High-Strength Main Tee Splice With Self-Aligning Camming
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Solution Overview
Problem
Existing main tee grid splice connectors are difficult to assemble and require excessive force due to dimensional variations and lack of self-alignment, leading to inconsistent connections.
Innovation Solution
The connector design features a vertically oversized receiving depression and horizontal alignment elements, including a lead angle and outward flare, allowing for self-alignment and reduced interference during assembly, with an audible click indicating completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the end tab is tightly vertically fitted to the receiving depression to achieve strong connection, then the tensile strength is improved, but the assembly difficulty increases and excessive force is required
Solution Approach 1:
The receiving depression base is deliberately designed with a vertical average dimensional tolerance larger than the maximum height of the end tab, changing the dimensional parameter from tight fit to clearance fit. This allows the end tab to be inserted without excessive force while still achieving proper vertical registration through the camming action and other alignment features.
2Manufacturing precision
If the connector parts have prominent surfaces or projections to ensure alignment, then the alignment precision is improved, but the smooth engagement is obstructed
Solution Approach 1:
The lead angle on the end tab and outward flare on the receiving pocket create camming surfaces that convert horizontal insertion force into vertical alignment motion. This dimensional transformation allows alignment to occur automatically during the assembly process without requiring prominent projections that would obstruct smooth engagement.
Solution Approach 2:
The connector is designed to self-align during assembly through the camming action of the lead angle and outward flare. The end tab automatically cams toward alignment with the mating connector as it is inserted, eliminating the need for external alignment tools or prominent alignment projections.
3Reliability
If the end connectors are made with tight dimensional tolerances to ensure consistent connection, then the connection reliability is improved, but the manufacturing cost increases and assembly force varies excessively
Solution Approach 1:
The receiving depression base is deliberately designed with a vertical average dimensional tolerance larger than the maximum height of the end tab, changing the dimensional parameter from tight fit to clearance fit. This allows the end tab to be inserted without excessive force while still achieving proper vertical registration through the camming action and other alignment features.
Solution Approach 2:
The connector is designed to self-align during assembly through the camming action of the lead angle and outward flare. The end tab automatically cams toward alignment with the mating connector as it is inserted, eliminating the need for external alignment tools or prominent alignment projections.
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
The design achieves a 48% increase in tensile strength, reduces material thickness, and ensures easy, consistent assembly with minimal force variation, even with dimensional tolerances, signaling completion with an audible click.
Implementation Method 1
The leading profile of the end tab is effective, in the vertical location established by the flange of the opposed tee, to cam the end tab towards alignment with the mating connector.
Implementation Method 2
These lead angle and outward flare elements provide relatively large, smooth camming surfaces, as compared to edge areas, that improve the smooth functioning of the connector.
Implementation Method 3
The resilient character of the receiving pocket of the opposed connector imparts kinetic energy to the end tab when its lock lance snaps over the locking edge of the opposed connector.
Data Source
Figure 1~2
Figure 3~6
AI summary
A connector for a main tee of a suspended ceiling grid that has improved tensile strength achieved by accurately proportioning an end tab and receiving depression so that full lateral abutment between these elements is obtained to assure full engagement between lock lance edges and mating stop edges.