Sheet Metal Connecting Element with Handling Tab for C-Profile Rails
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Solution Overview
Problem
The assembly of connecting elements for butt-aligned C-shaped profile rails is challenging, especially when the last rail is being attached, as it is difficult to access and position the connecting element blindly, leading to potential incomplete insertion due to imprecision in rail manufacturing and increased effort required.
Innovation Solution
A sheet metal connecting element with a tab and stepped lateral legs that provides tactile feedback and allows for crimping, featuring a resilient latching lug and beveled ends for easier insertion and secure fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the connecting element is inserted into the profile rail to achieve secure connection, then the connection strength is improved, but the ease of operation deteriorates because the connecting element becomes difficult to access and position when the rail opening points upwards
Solution Approach 1:
A tab element is introduced as an intermediary component that extends from the connecting element through the profile rail opening. This tab serves as a mediator that allows the installer to visually locate, grasp, and position the connecting element accurately, thereby resolving the contradiction between secure insertion and ease of operation.
2Reliability
If the connecting element is pushed far enough into the profile rail to ensure proper connection, then the reliability of connection is improved, but the ease of operation deteriorates because the installer cannot visually check the position of the connecting element
Solution Approach 1:
The tab element provides visual feedback by extending through the profile rail opening, allowing the installer to observe the position and insertion depth of the connecting element. This feedback mechanism ensures reliable connection while maintaining ease of operation through visual verification.
3Manufacturing precision
If the profile rails are manufactured with high precision to reduce play, then the manufacturing precision is improved, but the device complexity increases due to the need for tighter tolerances and more precise assembly
Solution Approach 1:
The design incorporates a tab element that changes the operational parameters of the assembly process. Instead of relying solely on precise dimensional parameters of the rail and connector, the tab provides a visual and tactile reference that simplifies the assembly process, effectively decoupling manufacturing precision requirements from assembly 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
Facilitates easier handling and secure attachment of connecting elements, ensuring complete insertion and permanent fastening with reduced effort, even in concealed positions, and accommodates dimensional deviations in profile rails.
Implementation Method 1
a resilient latching lug is provided for snapping into the joint between the profile rails. Such a locking lug, which can for example be designed as a resilient sheet metal lug, fixes the connecting element at least temporarily in the end position
Implementation Method 2
the lateral legs can, on the one hand, give way resiliently in the event of dimensional deviations when the connecting element is inserted into the profile rail
Implementation Method 3
to permanently connect the profile rails to the connector by crimping
Data Source
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AI summary
The invention relates to a connecting element for connecting two aligned C-shaped profile rails (12). The connecting element (10) is in the form of a sheet metal profile the cross-section of which, adapted to the profile rails (12) to be connected, is such that said sheet-metal profile can be slid into said profile rails (12) from the fronts thereof in a captive manner. A handling tab (14) that is accessible after the connecting element has been slid into a profile rail (12) is moulded onto or mounted on said connecting element.