Double-Hemmed Cable Cleat Structure for Short-Circuit Strength

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Solution Overview

Problem

Existing cable cleats face issues such as cable damage, failure during short circuit events, and high manufacturing costs due to complex processes and material inefficiencies, particularly with single hem clamping flanges and hinges.

Innovation Solution

A cable cleat with a one-piece metal shell featuring double hemmed clamping flanges and rounded edges, eliminating the need for protective liners and hinges, manufactured using thinner gauge stainless steel and simplified processes to reduce scrap and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a single hem clamping flange is used, then the manufacturing process is simpler, but the strength and reliability during short circuit events is insufficient

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidstrength during short circuit

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The clamping flange is divided into multiple hem segments (first hem and second hem) instead of using a single hem structure. This segmentation distributes the mechanical stress across multiple folded layers, significantly increasing the flange's strength and resistance to pull-through forces during short circuit events while maintaining a relatively simple manufacturing process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The clamping flange is extended in the radial direction by adding multiple hem layers (first hem, second hem) beyond the basic single hem structure. This dimensional extension creates a multi-layered folded structure that increases material thickness and structural integrity at the clamping location without fundamentally changing the manufacturing approach.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Object-affected harmful factors

If protective liners are used to prevent cable damage, then cable protection is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvecable damage preventionVSAvoidmanufacturing complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The potentially harmful sharp edges of the metal shell are converted into beneficial rounded edges through a rolling process. This eliminates the need for protective liners by transforming the harmful feature (sharp edges) into a beneficial one (rounded, cable-friendly edges), thereby reducing manufacturing complexity while maintaining cable protection.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The protective liner component is completely removed from the cable cleat assembly. Instead of adding a separate protective element, the shell itself is modified through edge rounding to provide the protective function, eliminating the need for additional materials and assembly steps.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If hinges are used to join shell pieces, then assembly flexibility is improved, but manufacturing complexity and scrap increase

Engineering Contradiction:

Improveassembly flexibilityVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The cable cleat is designed as a one-piece monolithic structure where the shell, clamping flanges, and mounting features are all formed from a single piece of metal. This merging of components eliminates the need for hinges, separate shell pieces, and associated assembly operations, thereby reducing manufacturing complexity and material scrap while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single-piece shell design performs multiple functions simultaneously: it provides structural containment, forms clamping flanges for cable securing, includes integrated mounting features, and provides cable protection through rounded edges. This multi-functionality eliminates the need for separate components like hinges that would be required in multi-piece designs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Reliability

If thicker gauge stainless steel is used, then strength during short circuit is improved, but material cost and manufacturing complexity increase

Engineering Contradiction:

Improvestrength during short circuitVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of using uniformly thick material throughout the entire cable cleat, the design employs localized thickening through multiple hemmed clamping flanges at critical stress points. The rest of the shell maintains a thinner, more manageable gauge that is easier to manufacture and form, while the double-hemmed flanges provide the necessary strength and reinforcement where short circuit forces are applied.

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP4254697B1Cable cleat with double hemmed clamping flange

Publication Date: 2025.12.31 PANDUIT CORP

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AI summary

A cable cleat assembly designed to secure cables during short circuit events. The cable cleat assembly is formed from a one-piece metal shell. The metal shell includes a bottom, sides extending from the bottom, and clamping flanges extending from the distal end of each side. The clamping flanges are double hemmed clamping flanges to reinforce the cable cleat assembly.