Ball-and-Socket 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 eventual enlargement of slots, causing excessive play and instability.
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 (75-150 degrees) using metal or high-strength plastic materials, providing structural integrity and adjustability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hook-and-slot systems are used for hanging horizontal rods, then the system structure is simple, but the hook components require precise 90-degree engagement which causes wear against the slots, leading to slot enlargement and excessive play over time
Solution Approach 1:
The patent replaces the conventional hook-and-slot connection with a ball-and-socket joint system. The ball component (spherical) fits into the socket component (cylindrical with angled bore), allowing rotational movement and angular adjustment. This curved geometry eliminates the linear sliding wear of hook-and-slot systems, as the ball rotates within the socket rather than the hook sliding along the slot edges.
Solution Approach 2:
The ball-and-socket joint provides dynamic adaptability by allowing the connection to accommodate various angles (75-150 degrees) rather than requiring a fixed 90-degree engagement. The angled bore in the socket and the ball's rotational capability enable the system to dynamically adjust to different positioning requirements while maintaining stable connection, preventing the excessive play that develops in rigid hook-and-slot systems.
2Adaptability or versatility
If conventional hook-and-slot systems require precise 90-degree engagement, then the connection is initially stable, but the system lacks adjustability and becomes less effective after slot enlargement
Solution Approach 1:
The ball-and-socket joint provides dynamic adaptability by allowing the connection to accommodate various angles (75-150 degrees) rather than requiring a fixed 90-degree engagement. The angled bore in the socket and the ball's rotational capability enable the system to dynamically adjust to different positioning requirements while maintaining stable connection.
Solution Approach 2:
The invention changes the engagement parameter from a fixed angular requirement (90 degrees) to a range of acceptable angles (75-150 degrees). The ball's spherical geometry and the socket's angled bore with relief features allow the connection to function effectively across this angular range, eliminating the need for precise 90-degree alignment while maintaining connection stability.
3Strength
If metal hooks are used in conventional systems, then the connection is strong, but the metal hook edges cause wear against the aluminum pole slots
Solution Approach 1:
The patent replaces the conventional hook-and-slot connection with a ball-and-socket joint system. The ball component (spherical) fits into the socket component (cylindrical with angled bore), allowing rotational movement and angular adjustment. This curved geometry eliminates the linear sliding wear of hook-and-slot systems, as the ball rotates within the socket rather than the hook sliding along the slot edges.
Solution Approach 2:
The socket component acts as an intermediary between the ball (attached to the rod) and the vertical support pole. The socket's cylindrical outer surface fits into the pole's cavity, distributing loads and preventing direct contact between metal components and the aluminum pole, thereby eliminating the wear problem while maintaining connection strength.
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 including a body with plural cavities formed therein, and at least one ball-cap component for attaching to an end of a rod, and including a ball region that is constructed to fit within one of the plural cavities of the top-cap component. The body may be formed with four of the plural cavities, with each of them having 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 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.