Cable Hanger Assembly With Resilient Tongue for Solar Cable Routing
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Solution Overview
Problem
Existing cable hangers are inadequate for managing the increased number of cables in utility-scale solar panel systems, requiring improved cable management solutions that provide secure and efficient cable suspension and attachment.
Innovation Solution
A cable hanger assembly with a base surface, perpendicularly extending sidewalls, and a resilient attachment surface featuring J-hooks and a serrated tongue segment for secure cable carrying and electrical bonding to the mounting surface, allowing for improved cable management and attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional cable hangers are used in utility-scale solar systems, then the structure remains simple, but cable management becomes inadequate for increased cable numbers
Solution Approach 1:
The patent implements nesting by placing one J-hook inside another, with the first J-hook extending from the first sidewall and the second J-hook extending from the resilient attachment surface. This nested configuration allows multiple cables to be suspended from a single hanger unit, improving cable management capability while maintaining a compact structure that does not significantly increase overall device complexity.
Solution Approach 2:
The hanger is segmented into distinct functional components: a base surface for cable resting, first and second sidewalls forming boundaries, and a resilient attachment surface with the tongue segment for mounting. This segmentation allows each component to perform its specific function efficiently, enabling improved cable management through the closed cable carrying area while keeping the overall design manageable.
2Stability of the object's composition
If a secure cable carrying area is formed with sidewalls and attachment surface, then cable stability improves, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functions into a single integrated hanger structure: the base surface, sidewalls, and resilient attachment surface are formed as one continuous component. This consolidation creates the closed cable carrying area that stabilizes cable positioning while simplifying manufacturing, as the entire structure can be produced in a single molding or forming operation rather than assembling multiple separate parts.
Solution Approach 2:
The resilient attachment surface incorporates a tongue segment with offset surfaces that provide flexibility and resilience. This flexible element can deform during installation to accommodate mounting surface variations, ensuring stable cable positioning while maintaining ease of manufacture through simple material selection and forming processes.
3Reliability
If a resilient attachment surface with tongue segment is used, then attachment reliability to mounting surface improves, but device complexity increases
Solution Approach 1:
The resilient tongue segment with offset surfaces provides self-aligning and self-adjusting attachment capabilities. During installation, the resilient surface deforms to accommodate variations in the mounting surface, automatically finding the correct engagement position without requiring precise alignment or additional adjustment mechanisms. This self-service feature improves attachment reliability while keeping the device structure simple.
Solution Approach 2:
The tongue segment incorporates offset surfaces that change the geometric parameters of the attachment interface. These offset surfaces create varying contact points and pressure distributions that enhance bonding reliability through friction and mechanical interlocking, while the overall attachment mechanism remains simple and does not significantly increase device complexity.
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 cable hanger assembly effectively manages and secures cables by forming a closed cable carrying area and providing electrical bonding, enhancing cable management in solar panel systems with improved stability and ease of attachment.
Implementation Method 1
the resilient tongue segment above and contacting the mounting surface... to electrically bond the cable hanger to the mounting surface
Implementation Method 2
a resilient attachment surface extending from a distal end of the second sidewall... The cable hanger is attached to the mounting surface by sliding the cable hanger such that the resilient attachment surface is below and contacting the mounting surface
Implementation Method 3
The resilient tongue segment may include a serrated edge that points downwardly from a plane formed by the resilient attachment surface to bite into the mounting surface to electrically bond the cable hanger to the mounting surface
Data Source
AI summary
A cable hanger assembly comprises a cable hanger for attachment to a mounting surface includes a base surface having a proximate end and a distal end, a first sidewall extending substantially perpendicularly from a proximate end of the base surface, where a first hook extends from a distal end of the first sidewall, and a second sidewall extending substantially perpendicularly from a distal end of the base surface. The cable hanger also includes a resilient attachment surface extending from a distal end of the second sidewall, where the attachment surface includes a resilient tongue segment extending from a sidewall surface of an opening in the attachment surface and extending substantially parallel with the resilient attachment surface and the base surface, where the resilient tongue segment includes a plurality of offset surfaces.