Rotatable Rail Connector for Adjustable Baluster Angles
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Solution Overview
Problem
Existing rail systems require precise angling and fixed connections between balusters and rails, limiting adaptability and aesthetic appeal, as they are typically stationary and constructed specifically for each installation location.
Innovation Solution
A rotatable rail connector that allows balusters to be pivoted to desired angles, comprising a base and projection with a threaded outer surface, enabling adjustable connections with various rail systems and angles, and an optional insert for wedge connections with metal balusters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If balusters are directly inserted into the rail with precise angling, then the rail system achieves proper function and aesthetic appearance, but the system loses adaptability and requires custom construction for each location
Solution Approach 1:
The connector incorporates a rotatable projection that allows the baluster angle to be dynamically adjusted after installation. The projection can rotate within the base to change the angulation of the connected baluster, transforming a static fixed-angle connection into a dynamic adjustable connection that maintains precision while providing adaptability to different locations and angles.
Solution Approach 2:
The connector is divided into separate functional components: a base that attaches to the rail, a rotatable projection that provides angular adjustment, and connection points for balusters. This segmentation allows each component to perform its specific function independently, enabling precise angling through rotation while maintaining adaptability through modular assembly.
2Ease of manufacture
If a separate connector piece with set angle is used to connect balusters to rails, then installation consistency and ease are improved, but the system loses adjustability and becomes fixed in one location
Solution Approach 1:
The connector transforms a static fixed-angle design into a dynamic adjustable-angle design by incorporating a rotatable projection. The projection can be rotated to different angles within the base, allowing the same connector to accommodate various baluster angulations while maintaining ease of installation through the same basic assembly process.
Solution Approach 2:
The connector enables change in the angular parameter of the baluster connection. By allowing the projection to rotate, the connection angle can be varied to suit different installation requirements, transforming a fixed-parameter connector into a variable-parameter connector that maintains installation simplicity.
3Reliability
If the rail system is constructed specifically for each location with fixed angles, then proper function and aesthetic appearance are achieved, but the system lacks flexibility and requires custom construction
Solution Approach 1:
The connector design achieves universal applicability by combining a standardized base that attaches to rails with a rotatable projection that accommodates various angles. This single connector design can be used across multiple locations and applications (stairs, ramps, decks) without requiring custom construction for each location, while still ensuring proper system function and aesthetic appearance.
Solution Approach 2:
The rotatable projection provides dynamic angle adjustment capability that allows the same standardized connector to adapt to different installation requirements. This eliminates the need for custom-constructed fixed-angle connectors for each location, reducing device complexity while maintaining reliable system function through proper angling adjustment.
Data Source
AI summary
A rail connector includes a base and an outwardly extending projection rotatably connected with the base. The base has a flat lower portion and an upper portion which contains an opening that is parallel to the base lower portion. The projection includes upper and lower ends, the lower end being arranged in the base opening and the upper end having a threaded outer surface and extending outwardly from the base. The base is connected with a rail and the projection is connected with a baluster. The projection is rotatable relative to the base and allows the baluster to pivot to a desired angle.