Patent Abstract:
A mounting system enables modular accessories to be fastened to any flat surface. Multiple, parallel accessory rails are mounted in parallel to provide a mounting system over substantially all of the area of a flat surface. The rails are spaced apart by channels to allow inverted rails to be inserted between and fastened to the parallel rails to expand the mounting capabilities of the mounting system. Removable attachment devices are engagable with the channels and the rails of the enclosure to expand the interconnection capabilities of the enclosure.

Full Description:
RELATED APPLICATIONS 
       [0001]    The present application claims the benefit of priority under 35 USC §119(e) to U.S. Provisional Application No. 61/471,211, filed on Apr. 4, 2011; to U.S. Provisional Application No. 61/471,689, filed on Apr. 4, 2011; to U.S. Provisional Application No. 61/472,185, filed on Apr. 5, 2011; and to U.S. Provisional Application No. 61/532,513, filed on Sep. 8, 2011. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention is in the field of mounting systems that enable accessories to be quickly connected to and disconnected from a base unit. 
         [0004]    2. Description of the Related Art 
         [0005]    The STANAG 4694 NATO Accessory Rail System is employed for the mounting of one or more auxiliary accessories to small arms (e.g. rifles, pistols, etc.). This system allows equipment such as a telescopic sight to be mounted along the same axis as the barrel of small arms and incorporates multiple accessories into a systematic whole. 
         [0006]    The STANAG 4694 NATO Accessory Rail System has a large degree of flexibility in regards to fastening mechanisms. Attachments for both the MIL-STD-1913 Picatinny Rail and the older STANAG 2324 NATO Rail systems can be used on a STANAG 4694 Rail and attachments for the STANAG 4694 are backwards compatible with the MIL-STD 1913. 
         [0007]    The STANAG 4694 NATO and MIL-STD 1913 Picatinny rail systems have a long history of use and are proven to be reliable mechanisms for fastening auxiliary devices. The present invention will use these systems as a basis for the design of a dynamic system for attaching accessories such as lights, sights, grips and various other accessories to the exterior of any device where precision alignment, flexibility and modularity are required. 
       SUMMARY OF THE INVENTION 
       [0008]    An aspect of embodiments in accordance with the present invention is a universal mounting device for a variety of applications. The system is based upon the aforementioned STANAG 4694 NATO Accessory Rail System. While the STANAG 4694 is a both a robust and highly effective system, it is limited by the fact the accessories may only be mounted along the center-line of a single rail. While this is an acceptable limitation for small arms it constricts its use in other applications. 
         [0009]    Naturally a system to allow attachments along and across planes, not lines, needs to be devised. As the STANAG 4694 provides a modular and efficient method for fastening auxiliary accessories across a straight line, it is utilized as the basis of the present invention. 
         [0010]    The underlying concept behind the system is simple, mount multiple STANAG 4694 rails in parallel and in such a way as to allow inverted rails to be inserted between the parallel rails and subsequently fastened through an appropriate mechanism. In addition to this the present invention provides a system by which the invention can be mounted and joined across orthogonal surfaces via the use of a STANAG 4694 mounted at a 45 degree angle in relation to the surfaces. 
         [0011]    The specifications of the STANAG 4694 are changed to allow for tolerance in the insertion of inverted rails. These changes are made to the height of the rail and the filleting of the bottom of the rails. 
         [0012]    Attachment of devices fitted with Picatinny or NATO specification fasteners is in the regular manner of these systems (e.g., over the parallel rails). Devices may also be attached to inverted Picatinny or NATO specification rails and fastened by means of a threaded screw threw a specially designed thrust plate that fits between the notches of the parallel rails. 
         [0013]    The system also provides the ability to implement custom designed pieces, such as riser rails similar in shape to construction I-beams. The riser rail is simply an example of a specially designed accessory and the system&#39;s modularity allows for the integration of a vast number of user defined accessories. 
         [0014]    Another aspect of embodiments in accordance with the present invention is an enclosure for a camera system or other electronics system. The enclosure includes a housing configured to contain at least a portion of the camera system or other electronics system. The enclosure has at least a top surface, a bottom surface, a first side surface and a second side surface. A plurality of rails are positioned on the surfaces of the enclosure. Each rail is configured to have an engagement portion having an outer flat surface, a first inner engagement surface and a second inner engagement surface. The first and second inner engagement surfaces are spaced apart by a width determined by base portion of the rail. The outer flat surface, the first and second engagement surfaces and the base portion are sized and positioned with respect to each other to conform to the STANAG 4694 NATO Accessory Rail System specification. A plurality of channels are positioned on the surfaces of the enclosure. Each channel is positioned between two adjacent rails. Each channel has a first channel engagement surface defined by the first inner engagement surface of one of the two adjacent rails and has a second channel engagement surfaced defined by the second inner engagement surface of the other of the two adjacent rails. The first and second channel engagement surfaces are spaced apart by a distance of at least the width of the base portion of each rail. 
         [0015]    Preferably, the enclosure further includes a rail at each corner of the enclosure. The rail at each corner has dimensions that conform to the STANAG 4694 NATO Accessory Rail System specification. In particular embodiments, each of the top surface and the bottom surface of the enclosure includes at least four rails and at least three channels. Also, in particular embodiments, each of the first side and the second side includes at least one rail and at least two channels. 
         [0016]    The enclosure further includes removable attachment rails and other attachment devices. For example, an exemplary attachment rail has at least one engagement portion sized to fit within one of the plurality of channels on the enclosure. The attachment rail further includes a mounting channel. The engagement portion of the attachment rail has first and second engagement surfaces sized and positioned to engage the first and second channel engagement surfaces of the channel of the enclosure. The attachment rail is secured to the enclosure with a thrust plate. The thrust plate is positionable in the mounting channel of the attachment rail. The thrust plate extends over at least a portion of the outer flat surface of the respective engagement portion of each of the rails adjacent the channel of the enclosure. A securing device extends from the thrust plate to the attachment rail. The securing device is adjustable to vary move the thrust plate toward the attachment rail to clamp the portions of the outer flat surfaces of the engagement portions of the rails between the thrust plate the attachment rail to thereby secure the attachment rail to the enclosure. In preferred embodiments of the enclosure, the outer flat surface of each of the rails on the enclosure has an alternating pattern of ridges and notches formed therein. For such embodiments, the thrust plate has an engagement surface having at least one ridge formed thereon. The thrust plate is positioned on the rails of the enclosure such that the ridge fits within at least one of the notches of at one of the rails before adjusting the securing device to clamp the engagement portions of the rails. 
         [0017]    In preferred embodiments, the removable attachment rail has an engagement portion having an outer flat surface. The outer flat surface has an alternating pattern of ridges and notches formed therein. The attachment rail further includes a bore positioned in one of the notches and extending through the attachment rail. A removable orthogonal attachment rail has a first end and a second end. At least one of the first end and the second end of the orthogonal attachment rail includes at least first and second grooves that define an end ridge therebetween. The end ridge is sized to fit within a notch of the attachment rail. The end ridge has a threaded bore formed therein. The orthogonal attachment rail is positioned orthogonally to the attachment rail with the threaded bore aligned with the bore in the attachment rail and with the end ridge of the orthogonal rail positioned within the one of the notches. A threaded fastener extends through the attachment rail and engages the threaded bore of the orthogonal attachment rail to secure the orthogonal attachment rail to the attachment rail. 
         [0018]    In particularly preferred embodiments, the enclosure further includes a tripod clamp. The tripod clamp comprises a channel formed in a first surface of the tripod clamp. The channel in the tripod clamp has a size and shape configured to receive the engagement portion of at least one rail on the lower surface of the enclosure therein. The channel in the tripod clamp has a first clamp channel engagement surface and a second clamp channel engagement surface positioned to be adjacent the first inner engagement surface and the second inner engagement surface of the at least one rail. A compression plate is positioned in the channel. The compression plate is moveable with respect to the channel to engage the outer flat surface of the at least one rail and to force the first and second clamp channel engagement surfaces against the first and second inner engagement surfaces of the at least one rail to thereby secure the tripod clamp to the enclosure. The compression plate is caused to move by an actuator coupled to the compression plate. Preferably, the tripod clamp channel is sized to span across two adjacent rails of the enclosure and the channel between the two rails such that the first inner engagement surface is part of the engagement portion of one of the two rails and the second inner engagement surface is part of the engagement portion of the other of the two rails, and such that the compression plate engages at least a portion of the outer flat surface of each of the two rails. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    Embodiments in accordance with aspects of the present invention are described below in connection with the attached drawings in which: 
           [0020]      FIG. 1  illustrates a front perspective view of a 3D camera that incorporates an embodiment of the mounting system in accordance with embodiments of the invention; 
           [0021]      FIG. 2  illustrates a rear perspective view of the 3D camera of  FIG. 1 ; 
           [0022]      FIG. 3  illustrates a perspective view of one section of an enclosure of the 3D camera system of  FIGS. 1 and 2  looking toward the front and top of the enclosure shell; 
           [0023]      FIG. 4  illustrates a perspective view of the enclosure shell of  FIG. 3  looking toward the rear of the enclosure shell; 
           [0024]      FIG. 5A  illustrates an elevational view of the enclosure shell of  FIGS. 3 and 4  viewed from the front; 
           [0025]      FIG. 5B  illustrates an elevational view of the enclosure shell of  FIGS. 3 and 4  viewed from the rear; 
           [0026]      FIG. 6  illustrates a plan view of the enclosure viewed from the top; 
           [0027]      FIG. 7  illustrates an elevational view of the enclosure viewed from the right side; 
           [0028]      FIG. 8  illustrates an enlarged elevational view of a rail and adjacent channels taken within the area bounded by the dashed circle  8  in  FIG. 3 ; 
           [0029]      FIG. 9  illustrates a cross-sectional elevational view of the enclosure taken along the line  9 - 9  in  FIG. 3 ; 
           [0030]      FIG. 10  illustrates a front elevational view of an alternative embodiment of the enclosure shell of  FIGS. 3-9  which includes an full channel at each side of the top and bottom surfaces; 
           [0031]      FIGS. 11A-11D  illustrate a top prospective view, a bottom perspective view, a right side elevational view and a front perspective view of a notched attachment rail that interconnects with the enclosure of  FIGS. 1-9  and the enclosure shell of  FIG. 10 ; 
           [0032]      FIGS. 12A and 12B  illustrate a top perspective view and a bottom perspective view of thrust plate for use with the notched attachment rail of  FIGS. 11A-11D ; 
           [0033]      FIG. 13  illustrates a perspective view of an engagement knob used in combination with the thrust plate of  FIGS. 12A and 12B  to secure the notched attachment rail of  FIGS. 11A-11D  to the enclosure of  FIGS. 1-9  and the enclosure shell of  FIG. 10 ; 
           [0034]      FIG. 14  illustrates a perspective view of an end-grooved attachment rail used in combination with the notched attachment rail of  FIGS. 11A-11D  to provide a vertical offset from the enclosure of  FIGS. 1-9  and the enclosure shell of  FIG. 10 ; 
           [0035]      FIG. 15  illustrates a solid attachment rail that is interconnectable with an end of the notched attachment rail of  FIGS. 11A-11D ; 
           [0036]      FIG. 16  illustrates an enlarged notched attachment rail having two mounting channels; 
           [0037]      FIG. 17  illustrates a perspective view of the enclosure shell of  FIGS. 3 and 4  with the notched attachment rail inserted in a channel between two rails; 
           [0038]      FIG. 18  illustrates an enlarged elevational view of the notched attachment rail and the enclosure shell of  FIG. 17  within the area bounded by the dashed circle  18  in  FIG. 17 ; 
           [0039]      FIG. 19  illustrates a perspective view of the enclosure shell and the notched attachment rail of  FIG. 17  further showing the thrust plate and the engagement knob to secure the notched attachment rail in a fixed position on the enclosure shell; 
           [0040]      FIG. 20  illustrates an enlarged elevational view of the notched attachment rail and the enclosure shell of  FIG. 19  showing the effect of the thrust plate and the engagement know in forcing the engagement surfaces of the notched attachment rail against the engagement surfaces of the two rails on the enclosure shell; 
           [0041]      FIG. 21  illustrates a perspective view of the enclosure shell, the notched attachment rail, the thrust plate and the engagement knob of  FIG. 19  further showing the interconnection of the end-grooved attachment rail to the notched attachment rail; 
           [0042]      FIG. 22  illustrates an enlarged perspective view of the enclosure shell, the notched attachment rail, the thrust plate, the engagement knob and the end-grooved attachment rail of  FIG. 21  looking upward beneath the notched attachment rail to show the insertion of the hex socket head screw to secure the end-grooved attachment rail to the notched attachment rail; 
           [0043]      FIG. 23  illustrates a perspective view of the enclosure shell, the notched attachment rail, the thrust plate and the engagement knob of  FIG. 19  further showing the attachment of the solid attachment rail of  FIG. 15  to the end of the notched attachment rail; 
           [0044]      FIG. 24  illustrates a perspective view of the 3D camera system of  FIGS. 1 and 2  with the notched attachment rail secured to the enclosure via the thrust plate and the engagement knob, with the end-grooved attachment rail secured to the notched attachment rail in a vertical position, and with the enlarged attachment rail of  FIG. 16  attached to the end-grooved attachment rail to provide an horizontally disposed attachment rail offset vertically from the top of the enclosure; 
           [0045]      FIG. 25  illustrates a perspective view of a tripod mounting clamp having a wide channel that clamps onto outer edges two adjacent rails on the enclosure; 
           [0046]      FIG. 26  illustrates a perspective view of the bottom of the enclosure with the tripod mounting clamp attached to two rails of the enclosure; 
           [0047]      FIG. 27  illustrates an enlarged plan view of the first enclosure shell of  FIG. 26  and the tripod mounting clamp to show the interaction of the compression plate against the top surfaces of the two rails; 
           [0048]      FIGS. 28A and 28B  illustrate top and bottom perspective views of an exemplary commercially available rail mounting lock; 
           [0049]      FIG. 29  illustrates the rail mounting lock of  FIGS. 28A and 28B  clamped to the enlarged notched attachment rail of  FIG. 16 ; and 
           [0050]      FIG. 30  illustrates a mounting plate configured with a plurality of rails and interposed channels for mounting on a vehicle, such as for example, a ground vehicle, a watercraft, an aircraft, or the like. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0051]    The universal rail mounting system is disclosed herein with respect to exemplary embodiments. The embodiments are disclosed for illustration of the universal rail mounting system and are not limiting except as defined in the appended claims. In particular, the system is described with respect to the shell of a 3D camera system to illustrate an exemplary implementation of the system. The universal rail mounting system is not limited to use with a camera system. 
         [0052]      FIGS. 1 and 2  illustrate front and rear perspective views, respectively, of a 3D camera system  100  that incorporates a universal rail mounting system  110  as part of an enclosure  120  of the 3D camera system. As illustrated, the front of the 3D camera system includes a lens mounting subsystem  130  having an extended lower support platform  132  that supports a first lens assembly  134  and a second lens assembly  136 . The two lens assemblies are mounted to a positioning assembly  138  that is controllable to vary the distance between the two lens assemblies about a centerline  140 . Each lens assembly is further positionable to vary the angle of the lens assembly with respect to the centerline to adjust the focal point. The lenses within each lens assembly are adjustable with respect to at least the aperture and the focal length. Each lens assembly includes a photodetector array that receives a respective image and generates an electronic representation of the image. An electronics subsystem (not shown) is housed within the enclosure. The electronics subsystem controls the lens mounting subsystem, controls the two lens assemblies and processes the electronic representations of the images. As illustrated schematically in  FIG. 2 , various connectors  144  are housed within a rear portion  142  of the enclosure to communicate with the electronics subsystem. The structure and control of the lens mounting subsystem and the two lens assemblies and the processing of the images are provided to illustrate an exemplary application for the universal rail mounting system described herein. The structure and control of the lens mounting subsystem and the two lens assemblies and the processing of the images are not part of this application and are not illustrated in detail or discussed further herein. 
         [0053]    In the illustrated embodiment, the enclosure  120  comprises a first enclosure shell  150  and a second enclosure shell  152 . The two enclosure shells may be identical as shown. Accordingly, the first enclosure shell is illustrated in more detail in  FIGS. 3-9 , and it is understood that in the illustrated embodiment, the second enclosure shell has a similar construction. As discussed below, the first enclosure shell receives the lens mounting subsystem  130  in a recess in a front portion of the first enclosure shell. The rear portion of the first enclosure shell nests within a corresponding recess in the front portion of the second enclosure shell. The rear portion of the second enclosure shell houses the connectors  144  and corresponds to the rear portion  142  of the enclosure. 
         [0054]      FIGS. 3 and 4  illustrate front and rear perspective views, respectively, of the first enclosure shell  150  alone.  FIGS. 5A and 5B  illustrate front and rear elevational views of the first enclosure shell.  FIGS. 7 and 8  illustrate a top plan view and a right side elevational view, respectively, of the first enclosure shell. As illustrated in  FIGS. 3 and 4 , the universal rail mounting system  110  is formed on an upper surface  160 , a lower surface  162 , a left side surface  164  and a right side surface  166 . On the four surfaces, the universal rail mounting system comprises a plurality of rails  170 . Each rail is spaced apart from an adjacent rail by a channel (valley)  172 . The structures of the rails and channels are described in more detail below. 
         [0055]    In the illustrated embodiment, a respective portion of the universal rail mounting system  110  is also formed on each of the four corners of the first enclosure shell  150 . A first corner rail  180  is formed or positioned between the upper surface  160  and the left side surface  164 . A second corner rail  182  is formed or positioned between the upper surface and the right side surface  166 . A third corner rail  184  is formed or positioned between the lower surface  162  and the right side surface. A fourth corner rail  186  is formed or positioned between the lower surface and the left side surface. In alternative embodiments, one or more of the corner rails may not be included. 
         [0056]    As illustrated in  FIGS. 1 and 2 , the bottom and lower corners of the lens mounting subsystem  130  and the portions of top, the sides and the upper corners of the lens mounting subsystem behind the support platform  132  have corresponding rails and channels formed thereon. The rails and channels on the lens mounting subsystem and the rails and channels on the first enclosure shell  150  and the second enclosure shell  152  are formed in precise locations and formed with precise dimensions such that when the first enclosure shell, the second enclosure shell and the lens mounting subsystem are joined to form the enclosure  120 , the rails and channels are aligned to form continuous rails and channels from the front to the back of the enclosure. 
         [0057]    As further illustrated in  FIG. 3 , the front of the enclosure shell  150  includes a recess  190 . The recess is shaped and sized to receive a protrusion  192  that extends from the back of the enclosure shell. In particular, the recess has inner dimensions that define the opening of the recess that correspond to outer dimensions of the protrusion. Accordingly, when the first enclosure shell is engaged with the second enclosure shell as shown in  FIGS. 1 and 2 , the protrusion of the first enclosure shell fits snugly within the recess of the second enclosure shell. Similarly, the lens mounting subsystem  130  has a rear protrusion (not shown), that fits within the recess in the first enclosure shell. After the respective rear protrusions are inserted into the recesses, the lens mounting subsystem and the first and second enclosure shells are securely attached by inserting bolts (not shown) through openings  194  through the enclosure shells and threading the bolts into threaded bores (not shown) in the lens mounting subsystem. As indicated above, the protrusion extending from the second enclosure shell in  FIGS. 1 and 2  corresponds to the rear portion  142  of the overall enclosure  120 . 
         [0058]    In the illustrated embodiment, the enclosure shell  150  and the universal rail mounting system  120  on the shell are formed from anodized aluminum; however, other suitable materials may also be used. For example, a suitable carbon fiber material may also be used. As further shown in  FIGS. 5 ,  6  and  8 , the enclosure shell in the illustrated embodiment, the enclosure shell is formed as an upper portion  200  and a lower portion  202 , which are joined at a seam or other interface  204  in a suitable manner (e.g., with fasteners or the like). In the illustrated embodiment, rear protrusion  192  and the recess  190  are offset such that a larger portion of each element is in the upper portion of the enclosure shell. The two portions of the enclosure shell may be formed by milling a block of aluminum or other suitable material, by extruding aluminum or other suitable material, or by another suitable manner. 
         [0059]      FIG. 8  illustrates an enlarged elevational view of the rail  170  and the two channels  172  on either side of the rail within the area bounded by the dashed circle  8  in  FIG. 3 . As indicated above, each rail is configured for compatibility with the standard STANAG 4694 NATO Accessory Rail System. In particular, the rail has a well-defined, generally T-shaped, cross-section having an overall width “W 1 ” and an overall height “H 1 ” measured with respect to the adjacent channel. The rail is generally configured as an upper portion  300  supported by a base portion  302 . The upper portion has a height “H 2 ” from the base portion to a horizontal flat top portion  310 . The flat top portion has a width “W 2 ” and is surrounded on each side by slanted upper side portions  312  that each slant downward and outward at an angle of 45 degrees with respect to the horizontal flat top portion. The slanted upper side portions are symmetrical about the center of the horizontal flat top portion. Each upper side portion terminates at the top of a respective substantially vertical intermediate side portion  320  that each has a height “H 3 .” The vertical intermediate side portions are spaced apart by the overall width “W 1 ” of the rail. A respective slanted lower side portion  322  extends downward and inward from each intermediate side portion at an angle of approximately 45 degrees. Each slanted lower side portion terminates at the base portion. The two slanted lower side portions are also symmetrical about the center of the horizontal flat top portion. In the preferred embodiment, the base portion has a width “W 3 ” that is substantially equal to the width “W 2 ” such that the upper slanted side portions and the lower slanted side portions are symmetrical about a horizontal line (not shown) between the centers of the vertical intermediate side portions. Furthermore, the each upper slanted side portion is positioned at an angle “A” with respect to the respective lower slanted side portion, which has a value of approximately 90 degrees. The height of the base portion is “H 4 ,” which is substantially equal to the difference in the height “H 1 ” and the height “H 2 .” As further illustrated in  FIG. 8 , the vertical sides of the base portion merge with the adjacent channels via fillets of radius “R.” 
         [0060]    In accordance with the STANAG 4694 NATO Accessory Rail System standard, the upper horizontal flat surface  310  serves as a reference surface for a rail grabber on an accessory (not shown); and the two slanted lower side portions  322  serve as the grabber surfaces which are engaged to secure the rail grabber to the rail  170 . The two slanted upper side portions  312  may also be engaged for accessories configured for compatibility with the older MIL-STD-1913 (Picatinny) rail system. 
         [0061]    Two adjacent rails  170  are spaced apart by an intermediate channel  172 . Each channel has a generally hourglass shape with an upper portion having a width “W 4 ” between adjacent horizontal flat top portions  310  of the two rails. An intermediate “waist” portion of the channel has a width “W 5 ” between the right intermediate vertical side portion  320  of one rail and the left intermediate vertical side portion of the adjacent rail to the right. A bottom portion of the channel has a width “W 6 ” between the base portions  302  of adjacent rails. In the illustrated embodiment, the width “W 5 ” of the waist portion of each channel is slightly larger than the width “W 3 ” of the base portion of each rail; and the width “W 6 ” of the bottom portion is slightly larger than the overall width “W 1 ” of each rail. 
         [0062]    As illustrated in  FIG. 8 , the profile of each channel  172  is selected to be complementary to the profile of each rail  170 . In particular, the profile of each channel is configured to receive an “inverted” rail inserted through an open end of the channel as will be discussed below with respect to exemplary attachments for the enclosure  120 . 
         [0063]    As indicated above, the dimensions of each rail are selected to be compatible with the standard STANAG 4694 NATO Accessory Rail System. Accordingly, the following dimensions are used in the preferred embodiment:
       W 1 : 21.2 mm+0.00/−0.13 (0.835 in.+0.000/−0.005)   W 2 : 15.6 mm+0.00 (0.610 in.+0.000)   W 3 : 15.6 mm+0.00 (0.610 in.+0.000)   W 4 : 21.4 mm−0.00 (0.844 in.−0.000)   W 5 : 15.7 mm+0.00 (0.619 in.−0.000)   W 6 : 21.4 mm−0.00 (0.844 in.−0.000)   H 1 : 9.4 mm−0.00 (0.370 in.−0.000)   H 2 : 6.2 mm (0.246 in.)   H 3 : 0.5 mm (0.021 in.)   H 4 : 3.2 mm (0.124 in.)   R: 1.5 mm+0.00 (0.06 in.+0.00)       
 
         [0075]    As shown in  FIGS. 1-9 , the upper portions  300  of the rails  170 ,  180 ,  182 ,  184  and  186  are not continuous from the front of the enclosure  120  to the rear of the enclosure. Instead, approximately one-half of the upper portions are removed to form a periodic structure of ridges  330  and notches (valleys)  332 . As shown in the cross-sectional view of the first enclosure shell  150  in  FIG. 9 , which is taken along the lines  9 - 9  in  FIG. 3 , the upper portion of the sectioned rail is complete for a length “L 1 ” to form a ridge and is then partially removed for a length “L 2 ” to form a notch. In the illustrated embodiment, the length “L 1 ” is approximately 0.190 inch (4.8 millimeters) and the length “L 2 ” is approximately 0.210 inch (5.3 millimeters). The alternating pattern of full upper portions (ridges) and partial upper portions (notches) is repeated for the length of the first enclosure for a distance of approximately 3.8 inches (96.5 millimeters) such that 10 complete “cycles” of the structure are provided. Accordingly, when the rear protrusion  192  of the first enclosure shell is inserted into the front recess  190  of the second enclosure shell  152 , the front-most full upper portion of the rail of the second enclosure shell is spaced apart from the rear-most full upper portion of the rail of the first enclosure shell by the distance “L 2 ” so that the periodic pattern of ridges and notches continues uninterrupted from the first enclosure shell to the second enclosure shell. 
         [0076]    In the embodiment illustrate in  FIGS. 1-9 , the top surfaces and the bottom surfaces of the first enclosure shell  150 , the second enclosure shell  152  and the lens mounting subsystem  130  each have four rails  170  and three complete channels  172  between the rails. Each surface further has a partial channel formed between each outside rail on the top surface and the bottom surface and the respective corner rails  180 ,  182 ,  184 ,  186 . The particular configuration is selected to provide a cameral body having an overall outside width of approximately 8.32 inches (211 millimeters) and having inside dimensions of approximately 8.85 inches (174 millimeters). The overall outside width can be increased by approximately 0.45 inch (11.5 millimeters) as illustrated in  FIG. 10  to provide sufficient room to form complete channels  172  at each side of the top and bottom surfaces of a modified first enclosure shell  152 ′. The second enclosure shell (not shown) and the lens mounting subsystem (not shown) are modified in a corresponding manner. 
         [0077]    As illustrated in  FIGS. 1-10 , the enclosure  120  comprising the first enclosure shell  150 , the second enclosure shell  152  and the lens mounting subsystem  130  advantageously provides multiple mounting rails  170  on the top, the bottom and both sides of the enclosure as well as the mounting rails  180 ,  182 ,  184  and  186  on the four corners of the enclosure. Accordingly, accessories compatible with the STANAG 4694 NATO Accessory Rail System or with the MIL-STD-1913 Picatinny Rail System can be mounted at multiple locations on the enclosure to extend outward in each of the four principal orthogonal directions (up, down, left and right) as well as at four directions displaced angularly by 45 degrees from the four principle directions. 
         [0078]    In addition to being able to mount accessories directly to the rails on the enclosure, interconnection components (adapters) are provided as illustrated in  FIGS. 11A-11D ,  12 A and  12 B,  13 ,  14 ,  15  and  16  to extend the flexibility in mounting accessories. 
         [0079]      FIGS. 11A and 11B  illustrate perspective views of a notched attachment rail  400  view from the top and bottom, respectively.  FIG. 11C  illustrates a right side elevational view of the notched attachment rail, and  FIG. 11D  illustrates a bottom plane view of the notched attachment rail. As illustrated below in connection with  FIGS. 17-24 , the notched attachment rail is configured to be positioned in a channel  172  between two adjacent rails  170  on the top surface, the bottom surface, the left surface or the right surface of the enclosure  120 . In particular, the notched attachment rail comprises an upper engagement portion  402  and a lower engagement portion  404 . Both engagement portions are sized and shaped to correspond to the generally T-shaped cross section of the rails on the enclosure and are therefore complementary to the channels of the enclosure. The two engagement portions are spaced apart by an intermediate body portion  406  having a height “H 11 ” between the two engagement portions of approximately 0.35 inch (8.9 millimeters). The notched attachment rail has a length “L 11 ” of approximately 3 inches (76.2 millimeters) from a first end  410  to a second end  412 . 
         [0080]    As further shown in  FIGS. 11A-11D , the two engagement portions  402 ,  404  of the notched attachment rail  400  are notched in a similar manner to the rails  170  such that alternating ridges  420  and notches  422  are formed on the outer half of each engagement portion. In the illustrated embodiment, a first ridge at each end has a length “L 12 ” of approximately 0.211 inch (5.36 millimeters) and the remaining ridges have lengths “L 13 ” of approximately 0.180 inch (4.57 millimeters). The notches have lengths “L 14 ” of approximately 0.214 inch (5.44 millimeters). A portion of the first ridge at each end of the notched attachment rail extends beyond the respective end of the intermediate body portion  406  to form a respective first end channel  430  and second end channel  432  between the extended ridges. 
         [0081]    In certain embodiments (not shown), the notched attachment rail  400  may be symmetrical on the top and the bottom; however, in the illustrated embodiment, the notched attachment rail has a mounting channel  440  formed across the upper engagement portion  402  and extending approximately a depth “D 11 ” into the intermediate body portion  406  measured from the base of the notches  422 . The mounting channel has a width “W 11 ” corresponding to the widths of two ridges  420 , the width of a full notch and portions of two notches of the upper engagement portion. In the illustrated embodiment, “D 11 ” is approximately 0.324 inch (11.23 millimeters) and “W 11 ” is approximately 0.844 inch (21.43 millimeters). In the illustrated embodiment, the mounting channel is centered with respect to the notch between the third and fourth ridges from the second end  412  of notched attachment rail. A threaded through bore  442  is formed substantially in the middle of the mounting channel. The bore extends through the intermediate body portion and exits in the notch between the third and fourth ridges from the second end of the lower engagement portion  404 . In the illustrated embodiment, the bore has a diameter of approximately 0.201 inch (5.1 millimeters). 
         [0082]    As best shown in  FIG. 11B , the notched attachment rail  400  further includes an unthreaded countersunk bore  444  centered with respect to the width of the lower engagement portion  404  and positioned substantially in the middle of a notch  412  between the second and third ridges  410  of the lower engagement portion. The countersunk bore extends through to the corresponding notch on the upper engagement portion. In the illustrated embodiment, the countersunk bore is sized to accommodate a ¼ inch hex socket head screw. For example, the countersunk bore has a main diameter of approximately 0.240 inch (6.1 millimeters) through the notched attachment rail, thus causing a portion of the second and third ridges on the upper engagement portion to be removed as shown in  FIG. 11A . The countersunk bore has a larger diameter on the lower engagement portion of approximately 0.438 inch (11.1 millimeters) to a depth of approximately 0.250 inch (6.35 millimeters) with respect to the surfaces of the adjacent ridges. 
         [0083]    The notched attachment rail  400  further includes a respective first threaded bore  450  and second threaded bore  452  formed in the respective center of each end channel  430 ,  432  at the first end  410  and the second end  412  of the attachment rail. In the illustrated embodiment, each bore has a diameter of approximately 0.201 inch. The bore at the first end extends to the countersunk bore  444 , and the bore at the second end extends to the channel  440 . 
         [0084]    As further shown in the end view of  FIG. 11D , the notched attachment rail  400  has a pair of engagement surfaces  460  formed on the upper engagement portion  402  proximate the intermediate body portion  406  and a pair of engagement surfaces  462  formed on the lower engagement portion  404  proximate the intermediate body portion. The engagement surfaces are angled at 45 degrees with respect to the intermediate body portion and correspond to the above-described engagement surfaces on the rails  170 . 
         [0085]    The notched attachment rail  400  is mounted to the enclosure  120  as illustrated in  FIGS. 17 and 18 . For simplicity, only the first enclosure shell  150  is shown in  FIG. 17 . As shown in more detail in  FIG. 18 , the notched attachment rail rests in a channel  172  between two adjacent rails  170  on the top of the first enclosure shell. In particular, the lower engagement portion  304  rests on the bottom of the channel. The lower engagement portion is sized such that small gaps are present between the engagement surfaces  462  of the lower engagement portion and the lower engagement surfaces  322  of the two adjacent rails. Accordingly, the notched attachment rail may be moved longitudinally within the channel to position the notched attachment rail at a selected location within the channel. For example, in  FIG. 17 , the notched attachment rail is positioned with a portion of the notched attachment rail extending forward beyond the front edge of the first enclosure shell. 
         [0086]    After selecting an approximate location for the notched attachment rail  400  as shown in  FIG. 17 , a thrust plate  500  is positioned in the channel  440  of the notched attachment rail as shown in  FIGS. 19 and 20 . The thrust plate is shown in more detail in  FIGS. 12A and 12B . The thrust plate has a generally rectangular planar upper surface  502  and a corresponding lower surface  504  having dimensions of approximately 1.25 inch (31.8 millimeters) by 0.75 inch (19.1 millimeters) separated by a thickness of approximately of approximately 0.125 inch (3.2 millimeters). The thrust plate has an unthreaded central through bore  510  formed substantially in the center of the two surfaces. The lower surface of the thrust plate has a first engagement tab  520  and a second engagement tab  522  formed proximate to the center of the shorter side of the surface and extending inwardly from the edge by approximately 0.305 inch (7.7 millimeters). The tab has a width of approximately 0.188 inch (4.8 millimeters) and has a thickness of approximately 0.063 inch (6.4 millimeters). 
         [0087]    As shown in  FIGS. 19 and 20 , when the thrust plate  500  is positioned with the lower surface  504  facing downwardly toward the bottom of the channel  440  of the notched attachment rail  400 , the lower surface extends outwardly from both sides of the attachment rail such that the engagement tabs  520 ,  522  extend downwardly over the adjacent rails  170  on both sides of the channel  172  of the first enclosure shell  150 . The longitudinal position of the notched attachment rail is adjusted so that the engagement tabs are positioned in corresponding notches  232  in the rail of the first enclosure shell and so that the adjacent portions of the lower surface rest on the tops of the ridges  230  of the rail. 
         [0088]    After positioning the thrust plate  500  and the notched attachment rail  400 , an engagement knob  550  (shown in  FIG. 13 ) is used to secure the thrust plate to the attachment rail and to thereby secure the attachment rail to the first enclosure shell  150 . The knob has upper gripping portion  552  and a lower threaded portion  554  that has threads that correspond to the threads in the through bore  442  at the bottom of the channel  440  in the notched attachment rail. The lower threaded portion passes through the unthreaded through bore  510  of the thrust plate and engages the threads in the through bore of the channel in the notched attachment rail. As the gripping portion is rotated, the engaged threads cause the thrust plate to be drawn toward the channel in the notched attachment rail. Since the ridges  230  of the rails  170  of the first enclosure shell prevent downward movement of the thrust plate, the notched attachment rail is drawing upward to cause the engagement surfaces  462  on the lower engagement portion  404  of the notched attachment rail to be forced against the engagement surfaces  322  of the rails of the first enclosure shell. Accordingly, the notched attachment rail is held securely in a fixed position. Furthermore, the precise angles and positions of the respective engagement surfaces of the notched attachment rail and adjacent rails of the first enclosure shell cause the upper engagement portion  402  of the notched attachment rail to be positioned in precise parallel alignment with the engagement portions of the rails on the first enclosure shell. Accordingly, the notched attachment rail effectively provides an additional rail for the first enclosure shell that is displaced at a higher elevation. 
         [0089]      FIG. 14  illustrates an end-grooved attachment rail  600  similar to the notched attachment rail  400 . The end-grooved attachment rail may be inserted into a channel  172  in like manner to the notched attachment rail, as described above; however, the end-grooved attachment rail is also adapted to be installed in an orientation orthogonal to the notched attachment rail as described below with respect to  FIGS. 21 and 22 . 
         [0090]    In the illustrated embodiment, the end-grooved attachment rail  600  has dimensions generally corresponding to the dimensions of the notched attachment rail  400 . The end-grooved attachment rail has a first end  610  and a second end  612 . The first end  610  has a first end channel  614  and the second end has a second end channel  616 . A plurality of ridges  620  and notches  622  correspond to the ridges and notches of the notched attachment rail  400 . Unlike the above-described notched attachment rail, the end-grooved attachment rail in  FIG. 14  has a first pair of parallel grooves  630 ,  632  formed in the first end channel and a second pair of parallel grooves  634 ,  636  formed in the second end channel. Each groove extends across the respective end channel adjacent respective end ridges  620 . Each groove has a width slightly larger than the length “L 13 ” of a ridge  420  of the notched attachment rail shown in  FIG. 11C . The two grooves in each pair of grooves are spaced apart by a distance that is slightly less than the length “L 14 ” of a notch  422  of the notched attachment rail to form a centered ridge  640  in the first end channel and to form a centered ridge  642  in the second end channel. 
         [0091]    The end-grooved attachment rail  600  further includes a mounting channel  650  corresponding to the channel  440  of the notched attachment rail  400  and includes a threaded through bore  652  corresponding to the through bore  442  of the notched attachment rail. A threaded blind end bore  660  is centered on the centered ridge  640  of the first end channel  614 . A threaded through bore  662  is centered on the centered ridge  642  of the second end channel  616  and extends to the mounting channel as described above for the notched attachment rail. 
         [0092]    The end-grooved attachment rail  600  of  FIG. 14  is mounted to the notched attachment rail  400  as illustrated in  FIGS. 21 and 22 . The end-grooved attachment rail is positioned with either the first end  610  or the second end  612  downward proximate to the extended portion of the notched attachment rail. In  FIGS. 21 and 22 , the second end is positioned proximate the notched attachment rail. The grooves  634 ,  636  in the second end channel  616  are aligned with the ridges  420  on the notched attachment rail on either side of the threaded through bore  444 . The centered ridge  642  of the second end channel is aligned with the notch  422  between the pair of ridges. The end-grooved attachment rail is then adjusted as necessary to align the threaded through bore  462  of the end-grooved attachment rail with the unthreaded countersunk through bore  444  of the notched attachment rail. As shown in the rotated enlarged view in  FIG. 22 , a hex socket head screw  650  is inserted through the countersunk through bore of the notched attachment rail to engage the threads of the threaded through bore of the end-grooved attachment rail to thereby secure the end-notched attachment rail in a vertical position with respect to the notched attached rail. The multiple alignment surfaces of the two alignment rails cause the end-grooved attachment rail to be precisely aligned with respect to the notched attachment rail and to thereby be precisely aligned with the first enclosure shell  150 . Accessories can be attached to the end-grooved attachment rail with orientations that are orthogonal to the orientations that the accessories would have had if attached directly to the rails on the enclosure. 
         [0093]      FIG. 15  illustrates an embodiment of a solid rail  700 . The solid rail has a single engagement portion  702  supported by a base portion  704 . The base portion is shorter than the intermediate body portion of the above-described notched attachment rail  400 . For example, in the illustrated embodiment, the base portion extends approximately 0.139 inch (3.5 millimeters) below the engagement portion. The length of the solid rail can be varied. In the illustrated embodiment, the length is approximately 3 inches (76.2 millimeters). An unthreaded countersunk through bore  710  is formed in the solid rail substantially in the center of the rail. In the illustrated embodiment, the bore is sized to accommodate a ¼ inch hex socket head screw. 
         [0094]      FIG. 23  illustrates an exemplary application for the solid rail  700 . The notched attachment rail  400  is secured in the first enclosure shell  150  as described above with the first end channel  430  facing outward as shown in  FIG. 19 . The solid rail is positioned with the body portion  404  in the first end channel of the notched attachment rail and with the unthreaded countersunk through bore  710  of the solid rail aligned with the first threaded bore  450  ( FIG. 19 ) notched attachment rail. A hex socket head screw  720  is inserted into the aligned bores and threaded into the threaded bore of the notched attachment rail to secure the solid rail to the notched attachment rail with the engagement portion  702  of the solid rail facing outward in a generally horizontal orientation. Accordingly, the solid rail provides a further surface for securing accessories at an orientation not provided by the rails on the first enclosure shell  150 . 
         [0095]      FIG. 16  illustrates an embodiment of an enlarged notched attachment rail  800  that is configured generally as two end-to-end copies of the notched attachment rail  400  of  FIGS. 11A-11D . The enlarged notched attachment rail has a first engagement portion  802  and a second engagement portion  804 . The enlarged notched attachment rail has a first end  810  and a second end  812 . In the illustrated embodiment the enlarged notched attachment rail is sized to accommodate 15 ridges  820  and 14 intervening notches  822  along each engagement portion versus the 8 ridges and 7 notches accommodated by engagement portions of the notched attachment rail. Note, however, that the first engagement portion has a first mounting channel  830  with a threaded central through bore  832  formed therein corresponding to the mounting channel  440  and bore  442  of the notched attachment rail. A second mounting channel  840  and a threaded central bore  842  are formed in the second engagement portion. Thus, two ridges and all or parts of three notches are removed from each engagement portion. As illustrated, the mounting channels are symmetrically disposed about the middle of the enlarged attachment rail. As further illustrated in  FIG. 16 , the enlarged notched attachment rail includes a first threaded bore  850  that extends from the first end into the first mounting channel and a second threaded bore  852  that extends from the second end  812  to the second mounting channel. 
         [0096]    In the illustrated embodiment, the enlarged notched attachment rail  800  includes a first countersunk unthreaded bore  860  generally located between the second and third ridges towards the center of the rail from the first mounting channel  830  and includes a second countersunk unthreaded bore  862  generally located between the second and third ridges towards the center of the rail from the second mounting channel  840 . In the illustrated embodiment, the countersunk portion of the first bore is on the same side as the second engagement portion, and the countersunk portion of the second bore is on the same side of the first engagement portion. 
         [0097]    The enlarged notched attachment rail  800  may be installed directly in a channel  172  of the first enclosure shell  150 , as illustrated above with respect to the notched attachment rail  400 . The enlarged notched attachment rail may also be installed to the top of the end-grooved attachment rail  600  as illustrated in  FIG. 24  to provide an elevated attachment rail generally parallel to the upper surface of the first enclosure shell. In  FIG. 24 , the complete 3D camera system  100  of  FIGS. 1 and 2  is again illustrated. The enlarged notched attachment rail is attached to the top of the end-grooved attachment rail  600 , which is secured to the notched attachment rail  400 , as described above with respect to  FIGS. 21 and 22 . A pair of ridges  820  on either side of the second counter sunk through bore  862  ( FIG. 16 ) are engaged with the grooves  630 ,  632  ( FIG. 14 ) of the first end channel  614  of the end-grooved attachment rail. A hex socket head screw  870  is inserted through the through bore in the enlarged notched attachment rail and engaged with the threaded bore  660  ( FIG. 14 ) of the end-grooved attachment rail to secure the enlarged attachment rail in a horizontal position elevated above the top of enclosure  120 . 
         [0098]      FIG. 25  illustrates an embodiment of a tripod mounting clamp  900  that allows a conventional tripod (not shown) to be coupled to the bottom of the 3D camera system  100 . The tripod mounting clamp comprises a body  902  that has a generally rectangular plan shape and a generally rectangular elevation shape. As further illustrated, the cross section of the tripod mounting clamp is formed by milling or by another suitable process to create an elongated channel  910  that corresponds to the channels  172  of the first enclosure shell  150  as described above. However, the elongated channel has a width between a first vertex  912  and a second vertex  914  that corresponds to the width of two channels  172  and an intermediate rail  170 . For example, in the illustrated embodiment, the width is slightly larger than approximately 2.289 inches (58.1 millimeters). The elongated channel includes a first upper engagement surface  920  and a first lower engagement surface  922  proximate the first vertex and a second upper engagement surface  924  and a second lower engagement surface  926  proximate the second vertex. The engagement surfaces are sized and angled as described above. The planar surface  930  between the lower engagement surfaces is generally rectangular. A central portion of the planar surface is removed to form a generally rectangular cavity  932  with filleted corners. A movable compression plate  940  is positioned within the cavity. The compression plate has a generally rectangular shape and has an outer perimeter that is slightly smaller than the inner perimeter of the cavity. The compression plate is coupled to an external actuator  950 . For example, in the illustrated embodiment, the actuator is a lever that turns about a coupling rod (not shown). When the lever is turned about the rod from the initial position (not shown) to a rotated position illustrated in  FIG. 25 , an internal mechanism (not shown) raises the compression plate upward to a position a distance “D” above the planar surface. The internal mechanism includes a conventional over-center latching mechanism so that when the compression plate is raised to a maximum extended position, force applied to the compression plate will not cause the compression plate to return to a lower position unless the external actuator is manually returned to the initial position. 
         [0099]      FIGS. 26 and 27  illustrate the tripod clamp  900  attached to the bottom of the enclosure  150  with the upper engagement surfaces  920 ,  922  engaging the respective outer lower engagement surfaces  322  of two adjacent rails  170  of the first enclosure shell  150  and with the compression platform  940  forced against the flat top portions  310  of the two rails. Accordingly, the tripod clamp is securely attached to the enclosure. As further illustrated in  FIG. 26 , the tripod clamp includes a threaded bore  960  that is sized to receive a conventional engagement bolt at the top of a conventional tripod. For example, the threaded bore is advantageously a conventional ¼-inch hole that is threaded to receive a corresponding bolt. The threaded bore may also be sized to accommodate other tripods. 
         [0100]    Although described above with respect to installation of the attachment rails with respect to the upper surface of the first enclosure shell  150 , the attachment rails may also be installed with respect to the bottom surface and either or both of the side surfaces of the first enclosure shell. Furthermore, the attachment rails may also be installed in a channel that spans across interconnected enclosure portions. For example,  FIG. 26  illustrates a tripod interconnection system  900  mounted to the bottom surface of the first enclosure shell. 
         [0101]    As discussed above, commercially available STANAG 4694 NATO rail and MIL-STD 1913 Picatinny rail accessories can be attached at multiple locations directly on the enclosure  120  or on any of the accessory rails that further expand the various angles and distances where such accessories can be installed. For example, various configurations of handles may be attached to the rails  170  for carrying and aiming the camera. Other devices can also be secured to the enclosure. For example, a laser aiming device may be attached to the rails of the enclosure or to one of the extended attachment rails to assist in directing the camera. Lighting devices, microphones and other devices associated with cameras may also be attached to the enclosure or to the attachment rails. 
         [0102]    As further discussed above, the enclosure  120  and the attachment accessories described in  FIGS. 11-16  are compatible with conventional STANAG 4694 NATO rail accessories. For example,  FIGS. 28A and 28B  illustrated upper and lower perspective views of a commercially available mounting device  1000 , such as, for example, an adjustable gun rail lock manufactured by American Defense Mfg, LLC., 2525 S 162 nd  Street, New Berlin, Wis. 53151, and described in U.S. Pat. No. 7,823,316 to Storch et al., which is incorporated herein by reference. The operation of the lock is described in the patent and is not described further herein.  FIG. 29  illustrates the mounting device installed on the enlarged notched attachment rail  800 , which is described above. As previously discussed, the enlarged attachment rail may be installed directly in one of the channels  172  on one of the surfaces of the enclosure; or the enlarged attachment rail may be installed in a vertically offset position as illustrated in  FIG. 24 . 
         [0103]    Although described herein primarily with respect to a camera enclosure having the rails and channels positioned on the surfaces and corners of the enclosure, other embodiments that incorporate the rails and channels are also contemplated. For example, as illustrated in  FIG. 30 , a mounting plate  1100  has an upper surface  1102  and a lower surface  1104 . The upper surface of the mounting plate is formed into a plurality of rails  1110  and interposed channels  1120  having the configurations described above. The mounting plate includes a plurality of mounting bores  1130  that receive fasteners (e.g., screws) that engage the surface  1140  (shown in phantom) of a vehicle (e.g., a ground vehicle, a watercraft, an aircraft or the like) so that the mounting plate is secured to the vehicle. The rails and channels are thereby useable to mount devices to the vehicle in a manner similar to the manner described above for the camera enclosure. Although the lower surface of the mounting plate is shown as a flat surface, it should be understood that the lower surface can be contoured to conform to the contours of the vehicle onto which the mounting plate is mounted. 
         [0104]    As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all the matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Technology Classification (CPC): 5