Support block assembly
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Solution Overview
Problem
Existing support block assemblies for rooftop applications require time-consuming and expensive assembly with fasteners, and there is a need for a more efficient and cost-effective method to secure struts to support blocks.
Innovation Solution
A support block assembly is developed where a strut is secured to a support block through anchors with tangs or dovetail-shaped grooves, forming a mechanical and/or chemical bond by overmolding the support block around the anchors or grooves, allowing for a secure and efficient attachment without the need for fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fastener assembly is used to secure strut to support block, then reliable mechanical connection is achieved, but assembly time and cost increase
Solution Approach 1:
The patent merges the support block and anchor into a single integrated component, eliminating the separate fastener assembly step. The anchor is built into the support block structure, allowing the strut to be secured without additional fasteners, thus reducing assembly time while maintaining connection reliability through the integrated design
Solution Approach 2:
The anchor features pre-formed tangs and the support block has pre-configured recesses that align with the strut. This preliminary configuration of attachment features allows for rapid assembly without requiring on-site fastener installation, reducing assembly time while ensuring proper alignment and secure connection
2Reliability
If traditional fastener assembly is used to secure strut to support block, then secure connection is achieved, but manufacturing cost increases
Solution Approach 1:
By combining the support block and anchor into one integrated component, the patent eliminates the need to manufacture and install separate fasteners. This reduces the total number of parts, simplifies the manufacturing process, and lowers material and labor costs while maintaining secure connection through the integrated anchor design
Solution Approach 2:
The integrated support block serves multiple functions: it provides structural support, incorporates the anchor mechanism for securing the strut, and eliminates the need for separate fasteners. This multi-functionality reduces the overall bill of materials and assembly complexity, thereby reducing manufacturing cost while ensuring secure connection
3Productivity
If overmolding process is used to form mechanical bond, then assembly speed increases, but manufacturing complexity increases
Solution Approach 1:
The patent segments the manufacturing process into distinct stages: first forming the support block with integrated anchor features, then overmolding the attachment portion. This segmentation allows each component to be optimized independently while maintaining overall simplicity, enabling faster assembly through the integrated design without excessive manufacturing complexity
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
This solution enables a faster and more cost-effective assembly process by forming a strong bond between the strut and support block, reducing installation time and expenses while providing adequate support for rooftop units and systems.
Implementation Method 1
The support block is overmolded on the tang of the anchor such that the tang extends into the support block and is encased within the support block to form a mechanical and/or chemical bond between the tang and the support block
Implementation Method 2
The support block is overmolded on the strut such that the support block extends into the dovetail-shaped groove of the lower side of the strut to form a mechanical and/or chemical bond between the strut and the support block
Data Source
AI summary
The present disclosure is directed to a support block assembly including a strut and an overmolded support block. The strut may include a base, and the support block may include an anchor coupled to the strut. The anchor includes a tang with the support block overmolded on the tang with the tang extending into and encased within the support block forming a bond between the tang and the support block. In an embodiment, the base may define at least one opening. The support block is overmolded on the strut such that the support block extends through at least one opening to form the bond between the strut and the support block. The strut may include a lower side defining a dovetail-shaped groove with the support block overmolded on the strut and extending into the dovetail-shaped groove to form a bond between the strut and the support block.