Thermoplastic Mounting Device for Fall Protection

Solution Overview

Problem

Existing mounting devices for fall protection systems are costly and heavy due to their high-quality, robust construction, which limits their economic viability and weight efficiency.

Innovation Solution

A mounting device with a substantially integrally formed, form-retaining base part and a flexible flap where the proximal part of the flap is incorporated into the core material, eliminating the need for a heavy clamping construction, and using thermoplastic materials for casting to ensure reliability and durability while reducing production costs and weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a heavy clamping construction with metal flange bodies and central bolt is used, then reliability and leak-tightness are improved, but weight and production cost increase

Engineering Contradiction:

ImprovereliabilityVSAvoidweight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent replaces the mechanical clamping system (metal flange bodies with central bolt) with a chemical bonding system. The flexible flap is embedded in a matrix material that cures to form a strong chemical bond, eliminating the need for mechanical fasteners and reducing overall weight while maintaining reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses composite materials by combining the flexible flap with a matrix material (such as polymer or rubber) to create a unified structure. This composite approach provides both the flexibility needed for attachment and the structural integrity required for reliability, while reducing weight compared to traditional metal constructions.

Inventive Principle:

Principle #40Composite materials

2Reliability

If a heavy clamping construction with metal flange bodies and central bolt is used, then reliability and leak-tightness are improved, but production cost increases

Engineering Contradiction:

ImprovereliabilityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces the mechanical clamping system (metal flange bodies with central bolt) with a chemical bonding system. The flexible flap is embedded in a matrix material that cures to form a strong chemical bond, eliminating the need for mechanical fasteners and reducing overall weight while maintaining reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent merges the flexible flap with the matrix material into a single integrated component. The flap is embedded directly into the matrix during manufacturing, creating a unified structure that eliminates separate assembly steps and reduces production complexity compared to assembling multiple metal parts.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If the proximal part of the flexible flap is fully enclosed by core material, then leak-tightness is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveleak-tightnessVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-positioning the flexible flap within the mold before pouring the matrix material. The flap is placed in its final embedded position during manufacturing, so that when the matrix material is poured and cured, the flap is automatically fully enclosed and sealed, eliminating the need for separate sealing operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the mechanical clamping system (metal flange bodies with central bolt) with a chemical bonding system. The flexible flap is embedded in a matrix material that cures to form a strong chemical bond, eliminating the need for mechanical fasteners and reducing overall weight while maintaining reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 lightweight, cost-effective mounting device that maintains reliability and durability, allowing for secure attachment to surfaces without compromising leak-tightness, suitable for fall protection systems and other applications.

Implementation Method 1

the core material comprises a thermoplastic plastic and is arranged at increased temperature on either side of the proximal part of the flap in a thermoforming process

Methodology Applied

Scientific EffectThermoforming:

Data Source

PatentUS9566458B2Mounting device and fall protection system

Publication Date: 2017.02.14 KEDGE SAFETY SYSTEMS BV

AI summary

A mounting device for mounting on a wall of an object comprises an at least substantially form-retaining base part (20) with at least one mounting member (10) and a substantially flexible flap (30), a distal part (32) of which extends substantially freely and laterally from the base part (20) and which is intended and adapted to be connected firmly to a surface of the wall of the object. The base part (20) comprises a form-retaining body which is formed integrally with a solid monolithic core, wherein a proximal part (31) of the flap (30) is incorporated at least substantially tightly in the core material of the body.