Segmented Rail Light Adapter for Curved Track Insertion
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Solution Overview
Problem
Existing rail light systems with adapters struggle to provide flexible use with curved support rails, often restricting the orientation and insertion direction of adapters, and require complex manufacturing processes.
Innovation Solution
The adapter features a supporting rail with a curved path and assembly slots, divided into segments with enhanced bendability in connecting areas, allowing flexible bending in two directions and simplifying production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the adapter body is made flexible to allow insertion into curved mounting rails, then the adaptability to curved paths is improved, but the structural stability and protection of internal components deteriorates
Solution Approach 1:
The adapter body is divided into multiple adapter segments (at least two) connected by connection areas. The segments can be made rigid for stability while the connection areas provide flexibility for bending around curved mounting rails. This segmentation allows the adapter to combine rigid segments for component protection with flexible joints for adaptability.
Solution Approach 2:
Different parts of the adapter body have different mechanical properties. The adapter segments are designed with higher rigidity for structural stability, while the connection areas between segments are designed with wave structures or elastic intermediate sections that provide localized flexibility. This local differentiation of mechanical properties resolves the contradiction between overall stability and localized adaptability.
2Ease of operation
If the adapter body is made uniformly flexible to enable bending in curved rails, then the ease of insertion is improved, but the manufacturing complexity increases
Solution Approach 1:
The adapter is segmented into rigid sections and flexible connection areas. The rigid segments can be manufactured using standard processes, while the flexible connection areas use specific structures (wave structures or elastic intermediate sections) that are simpler to manufacture than a uniformly flexible body. This segmentation reduces overall manufacturing complexity.
Solution Approach 2:
The connection areas incorporate wave structures with crests and troughs or elastic intermediate sections that provide flexibility through geometric design rather than requiring the entire adapter body to be made from flexible materials. This approach simplifies manufacturing compared to creating a uniformly flexible adapter body.
3Strength
If the adapter segments are made rigid for component protection, then the protection of internal components is improved, but the flexibility to follow curved paths deteriorates
Solution Approach 1:
The adapter body is divided into rigid adapter segments that protect internal components and flexible connection areas that enable bending. The segments maintain structural integrity and strength for component protection, while the connection areas with wave structures or elastic intermediate sections provide the necessary flexibility to follow curved mounting rail paths.
Solution Approach 2:
The adapter has non-uniform mechanical properties: rigid segments for strength and protection, and flexible connection areas for adaptability. This local differentiation allows the adapter to simultaneously provide component protection through rigid segments and path following through flexible joints.
4Ease of manufacture
If the adapter is designed as a single piece for simplicity, then the manufacturing is simplified, but the flexibility and adaptability to curved configurations is reduced
Solution Approach 1:
The adapter is divided into multiple segments connected by flexible joints, which can actually simplify manufacturing by allowing each segment to be produced separately using standardized processes, then assembled. The connection areas with wave structures or elastic intermediate sections can be integrated during molding or assembly, providing flexibility without significantly increasing manufacturing complexity.
Solution Approach 2:
The connection areas incorporate geometric flexibility features (wave structures) that can be manufactured using standard molding techniques, providing curved path adaptability without requiring complex multi-material or multi-step manufacturing processes.
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
This design enables the adapter to be used in a variety of curved support rail configurations without orientation restrictions, while also simplifying manufacturing and ensuring precise accommodation of internal components.
Implementation Method 1
The connection area(s) is/are each formed with at least one wave structure with wave crests and wave troughs... allows the adapter body to bend flexibly around at least two axes
Implementation Method 2
the connection area(s) is/are each formed with at least one elastic intermediate section... enables bendability in the connection areas
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The invention relates to an adapter (1; 1'; 1") for a track lighting system, which comprises a mounting rail (100; 100') shaped following a path (101) that is at least partially curved and is provided with at least one mounting slot (103; 103, 130) along a longitudinal extension (102) of the mounting rail. The adapter can be inserted into the mounting slot for electrical contacting a conductor assembly (106) of the mounting rail. The adapter has an adapter body (2; 2'; 2") which is divided along a longitudinal extension (3) of the adapter body into two or more adapter segments (4, 5, 6), wherein adjacent adapter segments are connected to each other in a connection area (7, 8; 7', 8'; 7", 8").The connection area allows the adapter body to be flexibly bent about at least two bending axes (9, 10), wherein the two bending axes are not parallel to each other and each runs non-parallel to the longitudinal extent of the adapter body. The adapter body is more flexible in the connection area than in the area of the adapter segments. Furthermore, a lighting arrangement (200; 300; 400) is proposed, comprising a support rail (100; 100'), an adapter according to the invention (1; 1'; 1"), and a lighting unit (150).