Monolithic Wall Mounting Bracket for Weld-Free Rail Support
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Solution Overview
Problem
Existing metal wall mounting brackets for cantilever arms face issues due to the costly and quality-risk-prone welding process, which also limits the use of pre-galvanised materials and complicates the manufacturing process. Additionally, these brackets often lack sufficient reinforcement for load-bearing connections.
Innovation Solution
A metal wall mounting bracket that uses a monolithic design with a wall plate, flange profiles, and a supporting rim to create a reinforced load-bearing connection without welding. The bracket features a socket with embracing portions and a supporting rim that interlock with the mounting rail, providing a two-point bearing of a load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join the rail supporting piece to the wall plate, then a load-bearing connection is achieved, but manufacturing cost increases and weld quality risks arise
Solution Approach 1:
The patent replaces the welding process with a mechanical connection system consisting of a rail supporting piece with a receiving portion that mechanically engages the mounting rail, eliminating welding operations while maintaining load-bearing capability through friction and geometric interlocking
Solution Approach 2:
The patent changes the connection mechanism from thermal (welding) to mechanical (friction-based clamping), altering the fundamental parameter of how the load-bearing connection is achieved and enabling the use of pre-galvanised materials without quality degradation
2Strength
If welding is used to join the rail supporting piece to the wall plate, then a load-bearing connection is achieved, but pre-galvanised materials cannot be used and toxic fumes are produced
Solution Approach 1:
The patent substitutes the thermal welding process with a mechanical connection system that uses friction and geometric interlocking, thereby eliminating toxic fume generation and enabling the use of pre-galvanised materials without compromising connection integrity
Solution Approach 2:
The patent converts the potential harm of welding to pre-galvanised materials into a benefit by designing a mechanical connection system that specifically advantages pre-galvanised materials, avoiding the harmful effects of welding while maintaining or improving connection quality
3Strength
If the wall plate provides reinforcement for the mechanical connection, then load-bearing capacity improves, but device complexity increases
Solution Approach 1:
The patent merges the wall plate and rail supporting piece into a single monolithic component formed from one piece of material, eliminating the need for separate reinforcement elements while maintaining load-bearing capacity through integrated structural design
Solution Approach 2:
The patent segments the monolithic component into functional zones (wall plate portion, rail supporting piece portion, and intermediate portion) that are formed as one piece, providing reinforcement where needed without adding separate complex components
Data Source
AI summary
A wall mounting bracket for mounting an elongate mounting rail as a cantilever arm to a wall or other supporting surface is provided including a wall plate having mounting holes for mounting the bracket to a wall by means of male fasteners, and a socket for inserting the end portion of the mounting rail, including at least two flange profiles, which at their distal end have an embracing portion to interlock with the end portion of the mounting rail thereby inhibiting movement of an inserted end portion parallel to the wall plate. At least one of the embracing portions has a fixing hole for passing through a male fastener to fix the end portion of the mounting rail to inhibit retraction of the end portion from the socket. A supporting rim is provided to interlock with the outer or inner side of the end portion of the mounting rail.