SUPPORT STRUCTURE AND METHOD FOR MANUFACTURING THEREOF

Abstract

A support structure for handrail post repair, the support structure comprising a support frame having a flange base for stabilizing the support structure and a tube comprising a rail end and a ground end such that the tube is connected to the flange base at the ground end, a support rod attached to the tube for securing a handrail post and at least one locking element extending through the tube.

Claims

1. A support structure for handrail post repair, the support structure comprising: a support frame having a flange base for stabilizing the support structure and a tube comprising a rail end and a ground end such that the tube is connected to the flange base at the ground end; a support rod attached to the tube for securing a handrail post; at least one locking element extending through the tube.

2. The support structure of claim 1, wherein handrail post is hollow and connects over the support rod and inside the tube.

3. The support structure of claim 1, wherein the flange base further comprises a plurality of apertures to allow for insertion of a plurality fasteners to secure the support frame to a surface.

4. The support structure of claim 3, wherein the plurality of fasteners are anchor bolts.

5. The support structure as claimed in claim 2, wherein the handrail post is locked in position to the support structure by the at least one locking element.

6. The support structure as claimed in claim 5, wherein the at least one locking element is positioned is a set screw that can adjustably set the height of the rail.

7. The support structure of claim 1, wherein the support rod protrudes a minimum of 5 inches.

8. The support structure as claimed in claim 1, wherein the tube has a length of 8 inches and the support rod has a length of 13 inches.

9. The support structure as claimed in claim 1, wherein the tube has a length of 6 inches and the support rod has a length of 11 inches.

10. The support structure as claimed in claim 1, wherein the tube has a length of 4 inches and the support rod has a length of 9 inches.

11. The support structure as claimed in claim 1, wherein the tube has a length of 3.75 inches and the support rod has a length of 8.75 inches.

12. A method for assembling a support structure, the method comprising: cutting a tube having a first end and a second end such that the tube exhibits a first predefined length; grinding edges of the first and the second ends of the tube; coupling a flange to the first end of the tube; cutting rust off of an existing handrail post; applying adhesive into the second end of the tube; inserting the handrail post into the tube; drilling a hole through the existing handrail post and into the tube; securing, via at least one lock element, through the tube and the existing handrail post; setting the existing handrail post; and bolting the flange to a surface.

13. The method for assembling a support structure of claim 12 wherein the handrail post is solid.

14. The method for assembling a support structure of claim 13 wherein the handrail post is hollow.

15. The method for assembling a support structure of claim 12 wherein method further comprises the steps of: cutting a support rod such that the support rod has a second predefined length; coupling the support rod with the tube; inserting the support rod within the tube; welding together the support rod within the tube; applying adhesive inside the existing handrail post; inserting the support rod into the existing handrail post; drilling a hole through the existing handrail post and support rod; and securing, via at least one pop rivet, through the existing handrail post and support rod.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Having thus described the disclosure in general terms, reference will now be made to the accompanying figures, wherein:

[0028] FIG. 1 illustrates a perspective view of a support structure, in accordance with an embodiment of the present disclosure;

[0029] FIG. 2 illustrates a perspective view of a support structure, in accordance with an embodiment of the present disclosure;

[0030] FIG. 3 illustrates a front view of a support structure, in accordance with an embodiment of the present disclosure;

[0031] FIG. 4 illustrates a top view of the support frame of the FIG. 3, in accordance with an embodiment of the present disclosure;

[0032] FIG. 5 illustrates a top view of the support frame of the FIG. 3, in accordance with an embodiment of the present disclosure

[0033] FIG. 6 illustrates a perspective view of a support rod of the support structure of FIG. 1, in accordance with an embodiment of the present disclosure;

[0034] FIG. 7 illustrates a flowchart depicting a method for assembling a support structure, in accordance with an embodiment of the present disclosure; and

[0035] FIG. 8 illustrates a schematic view that shows alignment of a tube on a flange, in accordance with an embodiment of the present disclosure;

[0036] FIG. 9 illustrates a schematic view that shows a step of forming a hole on a tube of a support structure, in accordance with an embodiment of the present disclosure;

[0037] FIG. 10 illustrates a schematic view that shows a step of applying adhesive inside a tube of a support structure, in accordance with an embodiment of the present disclosure;

[0038] FIG. 11 illustrates a schematic view that shows a step of inserting the support rod of inside a post, in accordance with an embodiment of the present disclosure;

[0039] FIG. 12 illustrates a perspective view of a handrail that employs a support structure, in accordance with an embodiment of the present disclosure; and

[0040] FIG. 13 illustrates a perspective view of a handrail that employs a support structure, in accordance with an embodiment of the present disclosure.

[0041] It should be noted that the accompanying figures are intended to present illustrations of exemplary embodiments of the present disclosure. These figures are not intended to limit the scope of the present disclosure. It should also be noted that accompanying figures are not necessarily drawn to scale.

DETAILED DESCRIPTION

[0042] Before describing the present invention in detail, it should be observed that the present invention utilizes a combination of components or processes, which constitutes a support structure and a method for assembling the support structure. Accordingly, the components or processes have been represented, showing only specific details that are pertinent for an understanding of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those with ordinary skill in the art having the benefit of the description herein. As required, detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific component level details and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present disclosure in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting but rather to provide an understandable description of the disclosure.

[0043] Some embodiments, illustrating its features, will now be discussed in detail. The words comprising, having, containing, and including, and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms a, an, and the include plural references unless the context clearly dictates otherwise. Although any methods and systems similar or equivalent to those described herein can be used in the practice or testing of embodiments, the preferred methods, and systems are now described. The disclosed embodiments are merely exemplary.

[0044] References to one embodiment, an embodiment, another embodiment, one example, an example, another example and so on, indicate that the embodiment(s) or example(s) so described may include a particular feature, structure, characteristic, property, element, or limitation, but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element or limitation.

[0045] As mentioned there remains a need for an efficient technique of repairing handrail posts. Accordingly, the present disclosure provides the support structure that solves the aforementioned problems of conventional handrails and associated components and repairing methods thereof. The support structure of the present disclosure, made from heavy-walled A36 steel tubing and solid square bar, offer a simple, economical solution to restore safety and functionality to loose, rusted, or broken handrail posts. The support structure of the present disclosure is designed to fit various shapes and sizes, they eliminate the need for complete rail replacement by preventing further rot and providing a durable, secure repair without the complexity of welding. This innovative approach addresses the overlooked handrail repair market, offering a practical and accessible solution for homeowners, contractor, and commercial handrails. This disclosed invention aims to eliminate a handrail post from any further contact with cement, therefore preserving the lifespan of the handrail posts.

[0046] The present disclosure pertains to or relates to a method of preventing rotting of metal posts that may be disposed below the ground or imbedded in cement. The support structure of the present disclosure may facilitate easy repairing of the metal posts by virtue of an existing leg. These repair feet slide inside a hollow handrail post or may slide over a handrail post acting as a casing/new base for metal posts to anchor on top of the cement. The support structure of the present disclosure may therefore eliminate concrete damage.

[0047] FIG. 1 illustrates a perspective view of a support structure 100, in accordance with an embodiment of the present disclosure. The support structure includes a support frame 106 and a support rod 104. The support rod 104 is inserted into a cavity 106 of the support structure

[0048] 100. The support rod 104 is sized such that the support rod 104 is slightly smaller than the cavity 106 to allow for welded material to be inserted into the area between the support frame and the support rod 104 in the cavity 106.

[0049] The support structure 100 may be adapted to support a handrail. Specifically, the support structure 100 may be coupled to a ground and may support the handrail. The support structure 100 may be easily replaceable and repairable in the events of corrosion of the support structure 100. The support structure 100 may therefore save a lot of time and labor in repairing and replacing in the events of corrosion. The support structure 100 may facilitate easy repair for the handrail.

[0050] The support structure 100 may be provided with square or round metal tube or solid. In some embodiments of the present disclosure, the support structure 100 may have a piece of solid square bar or tube support rod 104 that may be inserted into the center and welded in place from the bottom of the support frame 106 and then welded to flange 102. In some embodiments of the present disclosure, the support structure 100 may be adapted to rest as such in an upright position. These support structures facilitate easy repair of the handrail for many homeowners, residential and commercial properties that may have loose broken or rotted out handrail posts. These support structures are not limited to just existing handrail posts. They can be used for a new installation of a new handrail as well.

[0051] The support structure 100 may therefore be a strong, secure, and an economical way to repair the handrail without incurring the expensive cost of having to replace the whole handrail itself. This advantageously improves functionality and safety for prolonged duration of time. Specifically, the support structure 100 may easily address the recurring issue of concrete causing metal handrail posts to rot out over time that are core drilled into cement and then anchored and held in place with cement. While the handrail itself often remains structurally sound, the rotting of the posts renders the handrail unsafe and unusable. The repair feet mitigate this problem by preventing concrete from eroding the metal posts, which typically become brittle and break away from their core-drilled positions 4 in the concrete. Featuring unique designs, these feet can be used on both existing and new rail installations without the need for welding. Crucially, they prevent handrail posts from needing to be set into concrete, thus eliminating future erosion. The repair process involves removing existing rust, adding adhesive inside hollow handrail posts, sliding the square bar extension into existing handrail post then securing through the post with a pop rivet attaching to the square bar inside the existing post and bolting down the base plate. Additionally flange 102 serves as a cosmetic cover for the existing hole in the cement.

[0052] In some embodiments of the present disclosure, dimensions of the hole of the support frame 106 may correspond to dimensions of the cross-section of the support rod 104 such that the support rod 104 is inserted into the support frame 106. Embodiments of the present disclosure are intended to include and/or otherwise cover any value for the dimensions of the hole of the support frame 106 and the dimensions of the cross-section of the support rod 104, without deviating from the scope of the present disclosure.

[0053] In some embodiments of the present disclosure, shape of the hole of the support frame 106 may be same to as of shape of the cross-section of the support rod 104 such that the support rod 104 is inserted into the support frame 106.

[0054] FIG. 2 depicts another embodiment of a repair device 200. The repair device 200 includes a flange 202 and a tube 204 with the flange including a plurality of holes 206. In one embodiment, flange 202 includes 4 holes 206a, 206b 206c and 206d each positioned near one of the corners of the flange. Flange 202 may be coupled to the tube 204 by way of a welding technique. Embodiments of the present disclosure are intended to include and/or otherwise cover any type of technique that may facilitate to couple the flange 202 to the tube 204, without deviating from the scope of the present disclosure.

[0055] In some embodiments of the present disclosure, the flange 202 may have a dimension that may be 33. In a preferred embodiment of the present disclosure, the holes each have a diameter. Holes 206 may be secured to the concrete using a plurality of fastening means. Embodiments of the present disclosure are intended to include and/or otherwise cover any dimensional value for the flange 202, without deviating from the scope of the present disclosure. The tub 204 may be any length but preferably 3, 4, 6, 7, 8, 10 or 12. Embodiments of the present disclosure are intended to include and/or otherwise cover any dimensional value for the tube, without deviating from the scope of the present disclosure

[0056] In some embodiments of the present disclosure, the flange 202 may have a shape that may be a rectangle, a square, a circle, a triangle, a rhombus, and the like. Embodiments of the present disclosure are intended to include and/or otherwise cover any type of known and later developed shape for the flange 202 that may provide adequate stability to the support structure 200, without deviating from the scope of the present disclosure.

[0057] The holes 206 may be disposed at corners of the flange 202. The holes 206 may facilitate to couple the support frame 200 with the ground. To couple the support frame 200 to the ground, a fastener (not shown) may be inserted in a corresponding hole 206. In other words, the support frame 200 may be coupled to the ground upon insertion of the fastener in the corresponding hole 206. For example, to couple the support frame 200 to the ground, the first fastener may be inserted in the first hole 206a, the second fastener may be inserted in the second hole 206b, the third fastener may be inserted in the third hole 206c, and the fourth fastener may be inserted in the fourth hole 206d.

[0058] In some embodiments of the present disclosure, the fastener may have a dimension of one of, , 5/16 and . Embodiments of the present disclosure are intended to include and/or otherwise cover any dimension for the fastener depending on the dimensions of the flange 202, without deviating from the scope of the present disclosure.

[0059] In some embodiments of the present disclosure, the fastener may be one of, a concrete fastener, an anchor, a sleeve, a wedge bolt, and tap con. Embodiments of the present disclosure are intended to include and/or otherwise cover any type of known and later developed fastener, without deviating from the scope of the present disclosure.

[0060] The tube 204 may include a first end 208a and a second end 208b. The first end 208a and the second end 208b may be disposed opposite to each other. In other words, the tube 204 may have a length that may span between the first end 208a and the second end 208b. The flange 202 may be coupled to the first end 208a.

[0061] In some embodiments of the present disclosure, the tube 204 may have a cross-sectional shape of a square, a rectangle, and a circle. Accordingly, the shape of the hole 208c may be one of, the square, the rectangle, and the circle. Preferably, the tube 204 may have the cross-sectional shape of the square. Accordingly, the preferred shape of the hole 208c may be the square. Embodiments of the present disclosure are intended to include and/or otherwise cover any shape for the cross-section of the tube 204, without deviating from the scope of the present disclosure.

[0062] In some embodiments of the present disclosure, the support frame 204 may be coupled to a flange 202 by way of a welding technique. Embodiments of the present disclosure are intended to include and/or otherwise cover any type of technique that may facilitate to couple tube 204 to the ground end of the tube 208a to a flange 202, without deviating from the scope of the present disclosure.

[0063] In some embodiments of the present disclosure, the support frame 200 may have a length that may be one of, 12 inches, 10 inches, 8 inches, 7 inches, 6 inches, 4 inches, and 3.75 inches. Embodiments of the present disclosure are intended to include any dimensional value for the length of the support frame 200, without deviating from the scope of the present disclosure. The flange 202 may have any number of apertures that may be structurally, dimensionally, and configurationally same or substantially similar to at least one aperture of the first through fourth apertures 206a-206d, without deviating from the scope of the present disclosure.

[0064] FIG. 3 illustrates a front view of a support frame 300. The support frame 300 includes a lock element 302. The lock element 302 may be coupled to the tube 304 by drilling or tapping a hole that is threaded to allow a screw to engage the hole. The lock element 302 may be disposed between the first end 304a and the second end 304b of the tube 304. Preferably, the lock element 302 may be disposed near to the second end 304b. The lock element 302 may exhibit a locked position and an unlocked position. The lock element 302 may be moved or displaced that may facilitate the lock element 302 to exhibit the locked position and the unlocked position. In some examples of the present disclosure, the lock element 302 is screwed into the opening such that the front of the lock element 302 engages a post placed into tube 304.

[0065] The lock element 302 may pass through a wall or a side of the tube 304. In other words, the lock element 302 may be partially inserted through the wall or the side of the tube 304. The lock element 302 may engage with a post once adhesive is added into it. The lock element 302 when removed from the wall or the side of the tube 304, may disengage the post inside it. The lock element 302, in the locked position, may engage with the post such that the lock element 302 blocks or restrict sliding motion of the post within the tube 304. The lock element 302, upon restricting the sliding motion of the post to exhibit a stable position i.e., the at least one height from the range of heights.

[0066] The lock element 302 may be adapted to facilitate adjustment of the at least one height from the range of heights of the post within the tube 304. Specifically, the lock element 302, in the unlocked position, may facilitate adjustment of the at least one height of the post within the tube 304. The lock element 302, in the unlocked position, may disengage from the post such that the lock element 302 permits or allows the sliding of post within the tube 304.

[0067] In some embodiments of the present disclosure, the lock element 302 may be a bolt, nut, a rivet, and the like. Embodiments of the present disclosure are intended to include and/or otherwise cover any type of mechanical fastener that may be the lock element 302, without deviating from the scope of the present disclosure.

[0068] FIG. 4 illustrates a top view of the support frame 300 in accordance with an embodiment of the present disclosure. The lock element 302 may include a head portion 302a and tail portion 302b. The head portion 302a may remain outside the wall or the side of the tube 304. The tail portion 302b may be inserted inside the wall or the side of the tube 304 to set at least one height of the post within the tube 304.

[0069] FIG. 5 illustrates a top view of the support frame 300, in accordance with an embodiment of the present disclosure. The lock element 302 is positioned on one side of the tube 304 with an separate lock element 400 positioned on a side of the tube 304 opposite the lock element 302. In some embodiment, one side of the tube 304 include 2 locking elements. Both lock elements 302 and 400 are adjusted to secure the post in the cavity at a predetermined height.

[0070] In some embodiments of the present disclosure, the lock elements 302 and 400 may be rotated to facilitate insertion and ejection from the wall or the side of the tube 304. In one example of the present disclosure, the lock elements 302 and 400 may be rotated in a clockwise direction that may facilitate insertion of the lock elements 302 and 400 in the side or the wall of the tube 304. In some other examples of the present disclosure, the lock elements 302 and 400 may be rotated in a counterclockwise direction that may facilitate ejection of the lock elements 302 and 400 from the side or the wall of the tube 304. In some embodiments of the present disclosure, the lock elements 302 and 400 may include threaded region that may be disposed or formed at the tail portion 302b. The threaded region may facilitate rotation of the lock elements 302 and 400 in one of, the clockwise direction and in the counterclockwise direction. Embodiments of the present disclosure are intended to include and/or otherwise cover any direction i.e., the clockwise direction and the counterclockwise direction for rotating the lock elements 302 and 400 that may either facilitate (i) insertion of the lock elements 302 and 400 in the wall or the side of the tube 304 or (ii) the ejection of the lock elements 302 and 400 from the wall or the side of the tube 304, without deviating from the scope of the present disclosure.

[0071] FIG. 6 illustrates a perspective view of the support rod 104 of the support structure 100, in accordance with an embodiment of the present disclosure. The support rod 104 may include a first portion 602 and a second portion 604. The first portion 602 may be disposed adjacent to the second portion 604. The first portion 602 may extend along a first length of the support rod 104. In a preferred embodiment, the length of support rod 104 is at least 5 inches past first portion 602. The support rod 104 may be inserted inside first portion 602 and welded together. Specifically, the first portion 602 may be coupled with a flange on the same end where the first portion 602 was welded with support rod 104. The dimensions of the first portion 602 may be machined to correspond to the dimensions of the post.

[0072] In some embodiments of the present disclosure, the cross-sectional shape of the first portion 602 may be same to the cross-sectional shape of post. For example, the cross-sectional shape of the first portion 602 and post may be one of, a square, a rectangle, and a circle, without deviating from the scope of the present disclosure.

[0073] In some embodiments of the present disclosure, the cross-sectional shape of the first portion 602 may be different from the cross-sectional shape of the second portion 604. For example, the cross-sectional shape of the first portion 602 may be a square and the cross-sectional shape of the second portion 604 may be round.

[0074] In some embodiments of the present disclosure, the support rod 104 and the support structure 602 may have the length that may be in range of 3, 4, 6, 7, 8, 10, and 12. Preferably, the support rod 104 may have the length that may be 5 coming out of first portion 602. In some examples of the present disclosure, the first portion 602 may have the length of 4 inches and the second portion 604 may have a total length of 9 with the length of 5 coming out of first portion 602. Embodiments of the present disclosure are intended to include and/or otherwise cover any dimensional value for the length of the support rod 104 and support structure 602 without deviating from the scope of the present disclosure.

[0075] FIG. 7 illustrates a process 700 for assembling the support structure 100, in accordance with an embodiment of the present disclosure. At step 702, the assembling of the support structure 100 may require cutting the support rod 104. Specifically, cutting the first portion 602 such that the first portion 602 exhibits a first predefined length. At step 704, the assembling of the support structure 100 may require grinding edges. Specifically, grinding the edges of the ground end 606 and post end 608 of the first portion 602. At step 706, the assembling of the support structure 100 may require cutting of a support rod 604 and cutting any existing rust from post. At step 708, the assembling of the support structure 100 may require cutting of the second portion 604. Specifically, cutting the second portion 604 such that the second portion 604 exhibits a second predefined length and coupling second portion 604 with first portion 602.

[0076] At step 710, the assembling of the support structure 100 may require inserting the support rod 104. Specifically, inserting the second portion 604 into first portion 602 and welding together. At step 712, the assembling of the support structure 100 may require coupling the ground end 606 of the first portion 604 with a flange via welding. At step 714, the assembling of the support structure 100 may require applying adhesive inside the post and inserting support rod 104 into the post. A hole is then drilled through post into the inserted support rod 104 and secured using a pop rivet. A flange is then bolted into ground, securing support structure 100 to ground.

[0077] In some embodiments of the present disclosure, the post may be inserted directly into a support frame 300 without support rod 104 and a lock element 302 may exhibit the locked position such that the lock element 302 engages with a post. In some embodiments of the present disclosure, the lock element 302 may exhibit an unlocked position such that the lock element 302 disengages with the post.

[0078] FIG. 8 illustrates a schematic view that shows alignment of the support frame 200 on a flange 800, in accordance with an embodiment of the present disclosure. The support frame 200 may be supported by a bracket 802. The bracket 802 may be an upright member that facilitates to support the tube 204 along a portion of a vertical axis of the support frame 200. The bracket 802 may facilitate to hold the tube 204 in an upright straight position. Specifically, the bracket 802 may facilitate to hold the tube 204 that facilitates smooth and precise welding of the flange 800 with the tube 204.

[0079] FIG. 9 illustrates a schematic view that shows a step of forming a hole 900 on the tube 304, in accordance with an embodiment of the present disclosure. The tube 304 may be held in a set up 906 that facilitates to form the hole 900 on the tube 304. Specifically, the set up 906 may stably hold the tube 304 that facilitates a drilling apparatus 908 to form the hole 900 in the wall of the tube 304. In one embodiment, the tube 304 is a square tube having the dimensions of 3/161. In another embodiment, the hole 900 is a 5/16 hole. In another embodiment, the hole 900 is threaded with a 5/16-18 tap. In one embodiment, a 33 3/16 flange is welded to the bottom of the tube 304.

[0080] FIG. 10 illustrates a schematic view that shows a step of applying adhesive inside the tube 304, in accordance with an embodiment of the present disclosure. The adhesive may be applied by an adhesive supplying member 1010. The adhesive supplying member 1010 may include a nozzle 1012. The nozzle 1012 may be inserted inside the tube 304 that may facilitate to efficiently apply the adhesive inside the tube 304 making it waterproof.

[0081] FIG. 11 illustrates a schematic view that shows a step of inserting the support rod 104 inside the post 1100, in accordance with an embodiment of the present disclosure. The support rod 104 may be inserted in the post 1100. The post 1100 may shroud or cover the support rod 104 to enable complete assembly of the support structure 100 and repairing the handrail.

[0082] FIG. 12 illustrates a perspective view of a hollow post handrail 1200 that employs the support structure 100, in accordance with an embodiment of the present disclosure. The hollow handrail post 1200 may be formed once the support structure 100 is completely assembled. The hollow handrail post 1200 may further facilitate the user to serve as a supporting means when the user walks or moves around the hollow handrail post 1200. The hollow handrail post 1200 may be robust by virtue of implementation of the support structure 100.

[0083] FIG. 13 illustrates a perspective view of a solid or hollow handrail post 1300 that employs the support structure 300, in accordance with an embodiment of the present disclosure. The solid or hollow handrail post 1300 may be formed once the support is completely assembled. The solid or hollow handrail post 700 may further facilitate the user to serve as a supporting means when the user walks or moves around the solid handrail post 700. The solid handrail post 700 may be robust by virtue of implementation of the support structure 300.

[0084] It should be understood according to the preceding description of the present invention that the same is susceptible to changes, modifications, and adaptations and that the said changes, modifications, and adaptations fall within the scope of the appended claims.