Walkable Cable Duct Cover With Integrated Fastening and Slip Resistance
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Solution Overview
Problem
Existing cable duct systems face challenges in assembly complexity, cost-effectiveness, and recyclability, particularly due to the need for drilling and using special tools for fastening, which complicates installation and increases the risk of damage and dirt ingress.
Innovation Solution
A walkable cable duct cover with a one-layer metal design featuring a structured central region for slip resistance and patterned fastening points that can be punched or embossed, allowing for easy attachment without drilling, and a method for producing such covers using a sheet metal strip with continuous bending and punching to create side parts and a cover part, enabling flexible length adjustment and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If drilling holes in the cover for fastening means, then secure attachment to cable duct tray is achieved, but assembly complexity increases and special tools are required
Solution Approach 1:
The cover is divided into a one-piece construction where the fastening means are integrated directly into the cover body rather than being separate components requiring drilling and assembly. The molded-in fastening elements are formed as integral parts of the cover during manufacturing.
Solution Approach 2:
The fastening means are pre-formed and molded into the cover during the manufacturing process, eliminating the need for on-site drilling and installation of separate fastening components. This preliminary formation of fastening elements simplifies assembly to a simple snap-fit operation.
2Reliability
If using aluminum checker plate with rivets, then slip resistance is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
Instead of covering the entire cover surface with expensive checker plate, the invention provides slip resistance only in the specific areas where foot contact occurs. The textured or ribbed surface pattern is applied locally to the top surface of the cover, while the rest of the cover remains as smooth, economical thermoplastic material.
Solution Approach 2:
The cover combines a thermoplastic base material with a textured or ribbed surface layer that provides slip resistance. This composite approach integrates the slip-resistant surface directly into the thermoplastic cover during molding, eliminating the need for separate aluminum checker plate and rivets.
3Reliability
If providing structured surface across entire cover, then slip resistance is maximized, but side edge bending becomes difficult
Solution Approach 1:
The structured surface pattern is applied only to the top surface of the cover where slip resistance is needed, while the side edges and bending regions remain as smooth, unstructured thermoplastic material that is easy to form and bend during manufacturing.
4Strength
If using multiple layers or composite construction, then structural strength is improved, but recyclability deteriorates
Solution Approach 1:
The cover is constructed as a homogeneous, one-piece thermoplastic component with the slip-resistant surface and fastening means all integrated into the same material matrix. This homogeneous thermoplastic construction allows the entire cover to be easily recycled together as a single material type, unlike multi-layer composite constructions.
Data Source
Figure 1~2a
Figure 2b~2c
Figure 3~4
AI summary
The present invention relates to a walkable cable duct cover with a cover part having a top and a bottom, and two side parts projecting from the cover part, each forming a side edge of the cable duct cover. The top of the cover part has a structured central area formed by stamping or embossing from the underside, providing a non-slip surface. On both sides of the structured central area, the top of the cover part has a smooth, unstructured edge area extending to the respective side edge, with a width of 5 mm or more. The invention further relates to a cable duct with a cable duct channel, a walkable cable duct cover as described above, and at least one cover retaining spring and/or at least one rotary latch for fastening the cable duct cover to the cable duct channel. A manufacturing method according to the invention for producing the walkable cable duct cover is also disclosed.