Sheet-Metal Cable Trough Module With Nested Hooking Flaps
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Solution Overview
Problem
Existing cable tray modules require additional fastening means like screws and nuts for secure connection due to weak joint strength between modules, even with reinforcing rails and tongue-and-groove configurations.
Innovation Solution
A U-shaped tray module design featuring longitudinal slots for hooking flaps, where one flap is straight and the other is bent, fitting within reinforcing rails, and notches and pins on the bottom wall for additional support, allowing secure tongue-and-groove connections without additional fastening means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tongue and grooving connection is used between adjacent tray modules, then assembly simplicity is improved, but connection strength is insufficient requiring additional fastening means
Solution Approach 1:
The connection system is segmented into multiple functional elements: tongue portion, groove portion, reinforcing rail, and hooking flaps. Each element performs a specific function in the connection process, distributing the connection strength across multiple components rather than relying on a single mechanism.
Solution Approach 2:
The hooking flaps are nested within the reinforcing rails during connection. The flaps engage with the rails by sliding inside them, creating a nested configuration where the flaps are housed within the rail structure, providing both connection and reinforcement simultaneously.
Solution Approach 3:
The connection mechanism combines multiple structural features (tongue, groove, reinforcing rail, hooking flaps) into a composite connection system. This composite approach integrates different connection methods into a unified structure that achieves both ease of assembly and high connection strength.
2Strength
If reinforcing rails are added to tray modules, then structural strength is improved, but device complexity increases
Solution Approach 1:
The reinforcing rails serve multiple functions: they provide structural reinforcement to the tray module, guide and contain the hooking flaps during connection, and act as the receiving structure for the nested flaps. This multi-functionality reduces the need for separate components.
Solution Approach 2:
The reinforcing rails are merged with the connection mechanism by integrating the hooking flaps directly into the rail structure. The rails and flaps work together as a unified connection system rather than separate elements, simplifying the overall device.
3Strength
If multiple fastening means are used to strengthen connection, then connection strength is improved, but ease of assembly deteriorates
Solution Approach 1:
The connection mechanism is designed to be self-assembling through the tongue and grooving configuration. The tongue of one module automatically engages with the groove of the adjacent module, and the hooking flaps self-align and slide into the reinforcing rails without requiring external fastening operations.
Solution Approach 2:
The hooking flaps are pre-configured in a position where they can slide into the reinforcing rails during the connection process. The reinforcing rails are pre-formed with the appropriate geometry to receive and guide the flaps, enabling automatic engagement without additional fastening steps.
Data Source
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AI summary
The module is a U-shaped profile (1) with a bottom wall (2) and lateral walls (3) with a first section (10) wherein the walls have an end in the form of a tube-shaped reinforcing rail (4) and a second section (11) wherein the lateral walls have hooking flaps (5, 6) and the end spans (100, 110) can be coupled to each other via tongue and grooving. The lateral walls (3) of the first section (10) have slots (7) for the coupling of the hooking flaps. Furthermore, one flap is a straight flap (5) which extends obliquely towards the interior of the module, while the other flap is a bent flap (6) with a first portion (60) which extends obliquely from the lateral wall towards the interior of the module and a second portion (61) extends obliquely outwards and when two modules are joined by tongue and grooving, the straight flap (5) fits inside of the respective reinforcing rail (4), resting against the inner face thereof which is closest to the interior of the tray module and the bent flap (6) fits into the respective reinforcing rail (4), resting against the inner face thereof which is furthest from the interior of the module.