Three-Dimensional Cable Duct with Hinged Segments for Simplified Injection Molding
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Solution Overview
Problem
The high production costs of three-dimensional cable ducts with complex tooling requirements for both the duct base and cover, making them expensive to manufacture.
Innovation Solution
A cable duct with a three-dimensional laying structure composed of interconnected floor segments that unfold into a single plane for injection molding, using film hinges for connection, allowing for a simpler mold design and assembly into a three-dimensional form, and a duct cover connected via latching elements, reducing the need for complex tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a three-dimensional cable duct with complex tooling is used for both duct base and cover, then the cable routing capability is improved, but the production cost increases significantly
Solution Approach 1:
The cable duct is divided into multiple floor segments that can be produced separately using simple molds and then assembled together to form the three-dimensional structure. This segmentation allows each segment to be manufactured with basic tooling while the final assembled structure provides complex cable routing capabilities.
Solution Approach 2:
The patent transitions from producing fully three-dimensional components requiring complex molds to producing essentially two-dimensional floor segments that are then assembled in three-dimensional space. This dimensionality change simplifies the molding process while maintaining the three-dimensional cable routing functionality.
2Shape
If complex tooling is used for injection molding the duct base and cover, then the three-dimensional structure is achieved, but the manufacturing complexity increases
Solution Approach 1:
The complex three-dimensional shape is segmented into multiple simpler floor sections that can each be produced with relatively simple injection molds. The complexity is distributed across multiple simple components rather than concentrated in a single complex mold.
Solution Approach 2:
The injection molding process is simplified by producing essentially two-dimensional floor segments rather than fully three-dimensional components. The three-dimensional structure is then achieved through assembly of these simplified segments, effectively moving the complexity from the molding dimension to the assembly dimension.
3Ease of manufacture
If the channel floor is divided into multiple floor segments, then the mold complexity is reduced, but the assembly complexity increases
Solution Approach 1:
Multiple floor segments are merged into a single integrated injection-molded component with hinge connections already incorporated. This merging eliminates the need for separate assembly of individual segments and their connections, reducing assembly complexity while maintaining the benefits of simplified molding.
Solution Approach 2:
The floor segments are designed with self-aligning hinge connections that automatically position themselves during assembly. The hinge structure provides self-guiding features that reduce the skill and complexity required for assembly operations.
Data Source
Figure 1~2
Figure 3
AI summary
A cable duct has a cable floor with side walls that are attached to the cable floor. The cable floor has a three-dimensional laying structure, running inside a base plane and also in a z-direction, and it is divided into several floor segments. The segments form a combined injection-molded component and are joined together by hinges, so that at least a major portion of all floor segments is located in the base plane. In addition, cover segments preferably form part of the combined injection-molded component, such that, by way of just one injection molding tool, the entire three-dimensional cable duct can be produced as a two-dimensional injection-molded component, from which the three-dimensional structure of the cable duct is produced.