Perforated Polymeric Cable Tray Eliminating Intersections
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Solution Overview
Problem
Existing mesh cable trays have hard-to-clean intersections that accumulate dirt and can catch small diameter cables, making them unsuitable for hygienic environments and prone to cable entanglement.
Innovation Solution
A mesh cable tray manufacturing method involving extrusion of a U-shaped polymeric channel with perforations forming coplanar transverse and longitudinal rods, eliminating intersections and allowing easier cable placement and cleaning, using thermoplastic or thermosetting materials for improved durability and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal rods with circular cross-section are welded together at intersecting points to form a mesh cable tray, then the mechanical strength is improved, but the intersections form hard-to-clean nooks and crevices that accumulate dirt
Solution Approach 1:
The continuous channel is segmented into discrete rod elements through perforation, creating a mesh structure where rods are separated by openings rather than continuously intersecting. This segmentation eliminates the welded intersection points that create dirt-trapping crevices, while the rod segments maintain structural strength through their distribution and arrangement in the mesh pattern.
Solution Approach 2:
Instead of joining rods at intersecting points to create a mesh (traditional approach), the invention inverts the process by starting with a continuous channel and removing material to create openings, thereby defining rods as the remaining portions. This inversion eliminates intersection problems while preserving the mesh structure's mechanical properties.
2Strength
If metal rods intersect on overlapping planes to form a mesh, then the mesh structure provides good mechanical strength, but cables with small diameter may get caught in the intersections
Solution Approach 1:
The mesh structure is created by segmenting the continuous channel into discrete rod portions separated by openings. This segmentation eliminates the overlapping intersection zones where small cables could become caught, providing clear pathways for cable routing while the distributed rod segments maintain the necessary mechanical strength through their geometric arrangement.
Solution Approach 2:
The invention extracts or removes portions of the continuous channel to create openings, thereby eliminating the problematic intersecting regions that trap cables. The remaining rod portions form a mesh that provides structural support without the cable-catching intersections characteristic of traditional welded mesh trays.
3Object-affected harmful factors
If a continuous channel is perforated to form openings creating transverse and longitudinal rods, then hygiene conditions are improved and cable placement is easier, but the manufacturing process complexity increases
Solution Approach 1:
The continuous channel serves multiple functions: it provides the overall structural framework of the cable tray, defines the mesh pattern through its perforation, and creates both the transverse and longitudinal rods simultaneously. This multi-functionality simplifies manufacturing by using a single base component rather than assembling multiple separate rod elements, thereby reducing process complexity despite the improved hygiene characteristics.
Solution Approach 2:
The manufacturing approach changes from assembling discrete metal rods with complex welding operations to perforating a continuous channel, transforming the process parameters from high-temperature joining operations to simpler cutting or punching operations. This parameter change reduces manufacturing complexity while achieving the desired mesh structure with superior hygiene properties.
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 method produces a cable tray with improved hygiene conditions, reduced cable entanglement risk, and easier cleaning, while maintaining mechanical strength and electrical insulation, suitable for various applications including food industry installations.
Implementation Method 1
maintaining mechanical strength and electrical insulation
Implementation Method 2
forming, by means of extrusion, a continuous channel made of a polymeric material with a U-shaped cross-section
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The present invention relates to a method of manufacturing a mesh cable tray (1), and the corresponding mesh cable tray (1). The method comprises the following steps: forming, by means of extrusion, a continuous channel made of a polymeric material with a U-shaped cross-section; and then perforating said continuous channel forming openings (7) in said channel, such that the remaining portions of said continuous channel (6) demarcating said openings (7) constitute the transverse rods (4) and the longitudinal rods (5) forming the mesh.