US20230374790A1 - Modular rail system - Google Patents
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- US20230374790A1 US20230374790A1 US18/228,483 US202318228483A US2023374790A1 US 20230374790 A1 US20230374790 A1 US 20230374790A1 US 202318228483 A US202318228483 A US 202318228483A US 2023374790 A1 US2023374790 A1 US 2023374790A1
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- connector
- expansion member
- members
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Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F11/00—Stairways, ramps, or like structures; Balustrades; Handrails
- E04F11/18—Balustrades; Handrails
- E04F11/1802—Handrails mounted on walls, e.g. on the wall side of stairs
- E04F11/1808—Handrail members; Connections between handrail members
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F11/00—Stairways, ramps, or like structures; Balustrades; Handrails
- E04F11/18—Balustrades; Handrails
- E04F11/1802—Handrails mounted on walls, e.g. on the wall side of stairs
- E04F11/1804—Details of anchoring to the wall
Definitions
- FIG. 6 is an enlarged, side elevational view thereof.
- FIGS. 2 - 19 illustrate an embodiment of connector 14 .
- Connector 14 comprises a connector span 26 and at least one expansion member 28 .
- connector 14 may comprise two expansion members 28 coupled on either end of a connector span 26 ( FIGS. 25 - 27 ).
- connector span 26 and expansion members 28 are releasably connectable (e.g. FIG. 19 ).
- connector span 26 and expansion members 28 are integrally connected (e.g. FIG. 20 ).
- connector span 26 is generally cylindrical in shape and comprises a primary span portion 30 having a first outer diameter and flanges 32 formed at either end of connector span 26 and each having a second outer diameter less than the first outer diameter. Flanges 32 thus form slightly recessed narrow end portions of an outer surface 34 of connector span 26 ( FIG. 6 ).
Abstract
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.
Description
- This application is a continuation of U.S. patent application Ser. No. 16/224,570 filed 18 Dec. 2018, which claims the benefit of US provisional patent application No. 62/607,849 filed 19 Dec. 2017. Each of the above-referenced patent applications is hereby incorporated by reference herein in its entirety.
- This application relates to a modular rail system. In some embodiments the modular rail system can be used to configure customized handrails, for example for use in elevator cabins.
- Modular handrails are known in the prior art. For example European patent application EP 1048799A1, Milesi, describes a modular structure for making handrails comprising bearing elements, supports and junction inserts that can be coupled together in different configurations. The supports are designed for coupling a handrail to the wall of a building. Each support comprises an integral fastening portion for mounting a handrail on the support wall. The Milesi modular structure thus employs structurally different components for different dedicated functions. For example, the junction inserts for coupling a bearing element to a support cannot be adapted for mounting directly on a support structure. While a light unit may be mounted in a support, the bearing elements are not designed to be light-emitting.
- Other modular rail systems are known in the prior art that include means for securely coupling rail components together. However, such systems often include fasteners that can only be deployed in a particular orientation and cannot be easily adapted for applications where it is desirable to alter the configuration of the modules while locating the fastening system hidden from view.
- The need has therefore arisen for a modular rail system having enhanced versatility where the component modules can be easily assembled in different combinations and configurations to produce customized rails having the desired appearance and functionality. The need has particularly arisen for a modular rail system where modules of the system, including span members, can be optionally illuminated to enhance the aesthetic appearance of the assembled rail and/or to direct light as desired at the site of installation.
- The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
- The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements.
- One aspect of the disclosure provides a modular rail system comprising 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. In one embodiment the system includes an actuator insertable through an aperture in the span member for adjusting the expansion member between the first and second configurations within the span member.
- Another aspect of the disclosure provides a modular rail system wherein at least one span member and/or at least one connector is illuminated. In a particular aspect the system may comprise a plurality of span members wherein 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 power supply externally of the rail system.
- In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions.
- Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.
-
FIG. 1A is an exploded, isometric view showing an embodiment of a rail system comprising a plurality of span members, connectors and mounting assemblies. -
FIG. 1B is a top plan view thereof; -
FIG. 1C is an isometric view of the rail system ofFIGS. 1A and 1B in an assembled configuration. -
FIG. 1D is a top plan view thereof. -
FIG. 1E is an alternative embodiment of a span member having a bent mitre end. -
FIG. 1F is a further alternative embodiment of a span member having a radius end. -
FIG. 1G is a further alternative embodiment of a span member having a radius end. -
FIG. 1H is a further alternative embodiment of a span member having a 90° end. -
FIG. 1I is a further alternative embodiment of a span member having a mitred shape. -
FIG. 1J is a further alternative embodiment of a span member having a kick end. -
FIG. 1K is a further alternative embodiment of a span member having a kick end. -
FIG. 1L is a further alternative embodiment of a span member having a kick end. -
FIG. 1M is a further alternative embodiment of a span member having a radius end. -
FIG. 1N is a further alternative embodiment of a span member having a bullet end. -
FIG. 1O is a further alternative embodiment of a span member having a bullnose end -
FIG. 2 is an exploded, first isometric view of an embodiment of a span member and connector comprising one expansion member. -
FIG. 3 is an exploded, second isometric view of the span member and connector ofFIG. 2 . -
FIG. 4 is an exploded, side elevational view of the span member and connector ofFIGS. 2-3 . -
FIG. 5 is an enlarged, end elevational view of an assembled span member and connector ofFIGS. 2-3 showing the set screw actuator fully inserted. -
FIG. 6 is an enlarged, side elevational view thereof. -
FIG. 7 is a side view of a span member and connector with a set screw actuator removed. -
FIG. 8 is a side view of the span member and connector ofFIG. 7 with the set screw actuator inserted. -
FIG. 9 is a side view of a span member and connector in an assembled configuration with the set screw actuator inserted. -
FIG. 10 is a first end view thereof. -
FIG. 11 is a second end view thereof. -
FIG. 12 is an enlarged side view of a connector having an expansion member inserted within a span member and showing the set screw actuator removed. -
FIG. 13 is an end elevational view thereof. -
FIG. 14 is an enlarged, side view of a connector having an expansion member inserted within a span member and showing the set screw actuator inserted. -
FIG. 15 is an end elevational view thereof. -
FIG. 16 is a first isometric view of an assembled connector comprising a single expansion member. -
FIG. 17 is a second isometric view of an assembled connector comprising a single expansion member. -
FIG. 18 is a longitudinal sectional view of the connector ofFIGS. 16-17 . -
FIG. 19 is an enlarged, exploded isometric view of the connector ofFIGS. 16-18 . -
FIG. 20 is an enlarged, isometric view of an alternative embodiment of a connector comprising two integral expansion members. -
FIG. 21A is a first isometric view of the connector ofFIG. 20 showing a set screw actuator withdrawn from an expansion member. -
FIG. 21B is a second isometric view of the connector ofFIG. 21A showing an elongated slot for receiving an electrical cable and a pair of spaced-apart mounting apertures -
FIG. 21C is side elevational view of the connector ofFIG. 21B . -
FIG. 22 is an isometric view thereof showing the set screw actuator inserted within an expansion member in a first orientation. -
FIG. 23 is an isometric view thereof showing the set screw actuator withdrawn from an expansion member. -
FIG. 24 is an isometric view thereof showing the set screw actuator inserted within an expansion member in a second orientation. -
FIG. 25 is an exploded, isometric view of a connector comprising two expansion members and one embodiment of a mounting assembly. -
FIG. 26 is an exploded, isometric view thereof showing two span members joined by the connector. -
FIG. 27 is an isometric view of the span members, connector and mounting assembly ofFIGS. 25-26 in an assembled configuration. -
FIG. 28 is an enlarged, assembled, first isometric view of the connector and mounting assembly ofFIGS. 25-27 . -
FIG. 29 is an enlarged, assembled, second isometric view thereof. -
FIG. 30 is a top plan view showing the connector coupling two span members together. -
FIG. 31 is an isometric, partially sectional view showing a connector in cross-section and a mounting assembly in longitudinal section. -
FIG. 32 is a side sectional view of the connector and mounting assembly ofFIG. 31 . -
FIG. 33 is a side view of the connector and mounting assembly showing the set screw actuator fully inserted. -
FIG. 34 is a top plan view thereof. -
FIG. 35 is an end elevational thereof. -
FIG. 36A is a partially exploded, isometric view of an embodiment of a rail system comprising a first mounting assembly for coupling a connector to a support and a second mounting assembly for coupling an end span to the support. -
FIG. 36B is an isometric view of the rail system ofFIG. 36A in a fully assembled configuration. -
FIG. 37A is a top plan view of the rail system ofFIG. 36A . -
FIG. 37B is a top plan view of the rail system ofFIG. 36B . -
FIG. 38 is a fully exploded, isometric view of the rail system ofFIG. 36A shown in isolation from the support. -
FIG. 39 is a top plan view of the rail system ofFIG. 38 . -
FIG. 40 is a fragmented, enlarged top plan view of the rail system ofFIG. 36A showing details of the connector and mounting assemblies. -
FIG. 41 is an exploded, top isometric view of an embodiment of a rail system configured for receiving a lighting element. -
FIG. 42 is an exploded, bottom isometric view of the rail system ofFIG. 41 . -
FIG. 43 is a top isometric view of the rail system ofFIGS. 41-42 in an assembled configuration. -
FIG. 44 is a front elevational view thereof; -
FIG. 45 is a bottom plan view thereof; -
FIG. 46 is a rear elevational view thereof; -
FIG. 47 is a top plan view thereof; -
FIG. 48 is an exploded, top isometric view of an embodiment of a rail system comprising an alternative mounting assembly for coupling a connector as illustrated inFIGS. 21A-21C to a support surface. -
FIG. 49 is an exploded, bottom isometric view of the rail system ofFIG. 48 . -
FIG. 50 is an isometric view of the rail system ofFIGS. 48-49 in an assembled configuration mounted on a support surface. -
FIG. 51 is a front elevational view thereof. -
FIG. 52 is a bottom plan view thereof. -
FIG. 53 is a rear elevational view thereof; -
FIG. 54 is a top plan view thereof; -
FIG. 55 is an exploded, top isometric view of an embodiment of a rail system configured for receiving an alternative embodiment of a lighting element. -
FIG. 56 is an exploded, bottom isometric view of the rail system of the rail system ofFIG. 55 . -
FIG. 57 is an isometric view of the rail system ofFIGS. 55-56 in an assembled configuration mounted on a support surface. -
FIG. 58 is a front elevational view thereof. -
FIG. 59 is a top plan view thereof. -
FIG. 60 is a rear elevational view thereof. -
FIG. 61 is a bottom plan view thereof. - Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.
- This application relates to a
modular rail system 10. In someembodiments rail system 10 can be configured to form a handrail, for example a handrail for use in the interior cabin of an elevator. -
Rail system 10 comprises a plurality ofspan members 12 and a plurality ofconnectors 14 for releasablycoupling span members 12 together (FIGS. 1A-1D ). As described below,span members 12 may be provided in different lengths, shapes, materials, colors and external finishes. By combiningspan members 12 andconnectors 14 in different modular combinations and configurations the aesthetic appearance and/or functionality of theresultant rail system 10 can be varied. -
FIGS. 2-11 illustrates an embodiment of anexemplary span member 12.Span member 12 comprises anouter surface 16, aninner surface 18 and at least one open end (FIGS. 2-4 ). In some embodiments span memberinner surface 18 defines a hollowinner compartment 22 in communication with open end 20 (FIG. 4 ). In some embodiments spanmembers 12 may be rectilinear tubes. In other embodiments spanmembers 12 may be curvilinear tubes (e.g.FIGS. 1A-1D show span members 12 forming part of arail system 10;FIGS. 1E-1O show variousexemplary span members members 12 may comprise two open ends 20. In other embodiments spanmember 12 may comprise oneopen end 20 and oneclosed end 21 which may form the terminus of arail system 10. For example, as shown inFIGS. 1N and 1O ,closed end 21 of aspan member 12 may formed in many alternative shapes and contours, such as semi-spherical, bullet-shaped, bull-nose, and bent-mitre. - In some embodiments span
members 12 may comprise anaperture 24 extending transversely betweenouter surface 16 andinner surface 18 proximate anopen end 20 thereof (FIG. 4 ). For example, in someembodiments aperture 24 may be spaced approximately 0.5 to 1 inch fromopen end 20. -
FIGS. 2-19 illustrate an embodiment ofconnector 14.Connector 14 comprises aconnector span 26 and at least oneexpansion member 28. In someembodiments connector 14 may comprise twoexpansion members 28 coupled on either end of a connector span 26 (FIGS. 25-27 ). As discussed further below, in someembodiments connector span 26 andexpansion members 28 are releasably connectable (e.g.FIG. 19 ). In otherembodiments connector span 26 andexpansion members 28 are integrally connected (e.g.FIG. 20 ). - In some
embodiments connector span 26 is generally cylindrical in shape and comprises aprimary span portion 30 having a first outer diameter andflanges 32 formed at either end ofconnector span 26 and each having a second outer diameter less than the first outer diameter.Flanges 32 thus form slightly recessed narrow end portions of anouter surface 34 of connector span 26 (FIG. 6 ). - As shown for example in
FIG. 19 , eachflange 32 has anannular end surface 36 and aninner surface 38 which defines the side wall of ashallow end compartment 40 ofconnector span 26. The depth ofcompartment 40 is defined by anend plate 42 surrounded by flangeinner surface 38. In someembodiments end plate 42 comprises a first threadedcentral aperture 44 and one or moresecondary apertures 46. In some embodimentscentral aperture 44 extends longitudinally through the body ofconnector span 26. As described further below, in someembodiments apertures expansion member 28 toconnector span 26 at a selected rotational position. -
Connector span 26 may also comprise a threadedaperture 50 which extends transversely through the body ofprimary span portion 30. In some embodiments transverseaperture 50 is in communication withlongitudinal aperture 44, as shown for example inFIG. 31 . As described further below,aperture 50 may be used to releasablycouple connector span 26 to other modular components ofsystem 10, such as a mounting assembly 94 (FIGS. 25 and 26 ). - As shown in
FIG. 19 , eachexpansion member 28 is generally cylindrical in shape and has a longitudinal axis which can be aligned with the longitudinal axis ofconnector span 26. In some embodiments eachexpansion member 28 comprises afirst portion 52 comprising a plurality ofwall segments 54 separated by alongitudinal slot 56 extending parallel to the longitudinal axis of member 28 (e.g.FIGS. 4 and 19 ). Eachwall segment 54 has anouter surface 58 and aninner surface 60. In someembodiments wall segment 54 may have chamferededges 54A merging with anend wall 64. In the embodiment ofFIG. 19 first portion 52 comprises twowall segments 54. In the embodiment ofFIG. 20 first portion 52 may comprise four ormore wall segments 54, each separated from anadjacent wall segment 54 by aslot 56. - Each
first portion 52 of anexpansion member 28 comprises anaperture 66 extending transversely through at least one of thewall segments 54. In someembodiments aperture 66 is threaded. As described further below,aperture 66 can be aligned with anaperture 24 of aspan member 12 when anexpansion member 28 is inserted through anopen end 20 of aspan member 12. -
Modular rail system 10 further comprises an actuator for adjustingexpansion member 28 between a first, reduced-diameter configuration, whereinexpansion member 28 is insertable into anopen end 20 of aspan member 12, and a second, expanded diameter configuration wherein the distance betweenopposed wall segments 54, and hence the width ofslots 56, is increased. As described further below, this enables theouter surfaces 58 of eachwall segment 54 to securely engage aninner surface 18 of aspan member 12. In some embodiments the actuator may comprise an elongate rod insertable through alignedapertures screw 68 which threadedly engagesaperture 66 and can be rotatably adjusted to extend transversely throughexpansion member 28 to engage a contact point on theinner surface 60 ofwall segment 54opposite aperture 66, as discussed further below. Further rotation ofset screw 68, applies a force to spreadopposed wall segments 54 apart, adjustingexpansion member 28 from the first, reduced-diameter configuration to the second, expanded diameter configuration. This enablesouter surface 58 ofwall segment 54 to contact and apply a force to aninner surface 18 ofspan member 12opposite aperture 24 to securely coupleconnector 14 andspan member 12 together. Conversely, in order to decouple aspan member 10 and aconnector 14, setscrew 68 may be rotated in the opposite direction, adjustingexpansion member 28 from the second, expanded diameter configuration to the first, reduced-diameter configuration. In some embodiments spanmember 10 cannot be decoupled fromconnector 14 untilset screw 68 is completely removed from alignedapertures rail system 10 will remain safely assembled even if one ormore set screws 68 become loose. By way of example,FIGS. 12 and 13 show setscrew 68 withdrawn fromapertures FIGS. 14 and 15 show set screw fully inserted through apertures aligned 24, 66 and contacting aninner surface 60 of awall segment 54opposite aperture 66. -
First portion 52 ofexpansion member 28 further comprises an annular groove orslot 76 and atransverse borehole 78 passing through slot 76 (FIG. 4 ).Borehole 78 forms an enlarged terminus end ofslot 56. This configuration enables a more uniform dispersal of forces asexpansion member 28 is adjusted between the reduced diameter and expanded diameter positions described above, avoiding metal fatigue and potential metal deformation and fracture asexpansion member 28 flexes. As shown in the drawings, eachwall segment 54 is semi-circular or quarter-circular in shape in some embodiments. The location ofslot 76 at the base ofwall segments 54 facilitates relatively uniform opening and closing ofwall segments 54 in a “clam-shell” like manner as setscrew 68 is rotated. This helps ensure that substantially the entireouter surface 58 of eachwall segment 54 engagesinner surface 18 ofspan 12 rather only a portion ofsurface 58 in the vicinity ofset screw 68. - In some embodiments a shallow groove (not shown) may be formed in an outer circumferential portion of
first end portion 52 ofexpansion member 28. Such a groove is provided for optionally receiving liquid glue or some other adhesive for use in applications where it is desired to more securely or permanently mountconnector 14 to aspan member 12 or some other modular component or support structure. - Returning to
FIGS. 4 and 19 , in some embodiments eachexpansion member 28 includes asecond portion 70 joined tofirst portion 52 forcoupling expansion member 28 to aconnector span 26.Second portion 70 comprises anannular collar 72 and anend flange 74.Collar 72 may have one or chamfered side edges 72A. As shown for example inFIGS. 3 and 4 ,end flange 74 defines anend surface 82 ofexpansion member 28 at one end thereof.Plate 82 has acentral aperture 88 formed therein, which is alignable with threadedaperture 44 ofconnector span 26. - In some embodiments each
expansion member 28 may be releasably coupled to aconnector span 26. In some particularembodiments expansion member 28 andconnector span 26 may be formed from different materials. For example,expansion member 28 may be formed from aluminum to provide enhanced flexibility and flexure characteristics andconnector 26 may be formed from stainless steel. When end flange 74 of anexpansion member 28 is inserted into acorresponding compartment 40 ofconnector span 26apertures pin 84 projecting fromend surface 82 ofend flange 74 is selectively positionable within one of theapertures 46 located onend plate 42 of connector span 26 (in someembodiments connecting pin 84 is rigidly connected to endsurface 82 although it is illustrated exploded-apart fromsurface 82 in some figures, such asFIGS. 2-4 ). This enables eachexpansion member 28 to be coupled toconnector span 26 at a selected rotational position, thereby varying the locations ofexpansion member apertures 66 relative toconnector span aperture 50. For example, it may be desired that alignedapertures screw 68 passing therethrough, be aligned withconnector span aperture 50 which is used to mount aconnector 14 on a support structure, such as asupport surface 95 as discussed further below. Alternatively, it may be desired that alignedapertures screw 68, be offset 90° or 180°, or some other angular offset, fromaperture 50. This can be achieved by varying the number and position ofapertures 46 formed inend plate 42 into which connectingpin 84 is selectively inserted. If desired, the preferred configuration could be decided by an installer on-site. Thus the structure ofconnectors 14 enhances the versatility and ease of installation ofrail system 10 while minimizing the number of required components. - Once an
expansion member 28 andconnector span 26 have been coupled together in the desired orientation, afastener 86 may be passed through awasher 87 and coupled to threadedaperture 44 ofconnector span 26, as shown for example inFIGS. 2-3 and 16-18 . Optionally, anotherexpansion member 28 may be similarly coupled toconnector span 26 at the other end thereof to form an assembled connector 14 (e.g.FIGS. 1A-1B and 25-27 ). -
FIGS. 20-34 illustrate another embodiment of aconnector 14 which is fabricated as an integral unit rather than an assembly of separate expansion member(s) 28 and aconnector span 26. In this embodiment eachexpansion member 28 is integrally connected toconnector span 26 and henceend plate 42 ofconnector span 26 andend plate 82 of eachexpansion member 28 are omitted. In thisembodiment connector span 26 andexpansion members 28 define a continuous hollow interior opening, for example for receivingelectrical cables 128 as described below. In this embodiment threadedapertures slot 90 may be formed in primary span portion 30 (FIGS. 21B and 21C ). A pair of mountingapertures 92 may also be providedadjacent slot 90. As described further below,apertures 92 may be used forcoupling connector 14 to a separate mounting assembly or support. - In the embodiment of
FIGS. 20-34 , eachexpansion member 28 comprises four curved (e.g. quarter circular)wall segments 54 and fourlongitudinal slots 56. Twoapertures 66 are provided, spaced at different radial positions onfirst end portion 52. In the illustrated embodiment,apertures 66 are spaced 90° apart. As discussed further below, this enablesconnector 14 to be deployed at different rotational positions relative to span 12, for example in a position where aslot 90 is facing a support wall surface or whereslot 90 is located on an undersurface ofconnector 14 facing downwardly. - As shown for example in
FIGS. 1C-1D and 27 , when anexpansion member 28 of aconnector 14 is adjusted to the first, reduced-diameter configuration and fully inserted throughopen end 20 into aninner compartment 22 of aspan member 12, an end surface ofspan member 12 engagesend surface 36 of aflange 32. Thus whenspan member 12 and aconnector 14 are fully coupled together narrow recessedflanges 32 are visible.Such flanges 32 thus provide a visual break or “pin stripe” between the outer surfaces ofprimary span portion 30 ofconnector span 26 andouter surface 16 ofspan 12. In some embodimentsouter surface 16 ofspan member 12 andprimary span portion 30 ofconnector span 26 have the same outer diameter. However, sincespan member 12 andprimary span portion 30 are not directly flush but rather are separated byflanges 32, small deviations in their outer diameters, for example due to machining of different materials, different metal tolerances etc., will be less visually noticeable. -
FIGS. 1A-1D and 25-35 illustrate an embodiment of a mountingassembly 94 for coupling aconnector 14 to asupport surface 95, such as an interior wall of an elevator cab.Assembly 94 may include amount connector 96 and a threadedfastener 98 having ahead portion 98A for securingmount connector 96 toaperture 50 formed in the body ofprimary span portion 30. In the illustratedembodiment mount connector 96, also known as a “spacer lock toggler”, is generally hourglass-shaped and includes largerdiameter end portions 100 which are each joined by taperedsurfaces 102 to a smaller diameter central portion 104 (e.g.FIG. 25 ). - Mounting
assembly 94 may further comprise amount housing 106 which is mountable on a support surface with asuitable fastener 116 having ahead portion 116A.Fastener 116 may be passed through awasher 117 and anaperture 108 formed inhousing 106 to securehousing 106 to a support structure, such assurface 95.Housing 106 includes an interior compartment sized to receivemount connector 96 and comprisesend portions end portion 109 may have a concave shape to match the convex curvature of theouter surface 34 of connector span 26 (FIG. 25 ). In some embodiments endportion 110 may have a flat contour or may comprise a shallow circular compartment for receiving a disk-shaped fixture mounted on the support surface.Housing 106 further includes anaperture 112 through which a threadedfastener 114 can be inserted (FIGS. 31 and 32 ). Whenfastener 114 is fully tightened a leading end offastener 114 engagesmount connector 96 to securely couplemount connector 96 andhousing 106 together. In someembodiments aperture 112 may be positioned to engage atapered surface 102 ofmount connector 96 such that tightening offastener 114 causeshousing 106 to be drawn towardconnector span 26 to engageconnector 14 more securely. - As discussed further below,
FIGS. 48-54 illustrate analternative mounting assembly 94A for coupling aconnector 14 to a support structure. In particular, in thisexample mounting assembly 94A is configured for mounting theconnector span 26 ofFIGS. 21B and 21C to asupport surface 95. In this embodiment amount housing 106A is directly coupled to supportsurface 95 by means of a pair offasteners 130 which are threadedly received in mountingapertures 92 formed inprimary span member 30. In this embodiment the interior ofhousing 106A is not configured to receive amount connector 96 but is hollow to enable the passage ofelectrical cables 128 fromconnector 14 throughslot 90 formed inprimary span portion 30 and further throughhousing 106A to anelectrical power supply 126 mounted on or near support surface 95 (FIG. 50 ), as described further below. - In some other further
embodiments rail system 10 may optionally be coupled to supportsurface 95, such as the interior wall of an elevator cabin, by means of aspan member 12 instead of or in addition to a mountingassembly connector span 26. For example, as shown inFIGS. 36A-40 ,system 10 may comprise at least one curvilinear “ghost mount”span member 12A having one end coupled to aconnector 14 as described above and having a terminus end configured for releasable attachment to asupport surface 95. By way of a specific example, each ghostmount span member 12A may be coupled to asupport surface 95 with a mountingassembly 118 received within aninterior compartment 22 ofspan member 12A nearopen end 20. Mountingassembly 118 may comprise a threadedfastener 116 for securing amount connector 96A to support surface 95 (FIG. 37A ).Mount connector 96A is received withincompartment 22 ofspan member 12A and may be releasably coupled to spanmember 12A with a threadedfastener 114A, as shown best inFIG. 40 . Ghostmount span member 12A may also optionally incorporate a mountingassembly 118A configured to accommodate the passage ofelectrical cables 128 throughspan member 12A andsupport surface 95, as described further below. Mountingassembly 118A comprises substantially the same components as mountingassembly 94A described above except it is configured to couple aspan member 12A to supportsurface 95 rather than aconnector 14. -
FIGS. 36A-40 illustrate an embodiment of arail system 10 comprising oneconnector 14 coupled to supportsurface 95 by means of a mountingassembly 94 and one “ghost mount”span member 12A coupled to supportsurface 95 by means of a mountingassembly 118. In otherembodiments rail system 10 could comprise two “ghost mount”span members 12A located at each end ofrail system 10, eachspan member 12A being connected to supportsurface 95 with a mountingassembly - In some embodiments
modular rail system 10 may comprise a lighting assembly for illuminating components ofsystem 10. As shown inFIGS. 41-47 , in one embodiment aspan member 12 may have an elongatedslot 120 formed therein (FIG. 42 ).Slot 120 is sized for receiving alighting element 122. For example,lighting element 122 may be releasably secured to a pair ofclips 124 positionable in spaced-apart relation within the interior of aspan member 12.Lighting element 122 may be connectable to apower supply 126 located external ofsystem 10, for example apower supply 126 mounted on or behindsupport surface 95 or another support structure to which mountingassembly FIG. 43 ). In some embodiments one or moreelectrical cables 128 connectinglighting element 122 topower supply 126 may be fed through the interior ofspan members members 14 and are not outwardly visible. For example, as shown inFIGS. 41-47 , anelectrical cable 128 may be passed through a ghostmount span member 12A topower supply 126. As illustrated inFIGS. 48-54 , alternatively or additionally anelectrical cable 128 may be passed through a connectingmember 14 topower supply 126, for example using aconnector 14 as illustrated inFIGS. 21B and 21C having a continuous interior opening. In particular, anelectrical cable 128 may be fed through the interior of span member(s) 12 and through aslot 90 of aconnector 14, and further through the interior of amount housing 106A to connect to power supply 126 (FIG. 50 ). In thisembodiment rail system 10 comprises analternative mounting assembly 94A including a mountinghousing 106A as described above having an internal cavity for receiving anelectrical cable 128, as best shown inFIG. 52 . - In the embodiment of
FIGS. 41-47 mounting assembly 118A forcoupling rail system 10 to asupport surface 95 comprises a pair of internally threadedapertures 119 formed in an end portion of each “ghost mount”span member 12A. Eachaperture 119 receives one end of anelongated fastener 130 which may be coupled at its other end to a mountingplate 132 by means of anut 134. In oneembodiment plate 132 could be mounted on an interior wall ofsupport surface 95, such as an inner wall within an elevator shaft ordinarily hidden from view. Mountingplate 132 comprises a pair ofapertures 136 each for receiving afastener 130 and acentral aperture 138 for receiving anelectrical cable 128. In oneembodiment power supply 126 could also be mounted within the elevator shaft proximate mountingplate 132. - In the embodiment of
FIGS. 48-54 a mountingassembly 94A comprising components substantially the same as mountingassembly 118A ofFIGS. 41-47 is employed. In this embodiment elongatedfasteners 132 are received in threadedapertures 92 formed in connector 14 (FIGS. 21B and 21C ) rather thanapertures 119 ofspan member 12A. Also, as discussed above, a mountinghousing 106A is employed rather than aspan member 12A forcoupling rail system 10 to supportsurface 95. As in the embodiment ofFIGS. 41-47 a mountingplate 132 could be mounted on an inner wall of mounting surface 95 (FIG. 50 ) for receivingfasteners 130 andelectrical cable 128. - In another embodiment all or a portion of
span members 12 and/orconnectors 14 may be transparent or translucent to enable light to be emitted from an interior thereof to an exterior thereof. In one embodiment shown inFIGS. 55-61 ,lighting element 122 may comprise one ormore lighting elements 122A, which may be in the form of annular discs or “pucks”, which are positionable within the interior of aspan member 12 and/or aconnector 14 to emit light through a transparent or translucent window formed in thatspan member 12 or anadjacent span member 12. For example, as shown inFIG. 55-61 , a translucent,colored span member 12B may be provided which is disposed between twonon-translucent span members 12C each coupled to arespective connector 14.Colored span members 12B may consist of acrylic rods andadjacent span members 12C may be formed from metal, for example. The light emittinglighting element 122A may be mounted within the interior of at least one ofspan members 12C to project light intoadjacent span member 12B (e.g.FIG. 59 ), causingspan member 12B to emit light of the desired color. In this example, one end of eachspan member 12C is connected to aconnector 14 with aset screw 68 extendable through anaperture 24 and the other end is connected directly to coloredspan member 12B with ascrew fastener 69 extendable through anaperture 24A. Each light emittinglighting element 122A may be coupled to apower supply 126 by means of anelectrical cable 128 passing through the interior ofrail system 10, as shown inFIG. 57 and as discussed above. - In some embodiments
modular rail system 10 can be used for example to create a customizedrail 10 to illuminate a wall and/or a floor surface of an elevator. For example, in the embodiment ofFIG. 42 arail system 10 is illustrated comprising aspan member 12 having anelongated slot 120 for receiving alighting element 122. In thisembodiment lighting element 122 is configured to direct light downwardly, e.g. toward the floor of an elevator.Slot 120 is in alignment withapertures 24 for coupling the slottedspan member 12 between a pair ofconnectors 14 as discussed above. Thus in this embodiment setscrews 68, which each extend through alignedapertures span member 12 to arespective connector 14, are hidden from view on the undersurface ofrail system 10. Theset screw 68 for coupling each ghostmount span member 12A to arespective connector 14 is also hidden from view on the back side ofspan members 12A facingsupport surface 95, such as the interior wall surface of an elevator cabin. - In the embodiment of
FIGS. 41-47 aconnector 14 suitable forilluminated rail systems 10 could be used (FIGS. 20-24 ) having anaperture 66 positioned in-line withslot 90. Optionally, in some configurations,connector 14 may be mounted on asupport surface 95 of the elevator cab using a mountingassembly 94A projecting therefrom. Either before or afterconnector 14 is coupled to mountingassembly 94A,span member 12 may be coupled toconnector 14 such that anexpansion member 28 ofconnector 14 is inserted into an open end ofspan member 12 andapertures lighting element 122 may be mounted inslot 120 and theelectrical cable 128 may be fed through the interior ofspan member 12 andconnector 14. In oneembodiment cable 128 may be passed through a ghostmount span connector 12A for connection to apower supply 126 as shown inFIG. 43 and discussed above. In anotherembodiment cable 128 may be passed throughaperture 90 of connector 14 (FIGS. 21B and 21C ) and a mountingassembly 94A comprising amount housing 106A for connection to apower supply 126 as shown inFIG. 50 and discussed above.Span member 12 and arespective connector 14 may be securely engaged by tightening setscrew 68 to causeexpansion member 28 to be adjusted from the reduced diameter first position to the expanded diameter second position as described above. Sinceset screw 68 will be located on the undersurface of rail system facing downwardly as discussed above it will not be readily visible. - In another example, both aligned
apertures set screw 68 andlighting element 122 may be oriented facingsupport surface 95, such as an interior wall of the elevator cab. Thus in in thisembodiment slot 120 is once again in alignment withapertures 24 but light emitted fromrail system 10 is directed inwardly towardsurface 95 rather than downwardly. - In other embodiments it may be desirable to direct the light emitted from
lighting element 122 in some other direction such as upwardly or outwardly toward the interior of the elevator cab. At the same time, it is desired to position the alignedapertures span member 12 andadjacent connector 14 on the back side ofrail system 10 facing thesupport surface 95, or the undersurface ofrail system 10 facing downwardly, so such apertures, and theset screw 68 which releasably couples eachspan member 12 and arespective connector 14 together, are hidden from view. - In such alternative embodiments elongated
slot 120 of aspan member 12 may be located at a position offset fromapertures 24, for example if it is desired to direct light fromlighting element 122 upwardly or outwardly into the interior of the elevator cab. Alternatively, slot 120 may be aligned with anaperture 24 ofspan member 10, but during assembly ofrail system 10aperture 24 could be aligned with anaperture 66 ofconnector 14 which is not in-line with slot 90 (FIGS. 21B and 21C ). Either way, in this example, setscrew 68 will again be located on the back or undersurface ofrail system 10 where it will not be readily visible andlighting element 122 will be configured to direct light upwardly, outwardly or in some other desired direction. Thus, as in the examples described above relating to embodiments ofconnector 14 where expansion member(s) 28 are releasably connectable toconnector span 26 at different selected rotational positions (e.g.FIG. 19 ),connector 14 can be configured so that alignedapertures screw 68 are in a desired orientation relative to slot 120 (and hence lighting element 122). - Referring to the embodiment of
FIGS. 55-61 ,span member 12B may be configured to emit light emanating fromlighting element 122A from all or part of the circumferential surface ofspan member 12B while setscrews 68 andscrew fasteners 69 may be located at a position ordinarily hidden from view, for example on the undersurface of rail system 10 (e.g.FIGS. 55-56 ). - As will be apparent to a person skilled in the art, in other embodiments of the invention,
rail system 10 may be assembled to mountspan members 12 andconnectors 14 in many different orientations to direct light in many different desired orientations. - As explained above,
span members 12 may be produced in many different materials and finishes and combinations thereof. Examples of suitable materials include stainless steel, yellow brass, copper, carbon fibre, aluminum, anodized black, bronze and anodized oxidized bronze. Examples of suitable finishes include brushed, polished, knurled and diamond-shaped textures. As explained above, sinceconnectors 14 provide a visual break betweenadjacent spans 12, materials of different materials, finishes or colors can either be grouped together or separated depending on the visual effect desired. - While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are consistent with the broadest interpretation of the specification as a whole.
Claims (65)
1. A modular rail system comprising:
(a) at least one connector having a longitudinal axis and comprising a connector span and at least one expansion member, wherein said 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
(b) at least one span member having an outer surface and an inner surface and at least one open end,
wherein said expansion member is insertable into an interior of said span member in said first configuration and is adjustable to said second configuration within said span member to securely engage said inner surface of said span member to releasably couple said connector and said span member together.
2. The system as defined in claim 1 , comprising an actuator for adjusting said expansion member between said first and second configurations.
3. The system as defined in claim 2 , wherein said actuator is insertable through a first aperture formed in said span member proximate said open end.
4. The system as defined in claim 3 , wherein said expansion member comprises at least one first wall segment and at least one second wall segment opposite said first wall segment and wherein said first wall segment comprises a second aperture alignable with said first aperture when said expansion member is inserted within said interior of said span member.
5. The system as defined in claim 4 , wherein said actuator is an elongate rod insertable through said first and second apertures when said apertures are in alignment, wherein said elongate rod is mechanically adjustable to contact an inner portion of said second wall segment to increase the distance between said first and second wall segments, thereby adjusting said expansion member from said first configuration to said second configuration.
6. The system as defined in claim 5 , wherein said elongate rod extends transversely relative to said longitudinal axis of said connector.
7. The system as defined in claim 6 , wherein elongate rod is threadedly connectable to said second aperture.
8. The system as defined in claim 7 , wherein said elongate rod is a threaded screw.
9. The system as defined in claim 8 , wherein the length of said screw exceeds the distance between said first and second wall segments such that said screw protrudes outwardly from said first aperture when said expansion member is not in said second configuration, thereby preventing decoupling of said connector and said span member until said screw is removed from said expansion member.
10. The system as defined in claim 4 , wherein each of said first and second wall segments is semi-circular.
11. The system as defined in claim 4 , wherein each of said first and second wall segments is quarter-circular.
12. The system as defined in claim 10 , comprising at least one slot located between said first and second wall segments extending parallel to said longitudinal axis of said connector, wherein a width of said slot varies when said expansion member is adjusted between said first and second configurations.
13. The system as defined in claim 4 , wherein said first and second wall segments comprise an end portion of said expansion member distal from said connector span, and wherein said expansion member further comprises a collar for coupling said end portion of said expansion member to said connector span.
14. The system as defined in claim 13 , wherein each of wall segments comprises a wall outer surface for securely engaging said inner surface of said span member in said second configuration and wherein said collar comprises an annular groove having a diameter less than the distance between said wall outer surface of said first wall segment and said wall outer surface of second wall segment.
15. The system as defined in claim 14 , wherein said slot terminates at said groove.
16. The system as defined in claim 14 wherein said expansion member comprises a borehole extending transversely through said expansion member in the vicinity of said groove.
17. The system as defined in claim 1 , wherein said expansion member is integrally connected to said connector span.
18. The system as defined in claim 1 , wherein said expansion member is releasably connectable to said connector span.
19. The system as defined in claim 1 , wherein said connector span comprises a primary span portion and first and second flanges formed at end portions thereof, wherein each of said first and second flanges has an outer diameter less than an outer diameter of said primary span portion.
20. The system as defined in claim 19 , wherein an outer diameter of said connector span is approximately equal to an outer diameter of said span member.
21. The system as defined in claim 20 , wherein one of said first and second flanges forms a visible spacer between said primary span portion of said connector and said span member when said connector and said span member are securely coupled together in said second configuration.
22. The system as defined in claim 21 , wherein each of said first and second flanges defines an open end of said connector span for receiving an end portion of a collar of said expansion member.
23. The system as defined in claim 21 , where each of said first and second flanges comprising an outer rim which contacts said span member in said second configuration.
24. The system as defined in claim 23 , wherein an outer diameter of each of said flanges is slightly larger than the outer diameter of said collar.
25. The system as defined in claim 1 , wherein said system comprises a mounting assembly for releasably coupling said connector to a support surface.
26. The system as defined in claim 25 , wherein said mounting assembly comprises a mounting aperture formed in said connector span, a mount housing connectable to said support surface, and a first fastener insertable into said mounting aperture for releasable securing said connector span to said mount housing.
27. The system as defined in claim 26 , wherein said mounting assembly comprises a mount connector releasably connectable to said connector span with said first fastener.
28. The system as defined in claim 25 , wherein said mounting assembly comprises a mount housing mountable on said support surface; a mount connector positionable within said mount housing and releasably connectable to said connector span; and a second fastener for releasably coupling said mount housing and said mount connector together.
29. The system as defined in claim 28 , comprising a first fastener for releasably coupling said mount connector to said connector span.
30. The system as defined in claim 29 , wherein said first fastener and said second fastener are threaded screws.
31. The system as defined in claim 25 , wherein said mounting assembly comprises at least one mounting rod for mounting said connector on said support surface.
32. The system as defined in claim 1 , wherein said at least one span member comprises a first span member and a second span member, and wherein said at least one expansion member comprises a first expansion member located at a first end of said connector and a second expansion member located at a second end of said connector, wherein said first span member is connectable to said first expansion member and said second span member is connectable to said second expansion member to couple said first and second span members together.
33. The system as defined in claim 32 , wherein said connector has a color and/or texture contrasting with at least one of said first and second span members.
34. The system as defined in claim 33 , wherein said connector has a color and/or texture contrasting with both of said first and second span members.
35. The system as defined in claim 1 , wherein said at least one span member comprises a plurality of span members and wherein said at least one connector comprises a plurality of connectors, wherein each of said connectors couples an adjacent pair of span members together.
36. The system as defined in claim 35 , wherein said plurality of span members and said plurality of connectors form a handrail mountable on a support surface.
37. The system as defined in claim 36 , wherein said support surface is the interior of an elevator cab.
38. The system as defined in claim 35 , wherein said plurality of span members comprise a first group of span members having first and second open ends and a second group of span members having an open first end and a closed second end for forming an end portion of said rail system.
39. The system as defined in claim 38 , wherein said closed second end has a shape selected from the group consisting of semi-spherical, bullet-shaped and cylindrical.
40. The system as defined in claim 35 , wherein at least some of said plurality of span members are linear tubes and a least some of said plurality of span members are curved tubes.
41. The system as defined in claim 35 , wherein said plurality of span members and said plurality of connectors are configurable to form a rail comprising rail segments having contrasting textures, finishes and/or colors.
42. The system as defined in claim 35 , wherein said plurality of span members comprise at least one end span member.
43. The system as defined in claim 42 , wherein said at least one end span member has a closed end.
44. The system as defined in claim 42 , wherein said at least one end span member is configured for releasably engaging a support surface.
45. The system as defined in claim 42 , wherein said at least one end span member comprises an end portion defining a cavity for receiving an insert mountable on said support surface, and a fastener for releasably coupling said end portion to said insert.
46. The system as defined in claim 45 , wherein said end portion is shaped for engaging said support surface.
47. The system as defined in claim 35 , wherein said plurality of span members and said plurality of connectors are each formed from metal selected from the group consisting of aluminum and stainless steel.
48. The system as defined in claim 35 , wherein at least one of said plurality of span members is a light emitting span member configured for receiving a lighting element.
49. The system as defined in claim 48 , wherein said light emitting span member is an elongated tube having a slot formed therein for receiving said lighting element.
50. The system as defined in claim 49 , wherein the system is configurable to direct light emitted from said lighting element in a desired direction relative to a support surface.
51. The system as defined in claim 48 , wherein at least part of said light emitting span member comprises a transparent or translucent window.
52. The system as defined in claim 51 , comprising a lighting element positionable within an interior of said light emitting span member for illuminating said window.
53. The system as defined in claim 49 , comprising a mounting assembly for mounting at least one of said plurality of connectors to a support surface, wherein said lighting element is connectable to an electrical supply externally of said rail system.
54. The system as defined in claim 53 , wherein said electrical supply is mountable on said support surface.
55. The system as defined in claim 53 , wherein said lighting element comprises an electrical supply cable extendable through said connector and said mounting assembly.
56. The system as defined in claim 1 , wherein said expansion member is connectable to said connector span at a selected one of a plurality of rotational positions.
57. The system as defined in claim 56 , wherein said connector span comprises a plurality of spaced apertures and said expansion member comprises at least one connecting pin positionable in a selected one of said apertures.
58. The system as defined in claim 35 , wherein said plurality of span members and said plurality of connectors are each between 1 and 2 inches in diameter.
59. A modular kit comprising a plurality of connectors and a plurality of span members as defined in claim 1 .
60. The kit as defined in claim 59 , comprising a mounting assembly for mounting at least one of said connectors to a support surface.
61. A modular rail system comprising:
(a) at least one connector having a longitudinal axis and comprising a connector span and at least one expansion member, wherein said 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
(b) at least one span member having an outer surface and an inner surface and at least one open end,
wherein said expansion member is insertable into an interior of said span member in said first configuration and is adjustable to said second configuration within said span member to securely engage said inner surface of said span member to releasably couple said connector and said span member together; and
(c) at least one span mounting assembly for mounting a span member to a support.
62. A rail system as defined in claim 61 , wherein said span mounting assembly couples an end span member to said support.
63. The rail system as defined in claim 61 , comprising at least one connector mounting assembly for mounting a connector to said support.
64. The rail system as defined in claim 61 , wherein said span mounting assembly comprises a mount securable to said support, a fitting within said span member sized to receive said mount, and a fastener for releasably coupling said span member to said mount.
65. The rail system as defined in claim 61 , wherein said expansion member is releasably connectable to said connecting span at a selected one of a plurality of rotational positions.
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US18/228,483 US20230374790A1 (en) | 2017-12-19 | 2023-07-31 | Modular rail system |
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CA2992936A1 (en) | 2017-12-19 | 2019-06-19 | Lustre Products Ltd. | Modular rail system |
CA182062S (en) * | 2017-12-21 | 2020-09-21 | Lustre Products Ltd | Modular rail system connector |
JP7365596B2 (en) | 2020-01-12 | 2023-10-20 | 株式会社 シコク | Auxiliary handrail |
USD1018260S1 (en) * | 2022-10-20 | 2024-03-19 | Railblaza Limited | Interface bracket |
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Also Published As
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US11739536B2 (en) | 2023-08-29 |
US20190186152A1 (en) | 2019-06-20 |
CA2992936A1 (en) | 2019-06-19 |
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