Polymer Channel Nut Holder With Gripping Flaps for Vertical Hold
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Solution Overview
Problem
Existing channel nut holders with metal housings are costly, and previous attempts at using polymeric materials face issues with slipping when oriented vertically, requiring multiple springs for different channel heights and thicknesses, leading to complex maintenance and increased labor costs.
Innovation Solution
A channel nut holder with a polymer housing and a spring back mechanism featuring gripping flaps at an acute angle, and a flexible strap system that accommodates various channel nut thicknesses, reducing the need for multiple springs and improving assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal housing is used for channel nut holder, then holding strength is improved, but cost increases
Solution Approach 1:
The patent uses polymeric material (polymer housing) instead of metal to create the channel nut holder, achieving a composite material solution that maintains adequate holding strength while significantly reducing manufacturing cost. The polymer housing is designed with specific structural features to compensate for the lower inherent strength of polymeric materials compared to metal.
2Ease of manufacture
If polymeric material is used for channel nut holder, then cost is reduced, but holding strength deteriorates causing slipping
Solution Approach 1:
The patent incorporates gripping flaps with curved surfaces that engage the channel nut through friction and mechanical interlocking. The curved geometry of the gripping flaps allows them to wrap around and secure the channel nut, preventing slipping while using cost-effective polymeric material.
Solution Approach 2:
The channel nut holder is segmented into multiple functional components including the polymer housing, gripping flaps, and spring back mechanism. This segmentation allows each component to be optimized for its specific function, with the gripping flaps providing mechanical engagement and the spring back mechanism providing continuous holding force.
3Adaptability or versatility
If multiple springs are used for different channel heights and nut thicknesses, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent designs a universal channel nut holder with a spring back mechanism that can accommodate various channel heights and channel nut thicknesses using the same spring. The spring back mechanism is configured to apply holding force regardless of the specific dimensions, eliminating the need for multiple different springs for different applications.
Solution Approach 2:
The spring back mechanism provides a dynamic holding force that automatically adjusts to accommodate different channel nut thicknesses and channel heights. The spring can compress and expand to maintain optimal holding force across various configurations, providing adaptability without requiring multiple specialized components.
4Adaptability or versatility
If multiple different springs and channel nuts are maintained, then adaptability is improved, but maintenance time and space increase
Solution Approach 1:
The universal spring back mechanism design allows a single spring to serve multiple functions across different channel heights and nut thicknesses. This universality dramatically reduces the inventory of parts that need to be maintained and the time required for maintenance operations, as technicians no longer need to identify and replace specific spring-nut combinations.
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 reduces costs by using polymer materials while maintaining secure hold on channel framing systems, simplifying maintenance, and eliminating the need for multiple springs, thus enhancing assembly ease and reducing part complexity.
Implementation Method 1
a spring back mechanism having a plurality of gripping flaps disposed on the top surface at an acute angle alpha (α) with respect to the central axis
Implementation Method 2
Previous attempts at making channel nut holders of polymeric materials, however, were known to have issues with slipping when placed in a strut of a channel framing system that is oriented vertically
Data Source
AI summary
A channel nut holder includes a polymer body having a central axis, top surface, plurality of side surfaces, and a bottom surface. A channel nut opening is positioned between the side surfaces. The channel nut opening is configured to receive a channel nut. The channel nut holder further includes a spring back mechanism having a plurality of gripping flaps disposed on the top surface at an acute angle alpha (α) with respect to the central axis.