Conductive Splice for Ladder Rack Bonding

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Solution Overview

Problem

Existing methods for bonding ladder rack sections require multiple complex and potentially dangerous steps, including removal of paint, drilling additional holes, and installation of grounding straps, to achieve secure and electrically conductive connections, especially in high-altitude installations.

Innovation Solution

The introduction of a ladder rack splice system that uses conductive screws with cutting and threaded portions to join ladder rack segments without the need for paint removal, additional hole drilling, or grounding strap installation, providing a solid physical and electrical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional bonding systems are used to join ladder rack sections, then secure and electrically conductive connections are achieved, but the installation process becomes complex and dangerous requiring paint removal, additional hole drilling, and grounding strap installation

Engineering Contradiction:

Improveelectrical conductivityVSAvoidinstallation steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The splice combines multiple functions (structural connection, electrical bonding, and grounding) into a single integrated component. The conductive screw simultaneously provides mechanical fastening and electrical connection, eliminating the need for separate grounding straps and paint removal steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductive screw serves multiple purposes: it acts as a structural fastener to join rack sections, provides electrical bonding through its conductive material, and creates a grounding path. This multi-functional component replaces several traditional separate components and steps.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional bonding systems require paint removal and additional hole drilling, then proper electrical bonding is achieved, but installation time and safety risks increase significantly

Engineering Contradiction:

Improveelectrical bondingVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The splice is pre-configured with conductive screws and attachment features during manufacturing. The screw holes and conductive elements are prepared in advance, eliminating the need for installers to perform paint removal or additional drilling operations during installation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conductive screw is designed to self-tap into the ladder rack sections, creating its own threading as it is driven in. This self-service capability eliminates the need for pre-drilled holes or separate threading operations, further reducing installation time and complexity.

Inventive Principle:

Principle #25Self-service

3Reliability

If multiple bonding steps are performed at high altitude, then secure electrical connection is achieved, but installer safety is compromised due to working 30 feet or more above ground

Engineering Contradiction:

Improvegrounding connectionVSAvoidinstaller safety

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The bonding function is segmented into discrete conductive screw components that can be individually installed. Each screw provides a complete bonding function independently, allowing installers to work with smaller, more manageable units rather than complex multi-step bonding procedures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The conductive screw acts as an intermediary component that bridges the ladder rack sections while providing electrical bonding. This mediator component simplifies the installation process by combining multiple functions into a single actionable element that can be installed safely from ground level or with minimal height exposure.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution simplifies the bonding process, ensuring safety and stability of the rack system while eliminating the need for additional steps, thus reducing installation risks and complexity.

Implementation Method 1

a plurality of conductive screws comprising a cutting portion and a threaded portion, the conductive screws configured to join the first portion or second portion to the corresponding first or second ladder rack segment

Methodology Applied

Scientific EffectCutting:

Implementation Method 2

Methodology Applied

Scientific EffectThreading:

Implementation Method 3

Ladder racks are frequently made of conductive materials, such as aluminum or galvanized steel... it may be necessary to connect the ladder racks to an electrical ground to reduce electrostatic interference and induced magnetic currents

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11381065B2Cable ladder rack bonding

Publication Date: 2022.07.05 BELDEN INC

AI summary

The present disclosure describes improved splices for joining ladder rack sections that provide a conductive ground connection, without requiring removal of paint, drilling additional holes, or installation of ground straps between sections. The splices also provide a solid physical connection between ladder rack sections, ensuring safety and stability of the rack system.