HANDRAIL CONNECTION SYSTEM

Abstract

A handrail pivot joint facilitates the use of handrail sections having square-cut ends, rather than miter cuts, at transitions between flat and sloped sections. Handrail sections have an adjustable angle via the pivot joint, allowing for precise alignment with the adjacent structures, such alignment between the pitch of stairs and the pitch of the handrail. The pivot joint also presents a clean appearance and a robust connection between handrail sections.

Claims

1. A pivotable joint for a handrail system, the pivotable joint comprising: a first endcap sized to be fixed to a first opening of a first tubular handrail; a second endcap sized to be fixed to a second opening of a second tubular handrail; and a pivot component defining a longitudinal axis, the pivot component fixed to the first endcap and pivotably connected to the second endcap, such that the second endcap is pivotable relative to the first endcap about the longitudinal axis.

2. The pivotable joint of claim 1, wherein the pivot component has a cylindrical outer surface defining the longitudinal axis.

3. The pivotable joint of claim 2, wherein: the pivot component is a truncated cylinder including the cylindrical outer surface and a planar surface substantially parallel to the longitudinal axis, the cylindrical outer surface is pivotably engaged with the second endcap, and the planar surface is fixed to the first endcap.

4. The pivotable joint of claim 3, wherein the second endcap includes a cylindrical recess correspondingly sized with the cylindrical outer surface of the pivot component, such that the cylindrical outer surface of the pivot component is pivotably received by the cylindrical recess when the pivot component is assembled to the first endcap.

5. The pivotable joint of claim 3, wherein the pivot component includes at least one counterbored aperture formed in the cylindrical outer surface and passing through the planar surface, the pivotable joint further comprising a fixation fastener received in the counterbored aperture, with a fastener head of the fixation fastener recessed below the cylindrical outer surface and a fastener shank of the fixation fastener passing through the planar surface and fixed to the first endcap.

6. The pivotable joint of claim 5, wherein the pivot component includes a pivot aperture formed in the planar surface and passing through the cylindrical outer surface, the pivotable joint further comprising a pivot fastener received in the pivot aperture, with a fastener head of the pivot fastener recessed below the planar surface and a fastener shank of the pivot fastener passing through the cylindrical outer surface and fixed to the second endcap.

7. The pivotable joint of claim 6, wherein the pivot aperture comprises an elongate opening which traverses an angular sweep of the cylindrical outer surface, the fastener shank moveable through the angular sweep to allow the pivoting of the second endcap relative to the first endcap through an angular adjustment range.

8. The pivotable joint of claim 7, wherein: the elongate opening has a first angular terminus defining a first axis generally parallel to an axis of the counterbored aperture, and the elongate opening has a second angular terminus opposite the first angular terminus, the second angular terminus defining a second axis angled relative to the axis of the counterbored aperture to define the angular sweep, whereby the angular adjustment range of the second endcap relative to the first endcap by is equal to the angular sweep.

9. The pivotable joint of claim 8, wherein the angular sweep is about 45 degrees.

10. The pivotable joint of claim 1, wherein at least one of the first endcap and the second endcap comprises an assembly including a base and a plate.

11. A railing system comprising: a first tubular handrail defining a first axial-end opening; a second tubular handrail defining a second axial-end opening; a first endcap fixed to the first axial-end opening; a second endcap fixed to the second axial-end opening; and a pivot component fixed to the first endcap and pivotably connected to the second endcap, such that the second tubular handrail is pivotable relative to the first tubular handrail.

12. The railing system of claim 11, wherein the pivot component defines a longitudinal axis about which the second tubular handrail is pivotable.

13. The railing system of claim 11, wherein: the first endcap defines a press fit or a friction fit with the first axial-end opening, and the second endcap defines a press fit or a friction fit with the second axial-end opening.

14. The railing system of claim 11, wherein the at least one of the first endcap and the second endcap includes a tube-fixation aperture configured to receive a fastener inserted through a sidewall of the respectively attached first or second tubular handrail.

15. A method of installing a handrail system using a pivotable joint, the pivotable joint including a first endcap, a second endcap and a pivot component fixed to the first endcap and pivotably connected to the second endcap, the method comprising: fitting the first endcap to a first handrail section; fitting the second endcap a second handrail section; and pivoting the second endcap relative to the first endcap, via the pivot component of the pivotable joint, until a desired angle is achieved between the first handrail section and the second handrail section.

16. The method of claim 15, further comprising, before to the steps of fitting and pivoting: fixing the first endcap to the pivot component by a fixation fastener received through a counterbore formed in a cylindrical outer surface of the pivot component, such that a fastener head of the fixation fastener is recessed below the cylindrical outer surface; and pivotably connecting the second endcap to the pivot component by a pivot fastener received through a pivot aperture formed in the planar surface and passing through the cylindrical outer surface, such that a fastener head of the pivot fastener is recessed below the planar outer surface.

17. The method of claim 16, wherein the step of pivoting includes traversing a shank of the pivot fastener through an angular sweep defined by elongate opening of the pivot aperture in the cylindrical outer surface.

18. The method of claim 17, wherein the step of pivoting includes establishing an angle between the first tubular rail and the second tubular rail between zero degrees and 45 degrees.

19. The method of claim 15, wherein the step of pivotably connecting comprises rotating a cylindrical outer surface of the pivot component within a correspondingly cylindrical recess formed in the second endcap.

20. The method of claim 15, wherein the steps of fitting are performed before the step of pivoting.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The above mentioned and other features of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, where:

[0010] FIG. 1 is a perspective view of a stairs installation having a handrail made in accordance with the present disclosure;

[0011] FIG. 2 is an enlarged perspective view of the handrail shown in FIG. 1, illustrating a pivot joint between two handrail sections;

[0012] FIG. 3 is another view of the pivot joint of FIG. 2, illustrating angular adjustment thereof;

[0013] FIG. 4 is a partially exploded view of the pivot joint of FIG. 2;

[0014] FIG. 5 is an elevation, cross-section view of the pivot joint of FIG. 2, taken along line 5-5 of FIG. 2;

[0015] FIG. 6 is a perspective, cross-section view of the pivot joint of FIG. 2, taken along line 6-6 of FIG. 2;

[0016] FIG. 7 is a perspective view of a pivot joint made in accordance with the present disclosure;

[0017] FIG. 8 is a left-side, elevation view of the pivot joint of FIG. 7;

[0018] FIG. 9 is a right-side, elevation view of the pivot joint of FIG. 7;

[0019] FIG. 10 is a top plan view of the pivot joint of FIG. 7;

[0020] FIG. 11 is a bottom plan view of the pivot joint of FIG. 7;

[0021] FIG. 12 is a rear elevation view of the pivot joint of FIG. 7;

[0022] FIG. 13 is a front elevation view of the pivot joint of FIG. 7;

[0023] FIG. 14 is an exploded view of the pivot joint of FIG. 7;

[0024] FIG. 15 is another exploded view of the pivot joint of FIG. 7;

[0025] FIG. 16 is a perspective view of another handrail system including a pivot joint made in accordance with the present disclosure; and

[0026] FIG. 17 is an exploded perspective view of an alternative pivot joint component in accordance with the present disclosure; and

[0027] FIG. 18 is an exploded perspective view of another alternative pivot joint component in accordance with the present disclosure.

[0028] Corresponding reference characters indicate corresponding parts throughout the several views. Unless stated otherwise the drawings are proportional.

DETAILED DESCRIPTION

[0029] The embodiments disclosed below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. While the present disclosure is primarily directed to a handrail system, other railing systems may be made in accordance with the principles of the present disclosure.

[0030] The present invention provides a handrail system shown in connection with a stairs installation 100 shown in FIG. 1. Stairs installation 100 includes staircase 102 having rails 108, 110 and 112 positioned for user to grasp. An end newel post 104 supports lower handrail 108, which is level to coincide with the landing at the bottom of staircase 102. A sloped handrail 110 is connected at its lower end to lower handrail 108 via pivotable joint 120, as described in detail below, and defines a pitch commensurate with the overall pitch of staircase 102. Intermediate newel posts 105 are provided along this sloped section as required or desired for a particular application. Upper handrail 112 is connected to the upper end of sloped handrail 110 by a second pivotable joint 120, and is also level to coincide with the level landing at the top of staircase 102. An upper end newel post 104 is provided as shown. Cables 106 span between the end newel posts 104 and are supported by intermediate posts 105 to provide a comprehensive barrier. Additional details regarding cable-type barrier construction compatible with railing systems as described herein can be found in US Patent Application Publication No. 2021/0277663, filed Mar. 5, 2021 and entitled CABLE TENSIONING SYSTEM FOR RAILINGS AND BARRIERS, and U.S. Pat. No. 9,932,754, filed May 6, 2016 and entitled CABLE TENSIONING SYSTEM AND METHOD, the entire disclosures of which are hereby expressly incorporated herein by reference.

[0031] While the handrail system disclosed herein is described in connection with stairs assembly 100, it should be appreciated that this is an illustrative application of the present disclosure, and other applications are also contemplated. Such other applications can include any system needing a handrail or barrier, such as ramps, balconies, and the like.

[0032] Turning now to FIG. 2, pivotable joint 120 is shown connected to lower handrail 108 and sloped handrail 110. This lower pivot connection will be described in detail, it being understood that other pivot connections, including the connection between upper handrail 112 and sloped handrail 110, are also made with pivotable joint 120 in the same manner. Pivotable joint 120 includes a pivot component 122, illustrative a truncated cylinder as described below, and a pair of endcaps 124, 126.

[0033] Fixed endcap 124 is sized to be received in a first opening 136 formed in the axial end of tubular handrail 110, as best seen in FIGS. 4-6. In particular, endcap 124 has a tube-fit portion which forms a press- or friction-fit with opening 136. In one embodiment, opening 136 has short-side protrusions 138 and long-side protrusions 140, formed during the manufacture of the tube 110, which may generate an interference fit with the tube-fit portion of endcap 124 by causing material deformation as endcap 124 is advanced into opening 136. Endcap 124 is fully seated when its flange seats against the end wall of handrail 110 circumscribing the opening 136 (FIGS. 3 and 5). Optionally, endcap 124 may include a tube-fixation aperture 144 in the tube-fit portion. Aperture 144 may receive a fastener, such as a set screw or pin (not shown), inserted through a hole drilled the sidewall of the tubular handrail 110. This fastener or pin supplements the press- or friction-fit to firmly axially fix endcap 124 in handrail 110.

[0034] Pivotable endcap 126 is fitted and fixed to opening 134 of handrail 108 (FIG. 2) in the same manner as endcap 124 described above, and other endcaps of other pivotable joints 120 used in connection with stairs installation 100 may also be fitted and fixed in the same manner. Endcap 126 may also include a tube-fixation aperture 148 used to affix endcap to handrail 108 in the same manner as discussed above with respect to tube-fixation aperture 144. Moreover, additional endcaps may also be provided to cap the open ends of lower handrail 108 and upper handrail 112. These termination endcaps may be formed in the same way as endcaps 124, 126, except without any provision for attaching to pivot component 122 as further described below.

[0035] Alternative endcaps 124, 126 are shown in FIGS. 17 and 18, respectively. Except as otherwise described below, endcaps 124, 126 are similar in structure and function to endcaps 124, 126 respectively, and reference numerals of endcaps 124, 126 are analogous to the reference numerals used in endcaps 124, 126, except with a prime () added thereto. Elements of endcaps 124, 126 correspond to similar elements denoted by corresponding reference numerals of endcaps 124, 126 respectively, except as otherwise described herein. Moreover, endcaps 124, 126 are interchangeable with endcaps 124, 126 in the context of installation 100.

[0036] As shown in FIG. 17, fixed endcap 124 is an assembly including a base 124A and a plate 124B. The base 124A has a cuboid-shaped body sized to form a press- or friction-fit with opening 136 of tubular handrail 110, as described herein with respect to endcap 124. Base 124A has threaded apertures 142 which receive fasteners 128 in the same manner as fasteners 128 are received in apertures 142. Plate 124B seats against and substantially or completely covers the axial end wall of tubular handrail 110 in the same manner as the flange of endcap 124. Plate 124B has apertures 143 which allow fasteners 128 to pass therethrough with a clearance fit.

[0037] Endcap 124 provides for low-cost manufacture separating the tube-fit and flange portions of endcap 124 into separate components 124A and 124B. The base 124A is a cuboid structure, as noted above, and therefore can be efficiently produced from bar stock. Plate 124B is, similarly, a cuboid structure which can be made from plate stock. Minimal machining and material waste results from the formation of endcap 124, while still providing the same functions as endcap 124.

[0038] Similarly, pivotable endcap 126 is an assembly including a base 126A and a plate 126B which combine to provide the same functionality of endcap 126 while ensuring efficient and low-cost manufacture. Base 126A includes hole 147, which cooperates with hole 146 to allow passage of fastener 130 as described herein with respect to aperture 146 of endcap 126 described below. Base 126A also includes a dovetail receiver 127 sized and configured to receive a correspondingly formed dovetail 129 formed at the lower surface of plate 126B. When dovetail 129 is mated with receiver 127, base 126A is axially fixed to plate 126B, and base 126A can be attached to handrail 108 as described herein with respect to endcap 126. Bases 124A and 126A may have tube-fixation apertures analogous to apertures 144 and 148 herein, for axial fixation of endcaps 124, 126 within their respective handrails 110, 108.

[0039] Pivot component 122 is interposed between the endcaps 124, 126 as shown in FIGS. 4-6, for example, and is fixed to fixed endcap 124 and pivotably connected to pivotable endcap 126. This configuration allows endcaps 124, 126 to pivot relative to one another about the longitudinal axis defined by pivot component 122.

[0040] In particular, pivot component 122 is fixedly connected to fixed endcap 124 via a pair of fasteners 128 which pass through counterbored apertures 150 and into threaded apertures 142, as best shown in FIG. 14. Counterbored apertures 150 are formed in a cylindrical outer surface 156 of pivot component 122 and have an entry diameter large enough to receive the head of fasteners 128 such that the fastener head is recessed below the cylindrical outer surface 156. The shank of fasteners 128 pass through the smaller-diameter portion of apertures 150 and cross a planar surface 158 of pivot component 122. When assembled, planar surface 158 abuts the flat surface of the flange of fixed endcap 124, and fasteners 128 are tightened to fix pivot component 122 to endcap 124.

[0041] Pivot component 122 is also pivotably connected to pivotable endcap 126 via pivot fastener 130. Pivot component 122 includes a pivot aperture 152 with an entry portion formed in planar surface 158 and an exit portion passing through cylindrical outer surface 156. That is, pivot aperture 152 is oriented in a generally opposite direction as compared to counterbored apertures 150, which are disposed at opposing sides of the centrally located pivot aperture 152 (FIG. 15). Pivot fastener 130 is received in pivot aperture 152 such that its fastener head is recessed below planar surface 158 (FIG. 5). The shank of fastener 130 passes through cylindrical outer surface 156 and into a clearance aperture 146 formed in pivotable endcap 126. A nut 132 threadably engages the shank of fastener 130 to rotatably couple pivot component 122 to endcap 126.

[0042] Rotation of endcap 126 relative to pivot component 122 is facilitated by two features: an elongated opening of pivot aperture 152 at cylindrical outer surface 156, and a cylindrical recess 154 formed in endcap 126 and sized to receive the correspondingly cylindrical surface of pivot component 122.

[0043] As best shown in FIG. 5, the elongate exit portion of aperture 152 traverses an angular sweep of the cylindrical outer surface. This angular sweep allows the shank of fastener 130 to rotate relative to pivot component 122 through an angular range equal to the angular sweep, which in turn allows the pivoting of endcap 126 relative to the fixed endcap 124 through an angular adjustment range. In the illustrative embodiment of FIG. 5, the elongate opening has a first angular terminus defining a first axis generally parallel to an axis of the counterbored apertures 150. Stated another way, the pivotable joint 120 has an aligned configuration in which the longitudinal axes of handrails 108 and 110 are parallel and coincident, and in this aligned configuration, fastener 130 is at a first terminus of the angular sweep of opening 152. Fasteners 130 and 128 are also parallel in this aligned configuration. At a second, opposing angular terminus of the elongate aperture 152, the full angular adjustment range of the pivotable endcap 126 relative to the fixed endcap 124 is achieved as fastener 130 reaches the opposite end of its angular sweep.

[0044] In one exemplary embodiment, this fully pivoted configuration creates a 45 degree angle between the longitudinal axes of handrails 108 and 110, which corresponds to a maximum rise and run of staircase 102 according to the United States OSHA (OSHA), which mandates a maximum 9.5 rise and minimum 9.5 run (tread depth) for each step. At this maximum angle, the flanges of endcaps 124, 126 may also touch.

[0045] In view of the foregoing discussion of pivot component and its connections to endcaps 124 and 126, it can be seen that pivot component is configured as a truncated cylinder including cylindrical outer surface 156 and planar surface 158. Cylindrical outer surface 156 is pivotably received within a correspondingly sized cylindrical recess 154, as shown in FIG. 15. This nested configuration ensures that pivot component 122 is pivotable only about its longitudinal axis (i.e., the axis defined by cylindrical outer surface 156), which is substantially perpendicular to the longitudinal axes of handrails 108 and 110. Planar surface 158 is substantially parallel to the longitudinal axis of cylindrical surface 156, ensuring this desired perpendicular arrangement upon assembly. For purposes of the foregoing discussion, substantially means within normal tolerances and within limits of normal operational variability, as understood by persons or ordinary skill in the art of manufacturing.

[0046] As noted above, the use of pivotable joint 120 facilitates installation of a handrail system with accuracy and ease using square-cut handrail tubes. An installer (or a manufacturer) may first assemble the pivotable joint 120 as shown in FIGS. 4-15. To assemble, pivot fastener 130 is first placed through aperture 152 as described above, and allowed to loosely fit therein. With the head of fastener 130 recessed below planar surface 158 (FIG. 5), planar surface 158 may be abutted to fixed endcap 124 and fasteners 128 may be used to fix pivot component 122 to endcap 124, as described above. When fully seated, fasteners 128 are recessed below the cylindrical outer surface 156 so that surface 156 can be seated, without impedance, into recess 154 of endcap 126. Pivotable endcap 126 may then be assembled to pivot component 122 by passing the exposed shank of fastener 130 through aperture 146 until surface 156 seats within and abuts recess 154. Nut 132 may be loosely threadably engaged with the shank of fastener 130 such that endcaps 124, 126 may freely pivot relative to one another.

[0047] Handrails 108, 110 may be prepared from lengths of raw tubular material by simply creating a square cut to the desired rail lengths. A square cut is one in which the resulting cut surface is contained within a plane that is perpendicular to the longitudinal axis defined by the tube. In other words, the axial ends of each handrail 108, 110 (and 112) are perpendicular to the sidewalls of the handrails 108, 110 (and 112), as illustrated in FIGS. 2-6. Advantageously, these square cuts are easy for installers to make either at the jobsite or in a shop prior to jobsite construction, regardless of the pitch changes needed among the handrails 108, 110, 112 to accommodate the configuration of staircase 102 and its adjacent landings.

[0048] Fixed endcap 124 may then be fitted to a first handrail section, such as sloped handrail 110 as shown in FIG. 5. Endcap 124 may be press-fit or interference-fit within opening 136 (FIG. 4), as described above. Optionally, a hole may be made in a sidewall of handrail 110 at the location of tube-fixation aperture 144 and a fastener may be installed to axially fix endcap 124 in its seated position.

[0049] Pivotable endcap 126 may then be pivoted to angularly adjust endcap 126 to the desired configuration. This may be done, for example, with the sloped handrail in its installed position relative to staircase 102 (FIG. 1), and with lower handrail 108 temporarily installed or aligned to measure the desired angle between handrails 108, 110, and therefore the desired angular position of pivotable endcap 126 in its final installed position. As this angular adjustment takes place, the shank of fastener 130 is allowed to traverse the angular sweep of pivot aperture 152, as described above, and the cylindrical outer surface 156 of pivot component 122 rotates within the correspondingly cylindrical recess 154 of endcap 126. The angle may be set between zero and 45 degrees.

[0050] Nut 132 is then tightened to fix the desired angular position of endcap 126 relative to endcap 124. The head of pivot fastener 130 may frictionally engage with its seat in the entry portion of aperture 152 to allow nut 132 to be tightened without fastener 130 rotating.

[0051] Lower handrail 108 can then be installed permanently to endcap 126, using a press fit or interference fit, and optionally a fastener received within tube-fixation aperture 148, in the same manner as described herein with respect to endcap 124 and handrail 110.

[0052] The foregoing process is repeated for other transitional sections of the finished handrail assembly, such as at the junction between sloped handrail 110 and upper handrail 112 shown in FIG. 1. Assembly of other components of the barrier system may also be accomplished as described in the aforementioned references incorporated by reference.

[0053] In the illustrative embodiment of FIGS. 2-15, handrails 108, 110 and 112 may be made from an aluminum material having relatively large wall thicknesses to provide the desired material strength and rigidity. In FIG. 16, an alternative embodiment of a pivotable joint made in accordance with the present disclosure is shown and configured for use with steel (e.g., stainless steel) handrails, such as handrails 108 and 110 as shown. Pivot component 120 has all the same components and configurations as pivot component 120 described herein, with references numbers for parts of pivot component 120 analogous to reference numbers used in connection with parts of pivot component 120, except with a prime () added thereto. However, endcaps 124 and 126 are dimensioned to fit within the larger opening, and be flush with the thinner side walls, of tubes 108 and 110. The remaining components of pivot component may also be made of a similar material as the tubes 108, 110 to which they are connected, such as stainless steel.

[0054] While this invention has been described as having an exemplary design, the present invention may be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.