Snap-On Bracket Clamp Assembly for High-Torque Mounting
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Solution Overview
Problem
Existing mounting clamps, particularly those with plastic components, face issues such as damage from high torque, bolt loosening, and the need to open the clamp to access fasteners, which complicates securement and connection of objects to support structures.
Innovation Solution
The introduction of snap-on bracket clamp assemblies, which consist of a metal bracket and a polymeric mounting clamp that can snap onto the metal bracket. This design allows the metal bracket to absorb high torque, preventing damage to the plastic clamp, and enables easy attachment and detachment without opening the clamp.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a plastic mounting clamp is used to secure objects to a support structure, then the clamp can be easily installed and provides sufficient holding force for low-to-medium torque applications, but the plastic boss surrounding the orifice becomes plastically deformed and/or cracking occurs under high torque
Solution Approach 1:
The mounting clamp is divided into two functional segments: a plastic clamp body for easy installation and object securing, and a separate metal reinforcement element (compression limiter or insert) for torque resistance. The metal element is positioned within the orifice to bear torque loads while the plastic portion maintains ease of installation and object engagement.
Solution Approach 2:
The mounting clamp combines two different materials with complementary properties: plastic (polymer) providing ease of installation, flexibility, and corrosion resistance, and metal providing high torque resistance and structural strength. This composite structure allows each material to perform its optimal function without compromising the other.
2Strength
If a metal compression limiter is integrated into the orifice to handle high torque, then torque resistance is improved, but the solution is not suitable for all applications and increases device complexity
Solution Approach 1:
The mounting clamp design provides universal applicability across different torque requirements by offering multiple configuration options: plastic-only clamps for low-to-medium torque applications, and metal-reinforced clamps for high torque applications. The same basic clamp structure can serve multiple functions and application scenarios without requiring complete redesign.
Solution Approach 2:
The metal compression limiter is designed as a sacrificial protective element that absorbs stress concentrations and potential damage from high torque applications. By positioning the metal element within the orifice, it serves as a disposable or replaceable component that protects the more expensive plastic clamp body from failure.
3Reliability
If a bolt is passed through the plastic mount to secure the clamp to the support structure, then the clamp can be fastened to the support structure, but the plastic boss becomes damaged under high torque
Solution Approach 1:
The metal compression limiter or reinforcement element serves as an intermediary component between the bolt and the plastic clamp body. It intercepts and bears the torque loads and stress concentrations that would otherwise be transmitted to the plastic boss, protecting the plastic material from damage while maintaining secure fastening capability.
4Reliability
If the clamp structure is designed to enclose objects and connect to support structures, then securement is achieved, but access to fasteners requires opening the clamp which complicates the process
Solution Approach 1:
The fastener access problem is solved by transitioning from a one-dimensional linear access path (through the clamp body) to a multi-dimensional access approach. The retainer arm design allows fasteners to be accessed from the side or rear of the clamp assembly, enabling installation and maintenance without requiring the clamp to be opened or disassembled from the object side.
Data Source
AI summary
A snap-on bracket clamp assembly may include a metal bracket configured to attach to the support structure. A snap-on bracket clamp assembly may include a mounting clamp formed of a polymeric material, the mounting clamp configured to snap onto the metal bracket, the mounting clamp comprising: a first connector hingedly connected to a second connector, the first and second connectors configured to surround the object, and the first and second connectors configured to connect with one another to form the object into a bundle.