Single-Piece Cable Loop Box Base for Concrete Casting
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Solution Overview
Problem
Existing cable loop boxes for precast concrete elements are labor-intensive and costly to produce due to their multi-component design, consisting of sheet metal and plastic, which complicates manufacturing and increases production costs.
Innovation Solution
A single-piece base for the cable loop box with integrated cable feed-through and holding elements, made from materials like plastic or sheet metal, allowing for a one-step manufacturing process and enhanced structural integrity, with increased wall thickness for support sections to maintain the cable loop in an angled state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cable loop boxes are made with multiple components (sheet metal box and plastic molded parts), then the cable loop can be held in the angled state with proper support, but the production becomes labor-intensive and costly
Solution Approach 1:
The patent combines the box body, support elements, and holding elements into a single integrated molded part. The base (10) is produced as one piece via injection molding, eliminating the need for separate sheet metal boxes and plastic molded parts. This merging of components resolves the technical contradiction by maintaining the cable loop positioning functionality while dramatically simplifying manufacturing.
Solution Approach 2:
The single molded base performs multiple functions simultaneously: it contains the cable loop, provides support elements (50) for positioning, includes holding elements (40) for securing the cable loop in the angled state, and forms the structural box body. This multi-functionality eliminates the need for multiple separate components while maintaining all necessary capabilities.
2Ease of manufacture
If the base is made as a single-piece structure, then production is simplified and costs are reduced, but the structural integrity to absorb spring forces must be ensured through increased wall thickness
Solution Approach 1:
The patent implements varying wall thicknesses in different regions of the single-piece base. The wall thickness (20) is increased specifically in areas subject to spring forces from the cable loop, while other areas maintain standard thickness. This localized reinforcement ensures structural integrity where needed without unnecessarily increasing material usage or manufacturing complexity throughout the entire component.
3Manufacturing precision
If holding elements and molded parts are added to maintain the angled state, then the cable loop positioning is improved, but the device complexity increases
Solution Approach 1:
The holding elements (40) and support elements (50) are integrated directly into the single molded base structure. These positioning features are formed as part of the injection molding process rather than being separate components. This merging maintains precise cable loop positioning capability while reducing the overall device complexity by eliminating the need to assemble multiple separate parts.
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
This design simplifies production, reduces costs, and ensures the cable loop can be held at a right angle, absorbing spring forces while preventing concrete intrusion during casting, thus enhancing the stability and efficiency of the cable loop box.
Implementation Method 1
The molded parts absorb the forces of the rope loop that occur due to the spring force of the rope in the angled state
Data Source
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AI summary
The base (6) has a rope holding element (9), and a rope guiding element (10) with an opening for leading out an end of a rope loop from a rope loop case (1). The rope loop is receivable in a bent condition in the base such that the rope loop is held between the rope guiding element and the rope holding element, where the base, rope guiding element and the rope holding element are formed as a single-piece. The rope guiding element exhibits a wall thickness between 1 millimeter and 5 millimeters, where the base is made of plastic or injectable or deep-drawn material.