Sheet Metal Head Connector for Cable Support Systems
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Solution Overview
Problem
Existing head connectors for cable support systems are complex and costly due to multiple parts, requiring intricate manufacturing processes and complex assembly, with flared connecting lugs that cannot be directly attached at ceiling-to-wall transitions and welded handle mounts needing additional corrosion prevention.
Innovation Solution
A compact head connection part with a U-shaped handle receptacle featuring retaining tabs and guide lugs, allowing for simple tool-free assembly and reduced manufacturing complexity, utilizing a single sheet metal part that can be stamped and bent, with adjustable side walls and a trapezoidal design for secure attachment to the ceiling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple parts with flared connecting lugs are used, then the head connector can be designed with separate components for assembly, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple separate components (web plate, side walls, connecting lugs, and handle mount) into a single integrated head connector component. This single piece is formed by stamping and bending a sheet metal blank, eliminating the need for separate manufacturing and assembly of multiple parts while reducing overall complexity.
2Ease of operation
If flared connecting lugs are used, then the head connector can be assembled with separate components, but the connecting lugs require distance from the ceiling support wall and cannot be attached directly at ceiling-to-wall transitions
Solution Approach 1:
The patent transitions from a multi-dimensional assembly problem (separate parts requiring spatial arrangement) to a two-dimensional sheet metal forming problem. By stamping and bending a flat blank into a three-dimensional single-piece component, the design achieves complex geometry without the assembly complexity of multiple parts, allowing direct attachment at ceiling-to-wall transitions.
3Ease of manufacture
If welded handle mounts are used, then the handle mount can be attached to the head connector, but additional corrosion treatment is required after welding
Solution Approach 1:
The handle mount is integrated into the head connector as a single piece formed by stamping and bending, eliminating the welding process entirely. This integration removes the source of corrosion risk associated with weld seams while simplifying the manufacturing process to a single forming operation.
4Ease of manufacture
If a single sheet metal part is used, then the manufacturing process is simplified to stamping and bending, but the structural integrity must be maintained without additional components
Solution Approach 1:
The patent changes the geometric parameters of the single sheet metal blank through stamping and bending operations to create a three-dimensional structure with enhanced structural integrity. The formed component includes a web plate, side walls, connecting lugs, and handle mount integrated in a configuration that maintains strength while simplifying manufacturing to a single forming process.
Data Source
Figure 1
Figure 2~2a
Figure 3~4
AI summary
The invention relates to a head connection part 2 for attaching a suspension stem 3 of a cable support system 1 to a ceiling, comprising a twin-wall sheet 6 attachable to a ceiling and two side cheeks 8, 8.1 molded onto opposite edges 7 of the twin-wall sheet 6 to form a U-shaped stem receptacle. At least one of the two side cheeks 8, 8.1 has at least one retaining tab 9, 9.1 projecting into the stem receptacle, designed to engage in a retaining recess 10 of a suspension stem 3 when the latter is mounted on the head connection part 2.