvature reduces stress concentration and minimizes wear on the cavity walls, while maintaining secure engagement through the ball-cavity interface.
Solution Approach 2:
The patent specifies that the ball and cavity components can be made from reinforced plastic or metal materials. Using composite or reinforced materials increases the wear resistance of the connection components, allowing them to withstand repeated engagement and disengagement without degrading the slot or cavity geometry.
3Adaptability or versatility
If ball-cap components are used to allow rotation at various angles, then adaptability is improved, but device complexity increases
Solution Approach 1:
The spherical ball component inherently provides rotational freedom about multiple axes while maintaining a simple geometric form. The ball-cavity interface naturally accommodates angular adjustments from 75 to 150 degrees without requiring additional complex mechanisms, as the spherical geometry allows smooth rotation within the cavity constraints.
Data Source
AI summary
A coupler system for connecting elongate, horizontally disposed rods to vertical supports includes a top-cap component for attaching to the top of a vertical support. The top-cap support includes a body with plural cavities, and at least one ball-cap component for attaching to an end of a rod. The ball-cap component includes a ball region that fits within one of the plural cavities. The body may be formed with four plural cavities, each having beveled edges. The ball-cap component may include a ball region, a neck region, and an angled region located adjacent the neck region and away from the ball region. The top-cap and ball-cap components may include insertion regions with opposing sets of ribs. The coupler system may further include a cover component, and the body may be formed with a central hole for receiving a fastener that secures the cover component to the top-cap component.