Polymeric Mesh Cable Tray Coplanar Rod Intersections
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Solution Overview
Problem
Existing mesh cable trays have hard-to-clean intersections and are unsuitable for installations with strict hygiene requirements due to dirt accumulation, and they can catch cables with small diameters at rod intersections.
Innovation Solution
A mesh cable tray is manufactured using a single polymeric material where transverse and longitudinal rods intersect on a single plane, allowing easier cable movement and cleaning, with a method involving injection molding to form segments of the tray, and optional features like rectangular or circular cross-sections and rounded corners to prevent cable damage and dirt accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal rods with circular cross-section are used to form intersections on overlapping planes, then the mesh cable tray provides good mechanical strength, but dirt accumulates in the intersections and creates hard-to-clean nooks and crevices
Solution Approach 1:
The patent transitions from three-dimensional overlapping plane intersections to two-dimensional coplanar intersections. All rod intersections occur on the same plane rather than overlapping at different heights, eliminating the creation of deep crevices and nooks where dirt can accumulate. This dimensional simplification maintains structural integrity while dramatically improving cleanability.
Solution Approach 2:
The patent specifies that rod intersections should have rounded corners rather than sharp edges. This curvature prevents dirt and debris from getting trapped in sharp corners and makes the intersections easier to clean. The rounded geometry eliminates the harmful sharp edges while maintaining the mechanical strength of the structure.
2Length of moving object
If metal rods with circular cross-section intersect on overlapping planes, then the mesh structure provides good ventilation, but cables with small diameter get caught in the intersections
Solution Approach 1:
By moving all intersections to a single coplanar level, the patent eliminates the multi-level obstacles that trap small-diameter cables. Cables can now pass through the mesh structure without encountering intersections at different heights, making cable placement and retrieval significantly easier while preserving the open mesh ventilation characteristics.
Solution Approach 2:
Rounded intersection corners prevent cables from catching on sharp edges. The curved geometry allows cables to pass smoothly through the mesh structure without getting snagged, improving ease of operation while maintaining the structural integrity needed for ventilation support.
3Length of moving object
If a long mesh cable tray is manufactured in a single injection molding operation, then the tray provides continuous structure, but the injection mold would have high cost due to large size
Solution Approach 1:
The patent divides the long cable tray into multiple segments that are manufactured separately in smaller, more cost-effective injection molds. These segments are then assembled together to form the complete long tray. This segmentation allows standard-sized molds to be used, significantly reducing mold costs while achieving the desired total length through assembly of multiple units.
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 provides improved hygiene conditions, easier cable placement, and reduced risk of cable entanglement, while allowing for longer tray production without a large injection mold, making it suitable for installations with strict hygiene needs.
Implementation Method 1
The present invention is defined by the accompanying independent claim 1. This method according to the invention provides a mesh cable tray formed by a single part made of a polymeric material, in which the transverse rods and the longitudinal rods form intersections on a single plane.
Data Source
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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 consists of forming the mesh cable tray (1) as a single part made of a polymeric material by molding in an injection mold. The injection mold used in said method is shaped such that the transverse rods (4) and the longitudinal rods (5) of the mesh cable tray (1) formed in said injection mold (6) are coplanar in the intersections thereof with one another.