Baluster Connector With Flanges And Necked-Down Seat
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional baluster connectors fail to provide a secure and easy-to-disconnect connection, often resulting in material waste and inconsistent fits due to manufacturing tolerances, and can be difficult to assemble with existing solutions.
Innovation Solution
A baluster connector with a body having a first end with flanges and a second end with an integral washer, featuring a necked-down portion for secure fastening and drainage, allowing for easy assembly and resistance to removal, suitable for various geometric shapes and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded fasteners or extruded boss-type connections are used to attach balusters to railings, then a secure connection is achieved, but material is wasted in the center of the baluster and the connection becomes difficult to disconnect
Solution Approach 1:
The connector is divided into distinct functional segments: a body portion that interfaces with the baluster, flanges for lateral engagement, a necked-down portion for fastener engagement, and a washer portion for bearing support. This segmentation allows each part to perform its specific function efficiently without material waste in the baluster center.
Solution Approach 2:
The connection function is extracted from the baluster itself and placed into a separate connector component. The connector contains all the material needed for secure attachment (flanges, necked-down portion, washer) without requiring any material to be removed or wasted within the baluster.
2Ease of manufacture
If pre-formed balusters with connection mounts are used, then manufacturing is simplified, but manufacturing tolerances cause insecure mounts between baluster and rail
Solution Approach 1:
The connector incorporates localized geometric features including tapered portions and flanges at specific locations to compensate for manufacturing tolerances. The tapered necked-down portion provides a tolerance-absorbing transition zone that ensures reliable fastener engagement regardless of minor variations in baluster dimensions.
3Strength
If friction-fit tapered bosses are used to create secure connection, then connection strength is improved, but manufacturing tolerance variations cause inconsistent fit and difficulty in seating baluster on connector
Solution Approach 1:
The connector employs a controlled taper parameter in the necked-down portion that optimizes the balance between connection strength and assembly ease. The taper angle and dimensions are specifically designed to provide sufficient friction fit for security while maintaining a gap large enough to accommodate manufacturing tolerances and allow easy seating.
4Strength
If tight fit between baluster and connector is achieved, then connection security is improved, but it becomes difficult to fully seat the baluster on the connector
Solution Approach 1:
The connector is designed with a preliminary large opening at the first end that is larger than the baluster diameter, allowing the baluster to be easily inserted and seated first. The secure tight fit is then achieved through the tapered necked-down portion and flanges that engage after the preliminary seating action is complete.
Data Source
AI summary
A baluster connector for interconnecting a baluster with a hollow end to a portion of a railing system by a fastener having a shaft and a head. The body portion can have an opening of sufficient size to pass the head of the fastener toward the second end of the body to seat against a necked-down portion within the interior of the body. Biasing flanges can extend away from the body to provide resistance when the body is positioned within a hollow end of a baluster.