Hardened Steel Teeth Saddle Connector for Metal Beam Penetration
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Solution Overview
Problem
Existing saddle connectors with teeth fail to securely attach to metal beams in suspended ceilings due to tooth bending when force is applied, as they are not designed to penetrate metal effectively.
Innovation Solution
A saddle connector with hardened steel, sharp, pointed teeth that can be pinched into the bulb of a metal beam using hand-operated pliers, allowing concentrated force to penetrate the metal, providing a secure and permanent connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional saddle connectors with teeth are used on metal beams, then the connector can be applied to wooden beams effectively, but the teeth bend and fail to penetrate the metal beam when force is applied
Solution Approach 1:
The teeth are changed from soft metal to hardened steel, fundamentally altering the material parameter to enable penetration of metal beams. The hardened steel teeth maintain their sharp edges and structural integrity under applied force, allowing them to penetrate the metal bulb of the beam rather than bending.
Solution Approach 2:
The connector combines hardened steel teeth with a metal channel body, creating a composite structure where the hardened steel provides penetration capability while the metal channel provides structural support and attachment functionality.
2Force
If force is applied to force teeth into the metal beam, then penetration can be achieved, but the teeth bend and fail due to insufficient hardness
Solution Approach 1:
The teeth are hardened through heat treatment or other hardening processes, changing the material parameter from soft to hardened steel. This allows the teeth to withstand the high forces required to penetrate metal beams without bending or failing structurally.
3Reliability
If self-tapping screws are used to attach the connector to the beam, then a secure connection is achieved, but the installation process becomes more complex and time-consuming
Solution Approach 1:
The hardened steel teeth automatically penetrate and embed themselves into the metal beam when force is applied with pliers, eliminating the need for separate fastening operations. The connector essentially attaches itself to the beam through the mechanical action of forcing the teeth into the metal, providing both speed and security.
4Strength
If the connector is made from hard material to enable tooth penetration, then penetration capability is improved, but the connector itself becomes more difficult to manufacture and install
Solution Approach 1:
The teeth are manufactured in a soft state for ease of forming and shaping, then hardened through heat treatment after manufacturing. This sequence allows the teeth to be formed using conventional metalworking processes on soft steel, then hardened to achieve the required penetration capability, combining manufacturing ease with functional performance.
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
Enables quick and firm connections between metal beams and wall moldings or other beams in suspended ceilings, with the option for additional strength from self-tapping screws in seismic areas.
Implementation Method 1
the full force being applied by the installer, with the mechanical advantage created by the pliers, can be concentrated on one tooth at a time, to overcome the substantial resistance to penetration offered by the beam
Data Source
AI summary
A saddle connector, having an inverted channel, engages a bulb of a beam in the grid of a suspended ceiling. The channel has hardened teeth staggered along the opposing walls of the channel. The teeth are forced into the bulb of the beam, one at a time, by the full force exerted by hand operated pliers.