Expandable Splice Block for Rod Alignment and Noise Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coupling systems for rods in railing systems face mechanical fragility and cosmetic drawbacks, particularly when rods need to be coupled together due to shipping length limitations, and often struggle with alignment and noise issues due to asymmetrical or non-rectangular cross-sections.
Innovation Solution
An expandable splice block system that includes a top and bottom plate coupled by a neck, with threaded inserts that push the top plate away from the bottom plate to accommodate alignment imperfections and fill hollow end portions, providing a secure and cosmetically pleasing connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If traditional coupling systems are used to join rod segments, then rod assembly is enabled for shipping compliance, but mechanical fragility and cosmetic drawbacks occur
Solution Approach 1:
The splice block incorporates an expandable mechanism that transitions from a compact state during insertion to an expanded state during operation. The bottom plate can be pushed away from the top plate using threaded inserts or springs, allowing the coupling system to adapt its internal dimensions dynamically to achieve reliable mechanical engagement while maintaining a compact external profile for shipping compliance.
Solution Approach 2:
The coupling system changes its internal dimensional parameters by expanding the distance between the top and bottom plates. This parameter change allows the splice block to accommodate rods of varying lengths and configurations, providing reliable mechanical coupling while the external dimensions remain within shipping limits. The expansion can be achieved through threaded inserts, springs, or other expansion mechanisms.
2Strength
If rigid fixed-structure coupling systems are used, then structural strength is maintained, but alignment imperfections and rattling noise occur
Solution Approach 1:
The expandable splice block provides a dynamic adjustment mechanism that allows the coupling system to self-align during the expansion process. As the bottom plate is pushed away from the top plate, the system can accommodate misalignments and non-rectangular cross-sections, eliminating rattling noise while maintaining structural strength through secure engagement of the rod ends between the plates.
Solution Approach 2:
The system changes its internal dimensional parameters to accommodate alignment imperfections. By allowing the distance between plates to vary and expand, the coupling system can adapt to rods with non-rectangular cross-sections and slight misalignments, eliminating harmful rattling noise while maintaining the necessary coupling strength through secure mechanical engagement.
3Adaptability or versatility
If asymmetrical coupling designs are used to accommodate non-rectangular cross-sections, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The expandable splice block design uses a universal top plate and bottom plate structure that can accommodate various rod cross-sections including non-rectangular shapes. The expansion mechanism allows the same basic component design to adapt to different rod configurations without requiring asymmetric or custom-shaped components, thereby maintaining ease of manufacture while achieving high adaptability.
Solution Approach 2:
Instead of designing asymmetric structures for different cross-sections, the system achieves adaptability by changing its internal dimensional parameters through expansion. The basic symmetric structure of the top and bottom plates remains simple to manufacture, while the expandable mechanism allows the internal cavity to adapt to various rod cross-sections, maintaining manufacturing simplicity while achieving versatility.
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 expandable splice block system securely couples rods, eliminates overhangs and rattling noise, and accommodates non-rectangular cross-sections, ensuring a tight and aesthetically pleasing fit.
Implementation Method 1
Some expandable splice blocks include a first threaded insert threadably coupled to the first threaded hole. The first threaded insert can be configured to push the top plate away from the first side as the first threaded insert is threaded towards the top plate.
Data Source
AI summary
Expandable splice blocks can be configured to mechanically couple a first rod to a second rod. Expandable splice blocks can include a top plate and a bottom plate. Bottom plates can include a first side coupled to a second side by a neck.