Modular Breakaway Connector with Segmented V-Shape Joints
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Solution Overview
Problem
Existing breakaway connectors for road signs, guardrails, and luminaires are typically single integrated pieces, limiting their versatility in accommodating different sizes and requiring full replacement upon damage, leading to increased costs and material usage.
Innovation Solution
A modular connector system comprising multiple segments with breakaway portions and a central rod, allowing for adjustable breakpoints and reusability of components, enabling the connector to break at specific points under lateral loads and facilitating repair by replacing only the rod.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single integrated breakaway connector is used, then the connector can provide support and break at a predetermined load, but it can accommodate only one size of fastener and one size of installation
Solution Approach 1:
The connector is divided into multiple separable segments (first connector segment, second connector segment, and intermediate breakaway segments) that can be assembled in different configurations. Each segment has standardized interfaces allowing various fastener sizes and installation types while maintaining overall connector functionality.
Solution Approach 2:
The modular connector segments are designed with universal interfaces that can accommodate different fastener sizes (nuts or bolts) and installation configurations. The same basic segment design can be used across multiple applications by varying the number and arrangement of segments.
2Ease of repair
If a single integrated breakaway connector is used, then the connector provides structural support, but the entire connector must be replaced when any portion is damaged
Solution Approach 1:
The connector is segmented into modular sections that can be independently replaced. When damage occurs, only the affected segment needs to be replaced rather than the entire connector, reducing material waste and repair costs.
Solution Approach 2:
The modular design allows intact segments to be recovered and reused after damage to one segment. The undamaged segments can be detached and reused in the repaired connector, minimizing material loss.
3Ease of manufacture
If a single integrated breakaway connector is used, then the connector design is simple, but multiple connectors of different variations are required to accommodate different sizes
Solution Approach 1:
The connector is divided into standardized segments that can be manufactured using the same processes and tools. This standardization simplifies manufacturing while the modular nature allows configuration variations to meet different size requirements.
Solution Approach 2:
A single standardized segment design serves multiple purposes across different connector configurations. The same basic segment can be used in various combinations to create connectors for different fastener sizes and installation types.
Data Source
AI summary
A connector system having first and second connector segments held together by a rod threadably received in an internal axial bore through each of the first and second connector segments. Each connector segment has a breakaway portion formed from an angled face on one connector segment that cooperates with the mating angled face on the abutting connector segment to form a V-shaped breakpoint between the two connector segments. An intermediate segment can be positioned there between to provide two breakpoints, and multiple intermediate segments can be used for additional breakpoints. Upon impact, the system breaks at the breakpoint and only the rod needs to be in most cases. A longitudinal bore through the rod permits adaption of the rod to selected loads.