Polymer Cable Ladder Snap-Fit Assembly
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Solution Overview
Problem
Existing cable ladders made of metal face difficulties in assembly and configuration changes, require specific tools, and necessitate careful grounding for electrical protection, whereas polymer-based solutions lack efficient snap-fitting mechanisms and high manufacturing costs.
Innovation Solution
A cable ladder with extruded polymer side rails and crosspieces featuring snap-fitting channels and recesses, allowing easy assembly and configuration without welding or grounding, using thermoplastic or heat-stable resin materials for enhanced mechanical strength and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal cable ladders are assembled using welding, rivetting or bending flanges, then the structural strength is improved, but the assembly operation becomes difficult and requires specific tools
Solution Approach 1:
The cable ladder is divided into modular components (side rails and crosspieces) that can be assembled independently through snap-fitting, eliminating the need for complex joining operations while maintaining structural integrity
Solution Approach 2:
Traditional mechanical joining methods (welding, rivetting) are replaced with a snap-fitting mechanism that uses elastic deformation and geometric interlocking to achieve strong connections without requiring specialized tools or skilled labor
2Stability of the object's composition
If metal cable ladders are assembled using welding or rivetting, then the structural stability is improved, but it becomes impossible to change the configuration once assembled
Solution Approach 1:
The connection system transitions from static permanent joints (welding/rivetting) to dynamic reversible joints (snap-fitting), allowing the structure to be easily disassembled and reconfigured while maintaining stability during use through the elastic retention force of the snap-fitting mechanism
3Strength
If metal cable ladders are used, then the mechanical strength is improved, but electrical protection requires careful grounding of all metal parts
Solution Approach 1:
Metal components are replaced with polymer materials that inherently provide electrical insulation, eliminating the need for grounding systems while maintaining adequate mechanical strength for cable support applications
Solution Approach 2:
The cable ladder is constructed from polymer materials that combine adequate mechanical strength with inherent electrical insulation properties, creating a composite structure that eliminates the need for separate grounding systems while supporting cable loads
4Reliability
If crosspieces are fixed to side rails by introducing ends in openings and crimping to form blocks, then the assembly is secured, but the assembly operation remains difficult
Solution Approach 1:
The crimping operation is replaced with a snap-fitting mechanism where elastic deformation of a rib section provides automatic retention force, eliminating the need for specialized crimping tools and complex forming operations while maintaining secure assembly
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 solution simplifies assembly, reduces manufacturing costs, ensures secure electrical protection, and provides robust mechanical strength while eliminating grounding requirements, enabling flexible cable fastening options and easy installation.
Implementation Method 1
a final section of said lower rib is a free end section which can experience a slight lowering by elastic bending with respect to said bending line
Implementation Method 2
each of said ends of the crosspiece fits and is snap-fitted into the channel of the corresponding side rail
Data Source
Figure 1
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AI summary
The present invention relates to a cable ladder formed by two side rails (1 a) and crosspieces (2A), all of them formed by extruded profiles made of a polymer material. The side rails (1) have a channel (4a) receiving a corresponding end of the crosspieces. The channel (4a) has a lower rib (5a) and an upper rib (6a). A projection (7a, 8a) of the lower rib (5a) or upper rib (6a) has openings (9a) along the longitudinal direction of the side rail (1). The ends of the crosspieces (2A) go through the opening (9a) of the projection (8a) and have a recess (10A) in which a corresponding portion of the channel (4a) is snap-fitted. The lower rib (5a) of the side rails (1 a) is bent over itself along a bending line (19a), such that a final section of the lower rib (5a) experiences downward expansion by elastic bending when the end of the crosspiece (2A) is introduced.