Sheet Metal Support Console for Cable Trays
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Solution Overview
Problem
Existing cable tray support brackets are either expensive to manufacture due to complex assembly processes or have limited load resistance, and they often require multiple parts, which increases costs and complexity in installation.
Innovation Solution
A support bracket formed by cutting and bending sheet metal into a U-shaped bar and a U-shaped heel, where the wings of the bar and heel are partially overlapping and connected by a single-piece connecting strip, allowing for effective force transmission without a two-part structure, and can be manufactured within a single cutting/folding machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to attach the heel to the bar, then the assembly is strong and durable, but the manufacturing cost increases and additional anti-corrosion coating is required
Solution Approach 1:
The patent combines the heel and bar into a single piece of sheet metal, eliminating the need for separate attachment processes like welding. The heel is formed by folding and bending the same sheet metal that forms the bar, creating an integrated structure that reduces manufacturing steps and costs while maintaining structural integrity.
Solution Approach 2:
The console is divided into functional segments (heel, bar, wings) that are all formed from a single continuous piece of sheet metal through folding and bending operations. This segmentation allows each part to be optimized for its function while avoiding the need for joining separate components.
2Adaptability or versatility
If a two-part structure with separate bar and heel is used, then assembly flexibility is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the bar and heel into a single monolithic structure made from one piece of sheet metal. The heel is formed by folding the sheet metal at specific locations, creating what appears to be separate functional parts while actually being a unified component that simplifies manufacturing and assembly.
Solution Approach 2:
The single piece of sheet metal serves multiple functions: it forms the support bar, the mounting heel, and the connecting wings all in one continuous structure. This multi-functionality reduces the total number of parts needed while maintaining the flexibility and adaptability of a multi-component design.
3Adaptability or versatility
If multiple separate parts are used for the console, then assembly flexibility is improved, but the installation complexity and time increase
Solution Approach 1:
The patent combines multiple functional elements (bar, heel, connecting wings) into a single pre-assembled unit made from one piece of sheet metal. This eliminates the need for on-site assembly of multiple separate parts, significantly reducing installation time while the folded wing structure still provides adaptability for different mounting configurations.
4Strength
If the heel height is increased to improve load resistance, then the load capacity increases, but the bending process limitations are reached
Solution Approach 1:
The patent uses extensive folding and bending to create a three-dimensional heel structure with multiple angles and planes from a flat sheet metal blank. The complex folded geometry provides high load resistance and structural rigidity without requiring excessive heel height, working within the capabilities of standard bending processes while achieving the structural integrity of a much taller heel.
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 results in a stronger, more economical cable tray support system that is easier to install and manufacture, with improved load resistance and reduced costs compared to traditional methods.
Implementation Method 1
the wings of the bar and the wings of the heel are in partial overlap and joined together in their overlap zones
Implementation Method 2
A support bracket formed by cutting and bending sheet metal
Data Source
Figure 1
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Figure 3
AI summary
The console (20) has a rod (21) intended to receive a chute, and a heel (22) provided on a support structure, where planar wings (A1-A4) of the rod and the heel are partially overlapped and secured together. The wings of the heel are folded down relative to a bottom plate (P0') of the heel in a direction, where the rod and the heel are cut from a single metal sheet blank and connected by a connecting strip. The connecting strip is folded over the bottom plate of the heel and a bottom plate (P0) of the rod in two opposite directions. Independent claims are also included for the following: (1) a cable tray (2) a method for manufacturing a support console.