Modular Rail System With Adjustable Expansion Connectors
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Solution Overview
Problem
Existing modular rail systems lack versatility in configuration and aesthetics, as they often require fixed orientations for fasteners and do not allow for easy adaptation or illumination of components, limiting their customization and functionality.
Innovation Solution
A modular rail system featuring adjustable connectors with expansion members that can change diameter configurations for secure coupling, combined with illuminated span members that can receive lighting elements and connect to external power supplies, enabling customizable configurations and enhanced aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed orientation fasteners are used to securely couple rail components, then connection reliability is improved, but configuration versatility deteriorates
Solution Approach 1:
The fastener system transitions from a fixed orientation to a rotatable mechanism that can adapt to different configurations. The span member includes a rotatable fastener that can be oriented in multiple directions, allowing the same fastener type to secure components in various arrangements while maintaining reliable connection.
Solution Approach 2:
The same fastener design serves multiple functions by being rotatable to different orientations. A single fastener type can secure span members in linear configurations, angular configurations, or other arrangements, eliminating the need for different fastener variants for different orientations.
2Adaptability or versatility
If modular components are designed for easy assembly in different configurations, then configuration versatility is improved, but assembly security deteriorates
Solution Approach 1:
The expansion member incorporates a dynamic diameter adjustment capability. During assembly, the expansion member is inserted in a collapsed state (smaller diameter) for easy insertion, then expanded to a larger diameter to securely engage with the receptacle, providing both ease of assembly and secure connection.
Solution Approach 2:
The expansion member changes its dimensional parameter (diameter) from a first smaller diameter during insertion to a second larger diameter during engagement. This parameter change enables the member to transition from an insertable state to a securely engaged state within the same component.
3Ease of operation
If fasteners are made visible and accessible for easy assembly, then ease of operation is improved, but aesthetic appearance deteriorates
Solution Approach 1:
Instead of having the fastener mechanism visible on the exterior, the design inverts the arrangement by placing the fastener mechanism on the interior or hidden surfaces. The expansion member is inserted through hidden openings or from the interior, keeping all fastening components concealed while maintaining ease of operation.
Solution Approach 2:
The fastener mechanism is extracted from the visible exterior and relocated to hidden or interior positions. The expansion member can be inserted through concealed openings or from the interior of the structure, separating the functional fastening element from the aesthetic exterior surface.
Data Source
AI summary
A modular rail system is disclosed where the component modules can be easily assembled in different combinations and configurations to produce customized rails having the desired appearance and functionality. In some embodiments the rail system comprises at least one connector having a longitudinal axis and comprising a connector span and at least one expansion member, wherein the expansion member is adjustable between a first configuration having a first diameter and a second configuration having a second diameter larger than said first diameter; and at least one span member having an outer surface and an inner surface and at least one open end, wherein the expansion member is insertable into an interior of the span member in the first configuration and is adjustable to the second configuration within the span member to securely engage the inner surface of the span member to releasably couple the connector and the span member together. The rail system may also include an actuator for adjusting the expansion member between the first and second configurations within the span member. In some embodiments the rail system comprises at least one span member and/or at least one connector that is illuminated to enhance the aesthetic appearance of the assembled rail and/or to direct light as desired at the site of installation. In a particular aspect the system may comprise a plurality of span members and at least one of the span members is a light emitting span member configured for receiving a lighting element. The lighting element may be connectable through a connector and/or a span member to an electrical supply externally of the rail system.