Sheet Metal Tray Module With Elastic Coupling Tabs
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Solution Overview
Problem
Existing cable tray modules with U-shaped metal sections and male-female coupling systems require additional fixing means like screws and nuts due to weak connections, and often lack sufficient space for assembly, making them inefficient and cumbersome.
Innovation Solution
A metal tray module with a U-shaped cross-section featuring a flat back wall and perpendicular side walls, including a tubular reinforcing rib and obliquely extending coupling tabs that fit into longitudinal notches, allowing for flexible deformation and secure male-female coupling without additional fasteners, and incorporating pass-through notches and projecting pins for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If tabs are arranged to slip through grooves and exercise pressure on the groove, then the connection between modules is achieved, but the connection strength is insufficient and additional fixing screws and nuts are required
Solution Approach 1:
The patent changes the geometric parameters of the connection elements by providing tabs with inclined surfaces that engage with corresponding grooves having complementary inclined surfaces. This angular geometry creates a mechanical interlock that resists both tensile and bending forces, eliminating the need for additional fasteners while maintaining ease of assembly.
Solution Approach 2:
The patent employs inclined and angled surfaces on the tabs and grooves rather than flat perpendicular surfaces. This angular geometry allows the connection elements to interlock mechanically, distributing forces more effectively and creating a stronger connection that resists pull-apart and bending efforts without requiring additional fixing means.
2Strength
If fixing means like screws and nuts are used to strengthen the connection, then connection strength is improved, but device complexity and assembly requirements increase
Solution Approach 1:
The patent merges the connection function and the strengthening function into a single integrated tab-groove mechanism. The tabs are formed as an integral part of the module structure and engage with grooves in adjacent modules to create a self-sufficient connection system that provides both assembly ease and connection strength without requiring separate fixing components.
Solution Approach 2:
The patent extracts the additional fixing means (screws and nuts) from the assembly process by designing a tab-groove connection system that inherently provides sufficient connection strength. This eliminates the need for separate fastening components and simplifies the overall device complexity while maintaining robust connections.
3Strength
If additional fixing means are required for connection, then connection strength is sufficient, but the space needed for assembly increases
Solution Approach 1:
The patent combines the connection and strengthening functions into the tab-groove interface itself, eliminating the need for additional fixing means that would require extra mounting space. The inclined surfaces and mechanical interlock provide sufficient connection strength within the existing footprint of the modules, enabling assembly in confined spaces.
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 a robust and space-efficient connection between adjacent modules, allowing for manual assembly without additional fixing means, ensuring resistance to tensile and bending efforts and simplifying the assembly process, even in confined spaces.
Implementation Method 1
the side walls are arranged so that they are flexible enough to experience a elastic deformation towards the inside part of the module as a result of a force exercised transversely with respect to the longitudinal direction of the module
Data Source
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AI summary
The module consists of a U-shaped metal section (1) with a back wall (2) and side walls (3) comprising a first section (10) where the walls are finished in the shape of a reinforcing rib (4) with a tubular shape, and a second section (11) where the side walls are respectively arranged with coupling tabs (5), the relevant ends (100, 110) of these sections being arranged to be connected by means of a male-female coupling. The side walls (3) of the first section (10) include longitudinal notches (6) to house the coupling tabs. The connecting tabs (5) are configured as straight tabs extending obliquely towards the inside part of the module, and the side walls (3) are essentially flexible and may experience a elastic deformation towards the inside part of the module as a result of a force (F) exercised transversely with respect to the longitudinal direction and recover their position as soon as such transversal force is no longer exercised; the coupling tabs (5) are tightly inserted in the notches (6) of an adjacent module which is attached by means of a male-female coupling provided at its relevant ends (100, 110).