Self-Tensioning Connector for Gap-Free Housing Alignment
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Solution Overview
Problem
Profile lighting systems suffer from gaps between housings, leading to light bleed and aesthetic issues, which existing connectors fail to adequately address.
Innovation Solution
A self-tensioning connector with cooperating subassemblies, including a bracket and a movable carriage with a latch, aligns and tensions the housings to eliminate gaps, using a resilient member to draw the housings together and prevent light bleed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mechanical connectors (screws, clips, welds) are used to join conduit to fittings, then the connection strength is sufficient, but the assembly time and labor cost increase significantly
Solution Approach 1:
The connector employs a dynamic self-tensioning mechanism where the biasing element continuously applies force to maintain optimal tension between the conduit and fitting. This dynamic adjustment allows the connector to adapt to varying installation conditions while maintaining a simple overall structure, resolving the contradiction between assembly speed and structural complexity.
Solution Approach 2:
The connector is designed to self-tension automatically through the biasing element, eliminating the need for manual adjustment or complex assembly procedures. The self-tensioning feature enables rapid installation without requiring additional tools or multiple operation steps, thereby improving productivity while keeping the device structure relatively simple.
2Adaptability or versatility
If rigid connection methods are used, then the connection strength is high, but the ability to accommodate movement and vibration is reduced
Solution Approach 1:
The biasing element changes the mechanical parameters of the connection by providing continuous dynamic tension adjustment. This allows the connector to accommodate movement and vibration while maintaining adequate connection strength through the sustained force applied by the spring mechanism, resolving the contradiction between adaptability and strength.
Solution Approach 2:
By introducing a dynamic biasing element, the connector transitions from a static rigid connection to a dynamic adaptive connection. The spring continuously adjusts to accommodate movements and vibrations while maintaining connection integrity, thereby improving adaptability without significantly compromising connection strength.
3Reliability
If the connector applies high tension to secure the conduit, then the connection reliability is improved, but the risk of damaging the conduit or fitting increases
Solution Approach 1:
The biasing element provides beforehand cushioning by applying controlled tension that prevents excessive force during installation and operation. The spring mechanism cushions against sudden movements or thermal expansion, maintaining reliable connection while protecting the conduit and fitting from damage through pre-configured force limitation.
Solution Approach 2:
The biasing element changes the force parameter from a fixed high tension to a dynamically adjusted tension that remains within safe limits. This parameter modification ensures adequate connection reliability while preventing conduit or fitting damage by maintaining tension within an optimal range rather than applying maximum force.
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 self-tensioning connector effectively aligns and joins housings, reducing light bleed and ensuring a consistent aesthetic quality by maintaining a continuous lighting product.
Implementation Method 1
a biasing element positioned within the connector and configured to tension the connector
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A self-tensioning connector for coupling mating ends of a first housing and a second housing in a linear configuration, the connector providing first and second cooperating subassemblies for fixedly mounting to the first and second housings respectively, the first subassembly mountable to the first housing and having a male engagement portion configured to project from the mating end of the first housing when mounted thereto, the second subassembly comprising: a plate mountable to the second housing; a moveable carriage supported on the plate, the carriage having a female engagement portion configured to project from the mating end of the second housing to receive and capture the male engagement portion and align the first and second housings; and a latch mounted on and biased against the movable carriage in a tensioned configuration, the latch providing an anchor configured to extend through an aperture in the carriage, wherein engagement of the male and female engagement members aligns the first and second subassemblies thereby aligning the first and second housings, and movement of the two housings towards one another brings the first housing into contact with the anchor releasing the anchor from the aperture and allowing the biasing means to force the carriage away from the mating end of the second housing to adopt an engaged configuration drawing the mating ends of the first and second housings together.