Ball-and-Cavity Rod Coupler for Wear-Resistant Angle Adjustment
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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 at various angles, using reinforced materials like metal or fiber-reinforced plastic, with beveled edges and ribs for structural integrity and adjustability, enabling secure and flexible connection between horizontal and vertical rods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hook-and-slot systems are used for connecting horizontal rods to vertical supports, then the connection can be made, 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 component has a curved spherical surface that engages with a matching cavity in the top-cap, eliminating the linear slot geometry. This spherical connection allows for self-aligning engagement while distributing contact forces across a curved surface, preventing the progressive enlargement and wear that occurs in linear slots.
2Ease of operation
If conventional hook-and-slot systems are used, then connection is possible, but engagement requires precise 90-degree alignment which reduces ease of installation
Solution Approach 1:
The patent introduces a dynamic, multi-degree-of-freedom ball-and-socket joint mechanism that allows the horizontal rod to engage the vertical support at various angles. The ball component can rotate and adjust its orientation within the cavity, enabling engagement without requiring precise 90-degree alignment. This dynamic joint provides angular adjustment capability while maintaining connection stability.
3Strength
If metal hooks are used in hook-and-slot systems, then strong connection is achieved, but the metal hook edges cause wear against the slots
Solution Approach 1:
The patent introduces a plastic or polymer material as an intermediary between the metal ball and the metal support structure. The top-cap containing the cavity is made of plastic material that interfaces with the metal ball, and the vertical support may also have plastic components. This plastic intermediary distributes contact forces, reduces friction, and prevents direct metal-to-metal contact that causes wear and enlargement of the connection interfaces.
4Adaptability or versatility
If conventional hook-and-slot systems are used, then simple structure is maintained, but the system lacks adjustability for various angles
Solution Approach 1:
The patent divides the connection system into separate, modular components: a ball component attached to the horizontal rod, a top-cap component with a cavity attached to the vertical support, and optional reinforcement elements. This segmentation allows each component to be optimized independently while providing angular adjustability through the ball-and-socket joint mechanism. The modular design enables versatility without excessive overall system complexity.
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 and a ball-cap component for attaching to an end of a rod. The top-cap component includes a body formed with plural cavities, and the ball-cap component includes a ball region that is constructed to fit within one of the plural cavities. The body may be formed with four plural cavities, with each defined by beveled edges. The ball-cap components 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 also include insertion regions with opposing sets of ribs. The coupler system may further include a cover component.