Modular Grab Bar Assembly for Rapid Length Customization
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Solution Overview
Problem
Existing grab bars for institutions at risk of self-harm, such as correctional facilities and mental health residential facilities, are limited in length options and require special ordering for non-standard lengths, leading to increased production time and cost.
Innovation Solution
A modular grab bar assembly with interchangeable body sections and end caps, allowing for customization in length and orientation, featuring couplings for secure assembly and ligature-resistant design to prevent self-harm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If grab bars are manufactured in fixed standard lengths (18, 24, or 36 inches), then production efficiency is maintained, but adaptability to different installation requirements is reduced
Solution Approach 1:
The grab bar is divided into multiple modular body sections that can be connected using couplings. Each body section has a standardized length, allowing efficient mass production, while the combination of sections enables customization to various total lengths. The coupling mechanism joins body sections end-to-end to create the desired overall length.
2Adaptability or versatility
If non-standard length grab bars are specially ordered and individually fabricated, then adaptability to specific length requirements is improved, but production time and cost increase significantly
Solution Approach 1:
By segmenting the grab bar into standardized body sections, the system allows quick assembly of custom lengths using pre-fabricated components. This eliminates the need for individual fabrication of non-standard lengths, reducing production time from weeks or months to a matter of assembling pre-made sections.
Solution Approach 2:
The standardized body sections and couplings serve multiple functions: they can be combined in various configurations to create grab bars of different lengths, and the same components can be used for both horizontal and vertical mounting orientations, providing universal applicability.
3Device complexity
If grab bars are designed as single fixed-length units, then structural simplicity is maintained, but flexibility in installation configurations is reduced
Solution Approach 1:
The grab bar system is segmented into body sections, end caps, and couplings. While this increases component variety, each individual component remains structurally simple and easy to manufacture. The modular nature allows flexible installation configurations without requiring complex single-piece designs.
Solution Approach 2:
The same modular components (body sections, couplings, end caps) can be assembled to create grab bars suitable for both horizontal and vertical orientations, providing installation flexibility without requiring different structural designs for different applications.
Data Source
AI summary
A grab bar assembly including a body, first and second end caps, and first and second couplings. The body includes a first end and a second end and is formed of one of a single body section or multiple body sections. The first end cap is attached to the first end of the body by the first coupling and the second end cap is attached to the second end of the body by the second coupling. The body sections may be of differing lengths so as to provide the grab bar assembly with a modular construction readily and easily allowing for a wide range of different length grab bar assemblies.