Patent Publication Number: US-2019186152-A1

Title: Modular rail system

Description:
RELATED APPLICATIONS 
     This application claims the benefit of U.S. provisional patent application No. 62/607,849 filed 19 Dec. 2017, which is hereby incorporated by reference in its entirety. 
    
    
     TECHNICAL FIELD 
     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. 
     BACKGROUND 
     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. 
     SUMMARY 
     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. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       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 of  FIGS. 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 of  FIG. 2 . 
         FIG. 4  is an exploded, side elevational view of the span member and connector of  FIGS. 2-3 . 
         FIG. 5  is an enlarged, end elevational view of an assembled span member and connector of  FIGS. 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 of  FIG. 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 of  FIGS. 16-17 . 
         FIG. 19  is an enlarged, exploded isometric view of the connector of  FIGS. 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 of  FIG. 20  showing a set screw actuator withdrawn from an expansion member. 
         FIG. 21B  is a second isometric view of the connector of  FIG. 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 of  FIG. 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 of  FIGS. 25-26  in an assembled configuration. 
         FIG. 28  is an enlarged, assembled, first isometric view of the connector and mounting assembly of  FIGS. 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 of  FIG. 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 of  FIG. 36A  in a fully assembled configuration. 
         FIG. 37A  is a top plan view of the rail system of  FIG. 36A . 
         FIG. 37B  is a top plan view of the rail system of  FIG. 36B . 
         FIG. 38  is a fully exploded, isometric view of the rail system of  FIG. 36A  shown in isolation from the support. 
         FIG. 39  is a top plan view of the rail system of  FIG. 38 . 
         FIG. 40  is a fragmented, enlarged top plan view of the rail system of  FIG. 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 of  FIG. 41 . 
         FIG. 43  is a top isometric view of the rail system of  FIGS. 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 in  FIGS. 21A-21C  to a support surface. 
         FIG. 49  is an exploded, bottom isometric view of the rail system of  FIG. 48 . 
         FIG. 50  is an isometric view of the rail system of  FIGS. 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 of  FIG. 55 . 
         FIG. 57  is an isometric view of the rail system of  FIGS. 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. 
     
    
    
     DESCRIPTION 
     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 some embodiments 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 of span members  12  and a plurality of connectors  14  for releasably coupling 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 combining span members  12  and connectors  14  in different modular combinations and configurations the aesthetic appearance and/or functionality of the resultant rail system  10  can be varied. 
       FIGS. 2-11  illustrates an embodiment of an exemplary span member  12 . Span member  12  comprises an outer surface  16 , an inner surface  18  and at least one open end  20  ( FIGS. 2-4 ). In some embodiments span member inner surface  18  defines a hollow inner compartment  22  in communication with open end  20  ( FIG. 4 ). In some embodiments span members  12  may be rectilinear tubes. In other embodiments span members  12  may be curvilinear tubes (e.g.  FIGS. 1A-1D  show span members  12  forming part of a rail system  10 ;  FIGS. 1E-1O  show various exemplary span members  12  or  12 A in isolation). In some embodiments span members  12  may comprise two open ends  20 . In other embodiments span member  12  may comprise one open end  20  and one closed end  21  which may form the terminus of a rail system  10 . For example, as shown in  FIGS. 1N and 1O , closed end  21  of a span 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 an aperture  24  extending transversely between outer surface  16  and inner surface  18  proximate an open end  20  thereof ( FIG. 4 ). For example, in some embodiments aperture  24  may be spaced approximately 0.5 to 1 inch from open end  20 . 
       FIGS. 2-19  illustrate an embodiment of connector  14 . Connector  14  comprises a connector span  26  and at least one expansion member  28 . In some embodiments connector  14  may comprise two expansion members  28  coupled on either end of a connector span  26  ( FIGS. 25-27 ). As discussed further below, in some embodiments connector span  26  and expansion members  28  are releasably connectable (e.g.  FIG. 19 ). In other embodiments connector span  26  and expansion members  28  are integrally connected (e.g.  FIG. 20 ). 
     In some embodiments 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 ). 
     As shown for example in  FIG. 19 , each flange  32  has an annular end surface  36  and an inner surface  38  which defines the side wall of a shallow end compartment  40  of connector span  26 . The depth of compartment  40  is defined by an end plate  42  surrounded by flange inner surface  38 . In some embodiments end plate  42  comprises a first threaded central aperture  44  and one or more secondary apertures  46 . In some embodiments central aperture  44  extends longitudinally through the body of connector span  26 . As described further below, in some embodiments apertures  44 ,  46  are used to releasably couple an expansion member  28  to connector span  26  at a selected rotational position. 
     Connector span  26  may also comprise a threaded aperture  50  which extends transversely through the body of primary span portion  30 . In some embodiments transverse aperture  50  is in communication with longitudinal aperture  44 , as shown for example in  FIG. 31 . As described further below, aperture  50  may be used to releasably couple connector span  26  to other modular components of system  10 , such as a mounting assembly  94  ( FIGS. 25 and 26 ). 
     As shown in  FIG. 19 , each expansion member  28  is generally cylindrical in shape and has a longitudinal axis which can be aligned with the longitudinal axis of connector span  26 . In some embodiments each expansion member  28  comprises a first portion  52  comprising a plurality of wall segments  54  separated by a longitudinal slot  56  extending parallel to the longitudinal axis of member  28  (e.g.  FIGS. 4 and 19 ). Each wall segment  54  has an outer surface  58  and an inner surface  60 . In some embodiments wall segment  54  may have chamfered edges  54 A merging with an end wall  64 . In the embodiment of  FIG. 19  first portion  52  comprises two wall segments  54 . In the embodiment of  FIG. 20  first portion  52  may comprise four or more wall segments  54 , each separated from an adjacent wall segment  54  by a slot  56 . 
     Each first portion  52  of an expansion member  28  comprises an aperture  66  extending transversely through at least one of the wall segments  54 . In some embodiments aperture  66  is threaded. As described further below, aperture  66  can be aligned with an aperture  24  of a span member  12  when an expansion member  28  is inserted through an open end  20  of a span member  12 . 
     Modular rail system  10  further comprises an actuator for adjusting expansion member  28  between a first, reduced-diameter configuration, wherein expansion member  28  is insertable into an open end  20  of a span member  12 , and a second, expanded diameter configuration wherein the distance between opposed wall segments  54 , and hence the width of slots  56 , is increased. As described further below, this enables the outer surfaces  58  of each wall segment  54  to securely engage an inner surface  18  of a span member  12 . In some embodiments the actuator may comprise an elongate rod insertable through aligned apertures  24 ,  66 . In a particular embodiment the actuator may be a set screw  68  which threadedly engages aperture  66  and can be rotatably adjusted to extend transversely through expansion member  28  to engage a contact point on the inner surface  60  of wall segment  54  opposite aperture  66 , as discussed further below. Further rotation of set screw  68 , applies a force to spread opposed wall segments  54  apart, adjusting expansion member  28  from the first, reduced-diameter configuration to the second, expanded diameter configuration. This enables outer surface  58  of wall segment  54  to contact and apply a force to an inner surface  18  of span member  12  opposite aperture  24  to securely couple connector  14  and span member  12  together. Conversely, in order to decouple a span member  10  and a connector  14 , set screw  68  may be rotated in the opposite direction, adjusting expansion member  28  from the second, expanded diameter configuration to the first, reduced-diameter configuration. In some embodiments span member  10  cannot be decoupled from connector  14  until set screw  68  is completely removed from aligned apertures  24 ,  66 . This ensures that rail system  10  will remain safely assembled even if one or more set screws  68  become loose. By way of example,  FIGS. 12 and 13  show set screw  68  withdrawn from apertures  24 ,  66  and  FIGS. 14 and 15  show set screw fully inserted through apertures aligned  24 ,  66  and contacting an inner surface  60  of a wall segment  54  opposite aperture  66 . 
     First portion  52  of expansion member  28  further comprises an annular groove or slot  76  and a transverse borehole  78  passing through slot  76  ( FIG. 4 ). Borehole  78  forms an enlarged terminus end of slot  56 . This configuration enables a more uniform dispersal of forces as expansion member  28  is adjusted between the reduced diameter and expanded diameter positions described above, avoiding metal fatigue and potential metal deformation and fracture as expansion member  28  flexes. As shown in the drawings, each wall segment  54  is semi-circular or quarter-circular in shape in some embodiments. The location of slot  76  at the base of wall segments  54  facilitates relatively uniform opening and closing of wall segments  54  in a “clam-shell” like manner as set screw  68  is rotated. This helps ensure that substantially the entire outer surface  58  of each wall segment  54  engages inner surface  18  of span  12  rather only a portion of surface  58  in the vicinity of set screw  68 . 
     In some embodiments a shallow groove (not shown) may be formed in an outer circumferential portion of first end portion  52  of expansion 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 mount connector  14  to a span member  12  or some other modular component or support structure. 
     Returning to  FIGS. 4 and 19 , in some embodiments each expansion member  28  includes a second portion  70  joined to first portion  52  for coupling expansion member  28  to a connector span  26 . Second portion  70  comprises an annular collar  72  and an end flange  74 . Collar  72  may have one or chamfered side edges  72 A. As shown for example in  FIGS. 3 and 4 , end flange  74  defines an end surface  82  of expansion member  28  at one end thereof. Plate  82  has a central aperture  88  formed therein, which is alignable with threaded aperture  44  of connector span  26 . 
     In some embodiments each expansion member  28  may be releasably coupled to a connector span  26 . In some particular embodiments expansion member  28  and connector 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 and connector  26  may be formed from stainless steel. When end flange  74  of an expansion member  28  is inserted into a corresponding compartment  40  of connector span  26  apertures  88  and  44  are aligned. A roll or connecting pin  84  projecting from end surface  82  of end flange  74  is selectively positionable within one of the apertures  46  located on end plate  42  of connector span  26  (in some embodiments connecting pin  84  is rigidly connected to end surface  82  although it is illustrated exploded-apart from surface  82  in some figures, such as  FIGS. 2-4 ). This enables each expansion member  28  to be coupled to connector span  26  at a selected rotational position, thereby varying the locations of expansion member apertures  66  relative to connector span aperture  50 . For example, it may be desired that aligned apertures  24 , 66 , and set screw  68  passing therethrough, be aligned with connector span aperture  50  which is used to mount a connector  14  on a support structure, such as a support surface  95  as discussed further below. Alternatively, it may be desired that aligned apertures  24 , 66 , and set screw  68 , be offset 90° or 180°, or some other angular offset, from aperture  50 . This can be achieved by varying the number and position of apertures  46  formed in end plate  42  into which connecting pin  84  is selectively inserted. If desired, the preferred configuration could be decided by an installer on-site. Thus the structure of connectors  14  enhances the versatility and ease of installation of rail system  10  while minimizing the number of required components. 
     Once an expansion member  28  and connector span  26  have been coupled together in the desired orientation, a fastener  86  may be passed through a washer  87  and coupled to threaded aperture  44  of connector span  26 , as shown for example in  FIGS. 2-3 and 16-18 . Optionally, another expansion member  28  may be similarly coupled to connector 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 a connector  14  which is fabricated as an integral unit rather than an assembly of separate expansion member(s)  28  and a connector span  26 . In this embodiment each expansion member  28  is integrally connected to connector span  26  and hence end plate  42  of connector span  26  and end plate  82  of each expansion member  28  are omitted. In this embodiment connector span  26  and expansion members  28  define a continuous hollow interior opening, for example for receiving electrical cables  128  as described below. In this embodiment threaded apertures  44  and  50  are omitted. Instead a slot  90  may be formed in primary span portion  30  ( FIGS. 21B and 21C ). A pair of mounting apertures  92  may also be provided adjacent slot  90 . As described further below, apertures  92  may be used for coupling connector  14  to a separate mounting assembly or support. 
     In the embodiment of  FIGS. 20-34 , each expansion member  28  comprises four curved (e.g. quarter circular) wall segments  54  and four longitudinal slots  56 . Two apertures  66  are provided, spaced at different radial positions on first end portion  52 . In the illustrated embodiment, apertures  66  are spaced 90° apart. As discussed further below, this enables connector  14  to be deployed at different rotational positions relative to span  12 , for example in a position where a slot  90  is facing a support wall surface or where slot  90  is located on an undersurface of connector  14  facing downwardly. 
     As shown for example in  FIGS. 1C-1D and 27 , when an expansion member  28  of a connector  14  is adjusted to the first, reduced-diameter configuration and fully inserted through open end  20  into an inner compartment  22  of a span member  12 , an end surface of span member  12  engages end surface  36  of a flange  32 . Thus when span member  12  and a connector  14  are fully coupled together narrow recessed flanges  32  are visible. Such flanges  32  thus provide a visual break or “pin stripe” between the outer surfaces of primary span portion  30  of connector span  26  and outer surface  16  of span  12 . In some embodiments outer surface  16  of span member  12  and primary span portion  30  of connector span  26  have the same outer diameter. However, since span member  12  and primary span portion  30  are not directly flush but rather are separated by flanges  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 mounting assembly  94  for coupling a connector  14  to a support surface  95 , such as an interior wall of an elevator cab. Assembly  94  may include a mount connector  96  and a threaded fastener  98  having a head portion  98 A for securing mount connector  96  to aperture  50  formed in the body of primary span portion  30 . In the illustrated embodiment mount connector  96 , also known as a “spacer lock toggler”, is generally hourglass-shaped and includes larger diameter end portions  100  which are each joined by tapered surfaces  102  to a smaller diameter central portion  104  (e.g.  FIG. 25 ). 
     Mounting assembly  94  may further comprise a mount housing  106  which is mountable on a support surface with a suitable fastener  116  having a head portion  116 A. Fastener  116  may be passed through a washer  117  and an aperture  108  formed in housing  106  to secure housing  106  to a support structure, such as surface  95 . Housing  106  includes an interior compartment sized to receive mount connector  96  and comprises end portions  109  and  110  each having a shape and contour to match the surface to which it is secured. For example, end portion  109  may have a concave shape to match the convex curvature of the outer surface  34  of connector span  26  ( FIG. 25 ). In some embodiments end portion  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 an aperture  112  through which a threaded fastener  114  can be inserted ( FIGS. 31 and 32 ). When fastener  114  is fully tightened a leading end of fastener  114  engages mount connector  96  to securely couple mount connector  96  and housing  106  together. In some embodiments aperture  112  may be positioned to engage a tapered surface  102  of mount connector  96  such that tightening of fastener  114  causes housing  106  to be drawn toward connector span  26  to engage connector  14  more securely. 
     As discussed further below,  FIGS. 48-54  illustrate an alternative mounting assembly  94 A for coupling a connector  14  to a support structure. In particular, in this example mounting assembly  94 A is configured for mounting the connector span  26  of  FIGS. 21B and 21C  to a support surface  95 . In this embodiment a mount housing  106 A is directly coupled to support surface  95  by means of a pair of fasteners  130  which are threadedly received in mounting apertures  92  formed in primary span member  30 . In this embodiment the interior of housing  106 A is not configured to receive a mount connector  96  but is hollow to enable the passage of electrical cables  128  from connector  14  through slot  90  formed in primary span portion  30  and further through housing  106 A to an electrical 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 support surface  95 , such as the interior wall of an elevator cabin, by means of a span member  12  instead of or in addition to a mounting assembly  94  or  94 A coupled to a connector span  26 . For example, as shown in  FIGS. 36A-40 , system  10  may comprise at least one curvilinear “ghost mount” span member  12 A having one end coupled to a connector  14  as described above and having a terminus end configured for releasable attachment to a support surface  95 . By way of a specific example, each ghost mount span member  12 A may be coupled to a support surface  95  with a mounting assembly  118  received within an interior compartment  22  of span member  12 A near open end  20 . Mounting assembly  118  may comprise a threaded fastener  116  for securing a mount connector  96 A to support surface  95  ( FIG. 37A ). Mount connector  96 A is received within compartment  22  of span member  12 A and may be releasably coupled to span member  12 A with a threaded fastener  114 A, as shown best in  FIG. 40 . Ghost mount span member  12 A may also optionally incorporate a mounting assembly  118 A configured to accommodate the passage of electrical cables  128  through span member  12 A and support surface  95 , as described further below. Mounting assembly  118 A comprises substantially the same components as mounting assembly  94 A described above except it is configured to couple a span member  12 A to support surface  95  rather than a connector  14 . 
       FIGS. 36A-40  illustrate an embodiment of a rail system  10  comprising one connector  14  coupled to support surface  95  by means of a mounting assembly  94  and one “ghost mount” span member  12 A coupled to support surface  95  by means of a mounting assembly  118 . In other embodiments rail system  10  could comprise two “ghost mount” span members  12 A located at each end of rail system  10 , each span member  12 A being connected to support surface  95  with a mounting assembly  118  or  118 A. 
     In some embodiments modular rail system  10  may comprise a lighting assembly for illuminating components of system  10 . As shown in  FIGS. 41-47 , in one embodiment a span member  12  may have an elongated slot  120  formed therein ( FIG. 42 ). Slot  120  is sized for receiving a lighting element  122 . For example, lighting element  122  may be releasably secured to a pair of clips  124  positionable in spaced-apart relation within the interior of a span member  12 . Lighting element  122  may be connectable to a power supply  126  located external of system  10 , for example a power supply  126  mounted on or behind support surface  95  or another support structure to which mounting assembly  94 A or  118 A is secured ( FIG. 43 ). In some embodiments one or more electrical cables  128  connecting lighting element  122  to power supply  126  may be fed through the interior of span members  12 ,  12 A and/or connecting members  14  and are not outwardly visible. For example, as shown in  FIGS. 41-47 , an electrical cable  128  may be passed through a ghost mount span member  12 A to power supply  126 . As illustrated in  FIGS. 48-54 , alternatively or additionally an electrical cable  128  may be passed through a connecting member  14  to power supply  126 , for example using a connector  14  as illustrated in  FIGS. 21B and 21C  having a continuous interior opening. In particular, an electrical cable  128  may be fed through the interior of span member(s)  12  and through a slot  90  of a connector  14 , and further through the interior of a mount housing  106 A to connect to power supply  126  ( FIG. 50 ). In this embodiment rail system  10  comprises an alternative mounting assembly  94 A including a mounting housing  106 A as described above having an internal cavity for receiving an electrical cable  128 , as best shown in  FIG. 52 . 
     In the embodiment of  FIGS. 41-47  mounting assembly  118 A for coupling rail system  10  to a support surface  95  comprises a pair of internally threaded apertures  119  formed in an end portion of each “ghost mount” span member  12 A. Each aperture  119  receives one end of an elongated fastener  130  which may be coupled at its other end to a mounting plate  132  by means of a nut  134 . In one embodiment plate  132  could be mounted on an interior wall of support surface  95 , such as an inner wall within an elevator shaft ordinarily hidden from view. Mounting plate  132  comprises a pair of apertures  136  each for receiving a fastener  130  and a central aperture  138  for receiving an electrical cable  128 . In one embodiment power supply  126  could also be mounted within the elevator shaft proximate mounting plate  132 . 
     In the embodiment of  FIGS. 48-54  a mounting assembly  94 A comprising components substantially the same as mounting assembly  118 A of  FIGS. 41-47  is employed. In this embodiment elongated fasteners  132  are received in threaded apertures  92  formed in connector  14  ( FIGS. 21B and 21C ) rather than apertures  119  of span member  12 A. Also, as discussed above, a mounting housing  106 A is employed rather than a span member  12 A for coupling rail system  10  to support surface  95 . As in the embodiment of  FIGS. 41-47  a mounting plate  132  could be mounted on an inner wall of mounting surface  95  ( FIG. 50 ) for receiving fasteners  130  and electrical cable  128 . 
     In another embodiment all or a portion of span members  12  and/or connectors  14  may be transparent or translucent to enable light to be emitted from an interior thereof to an exterior thereof. In one embodiment shown in  FIGS. 55-61 , lighting element  122  may comprise one or more lighting elements  122 A, which may be in the form of annular discs or “pucks”, which are positionable within the interior of a span member  12  and/or a connector  14  to emit light through a transparent or translucent window formed in that span member  12  or an adjacent span member  12 . For example, as shown in  FIGS. 55-61 , a translucent, colored span member  12 B may be provided which is disposed between two non-translucent span members  12 C each coupled to a respective connector  14 . Colored span members  12 B may consist of acrylic rods and adjacent span members  12 C may be formed from metal, for example. The light emitting lighting element  122 A may be mounted within the interior of at least one of span members  12 C to project light into adjacent span member  12 B (e.g.  FIG. 59 ), causing span member  12 B to emit light of the desired color. In this example, one end of each span member  12 C is connected to a connector  14  with a set screw  68  extendable through an aperture  24  and the other end is connected directly to colored span member  12 B with a screw fastener  69  extendable through an aperture  24 A. Each light emitting lighting element  122 A may be coupled to a power supply  126  by means of an electrical cable  128  passing through the interior of rail system  10 , as shown in  FIG. 57  and as discussed above. 
     In some embodiments modular rail system  10  can be used for example to create a customized rail  10  to illuminate a wall and/or a floor surface of an elevator. For example, in the embodiment of  FIG. 42  a rail system  10  is illustrated comprising a span member  12  having an elongated slot  120  for receiving a lighting element  122 . In this embodiment lighting element  122  is configured to direct light downwardly, e.g. toward the floor of an elevator. Slot  120  is in alignment with apertures  24  for coupling the slotted span member  12  between a pair of connectors  14  as discussed above. Thus in this embodiment set screws  68 , which each extend through aligned apertures  24 ,  66  for coupling an end of the slotted span member  12  to a respective connector  14 , are hidden from view on the undersurface of rail system  10 . The set screw  68  for coupling each ghost mount span member  12 A to a respective connector  14  is also hidden from view on the back side of span members  12 A facing support surface  95 , such as the interior wall surface of an elevator cabin. 
     In the embodiment of  FIGS. 41-47  a connector  14  suitable for illuminated rail systems  10  could be used ( FIGS. 20-24 ) having an aperture  66  positioned in-line with slot  90 . Optionally, in some configurations, connector  14  may be mounted on a support surface  95  of the elevator cab using a mounting assembly  94 A projecting therefrom. Either before or after connector  14  is coupled to mounting assembly  94 A, span member  12  may be coupled to connector  14  such that an expansion member  28  of connector  14  is inserted into an open end of span member  12  and apertures  24  and  66  are aligned. As discussed above, a lighting element  122  may be mounted in slot  120  and the electrical cable  128  may be fed through the interior of span member  12  and connector  14 . In one embodiment cable  128  may be passed through a ghost mount span connector  12 A for connection to a power supply  126  as shown in  FIG. 43  and discussed above. In another embodiment cable  128  may be passed through aperture  90  of connector  14  ( FIGS. 21B and 21C ) and a mounting assembly  94 A comprising a mount housing  106 A for connection to a power supply  126  as shown in  FIG. 50  and discussed above. Span member  12  and a respective connector  14  may be securely engaged by tightening set screw  68  to cause expansion member  28  to be adjusted from the reduced diameter first position to the expanded diameter second position as described above. Since set screw  68  will be located on the undersurface of rail system  10  facing downwardly as discussed above it will not be readily visible. 
     In another example, both aligned apertures  24 ,  66  receiving a set screw  68  and lighting element  122  may be oriented facing support surface  95 , such as an interior wall of the elevator cab. Thus in in this embodiment slot  120  is once again in alignment with apertures  24  but light emitted from rail system  10  is directed inwardly toward surface  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 aligned apertures  24 ,  66  of span member  12  and adjacent connector  14  on the back side of rail system  10  facing the support surface  95 , or the undersurface of rail system  10  facing downwardly, so such apertures, and the set screw  68  which releasably couples each span member  12  and a respective connector  14  together, are hidden from view. 
     In such alternative embodiments elongated slot  120  of a span member  12  may be located at a position offset from apertures  24 , for example if it is desired to direct light from lighting element  122  upwardly or outwardly into the interior of the elevator cab. Alternatively, slot  120  may be aligned with an aperture  24  of span member  10 , but during assembly of rail system  10  aperture  24  could be aligned with an aperture  66  of connector  14  which is not in-line with slot  90  ( FIGS. 21B and 21C ). Either way, in this example, set screw  68  will again be located on the back or undersurface of rail system  10  where it will not be readily visible and lighting 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 of connector  14  where expansion member(s)  28  are releasably connectable to connector span  26  at different selected rotational positions (e.g.  FIG. 19 ), connector  14  can be configured so that aligned apertures  24 , 66  receiving set 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  12 B may be configured to emit light emanating from lighting element  122 A from all or part of the circumferential surface of span member  12 B while set screws  68  and screw 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 mount span members  12  and connectors  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, since connectors  14  provide a visual break between adjacent 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.