Rail Suspension Device with Interlocking Guide Slots
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing suspension devices for support rails, such as those used in suspended ceilings, require costly additional manufacturing steps like riveting or complex material configurations, leading to increased production costs and storage requirements due to the need for multiple variants to accommodate different support rail shapes.
Innovation Solution
A suspension device design that connects a flat base part and a resilient connecting part via plug-in guide slots, eliminating the need for additional fastening elements and allowing for secure force transmission under tensile and compressive loads, while minimizing material usage and enabling easy adjustment to fit various support rail configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If riveted or screwed connections are used to fasten components together, then the connection strength is improved, but the manufacturing cost and process complexity increase due to additional production steps
Solution Approach 1:
The patent merges the base part and connecting part into a single integrated component made from a single sheet of material. The connecting part is formed by folding and shaping the same sheet material that forms the base part, eliminating the need for separate components and fastening operations. This integration maintains connection strength while dramatically simplifying manufacturing.
Solution Approach 2:
While integrating the component, the patent creates distinct functional zones within the single piece: a base part for mounting, a connecting part for attachment, and intermediate connection elements formed by folding. This segmentation of function within unity of material allows the single component to perform multiple roles that previously required separate parts and fasteners.
2Ease of manufacture
If one-piece suspension devices made entirely of spring steel are used, then the manufacturing process is simplified by eliminating additional connection steps, but the material cost increases
Solution Approach 1:
The patent applies different material properties to different regions of the single component. The base part is made from standard sheet metal suitable for mounting, while the connecting part is formed with spring-like characteristics through folding and shaping. This local differentiation of material properties allows each zone to perform its specific function optimally without requiring the entire component to be made from expensive spring steel.
3Adaptability or versatility
If multiple variants of suspension devices are kept available for different support rail shapes, then the adaptability to various rail configurations is improved, but the storage costs increase
Solution Approach 1:
The patent creates a dynamically adaptable suspension device where the connecting part can be folded and shaped into different configurations to match various support rail profiles. The foldable nature of the connecting part allows it to conform to different rail shapes (I-beams, channels, angles, etc.) without requiring separate pre-formed variants, thus providing versatility while minimizing inventory requirements.
4Reliability
If the connecting part is made resilient to clamp fastening parts, then the securing capability is improved, but the need for separate resilient material increases component complexity
Solution Approach 1:
The patent combines the resilient clamping function with the structural connecting part by forming the clamping elements as integral folds and bends in the same sheet material. The connecting part itself provides the resilient action through its folded geometry, eliminating the need for separate springs or resilient components. This merging maintains securing capability while reducing overall component complexity.
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
This design simplifies production, reduces costs, and ensures secure attachment and stability by absorbing loads through frictional and form fits, preventing unwanted decoupling, thus reducing storage needs and overall costs.
Implementation Method 1
the connecting part is designed for adjustably connecting the base part to a fastening part... the connecting part can be made of spring steel... clamped to the connecting part by the spring tension of the resilient material
Implementation Method 2
The overlapping of the holding sections with the corresponding overlapping areas simultaneously achieves a frictional and/or form fit in the longitudinal direction of the guide slots, so that decoupling between the first and second component is also difficult in this direction
Data Source
Figure 1~3
Figure 4~5
Figure 6~7
AI summary
A component assembly and a suspension device for supporting rails, in particular for suspended ceilings or the like, are described. The component assembly comprises a first component which is flat at least in certain areas and a second component which is flat at least in certain areas and fastened to the base part. At least two guide slots extending substantially parallel are formed both in the first component and in the second component. The regions of the first and of the second component that are arranged between the guide slots each form retaining portions. The first component and the second component are plugged together in the longitudinal direction of the guide slots in such a way that the retaining portion of the first component overlaps an overlapping region of the second component that adjoins the retaining portion of the second component in the longitudinal direction of the guide slots and in such a way that the retaining portion of the second component overlaps an overlapping region of the first component that adjoins the retaining portion of the first component in the longitudinal direction of the guide slots. Furthermore, a method for producing such a component assembly is described.