SUPPORT STRUCTURE AND METHOD FOR MANUFACTURING THEREOF
20250369231 ยท 2025-12-04
Inventors
Cpc classification
International classification
Abstract
Disclosed is a support structure that includes a support frame or a support rod or both. The support frame includes a flange, a tube, and/or a lock element. The tube includes a first end such that the support end is coupled, then welded, to the first end. The ground end of the support rod is coupled to a flange then welded together. A lock element may be coupled to the tube such that the lock element exhibits a locked position and an unlocked position. The support rod is configured to slide within the existing hollow handrail post. The lock element may be used on hollow or solid existing handrail posts to lock repair foot to post securely.
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; and a a support rod attached to the tube for securing a handrail post.
2. 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; and wherein the tube is hollow and the handrail post is solid and is inserted into the tube and connected to the support frame.
3. The support structure of claim 1, wherein handrail post is hollow and connects over the support rod and inside the tube.
4. 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.
5. The support structure of claim 4, wherein the plurality of fasteners are anchor bolts.
6. The support structure as claimed in claim 2, wherein the handrail post is locked in position to the support structure by a locking element.
7. The support structure as claimed in claim 6, wherein the locking element is positioned is a set screw that can adjustably set the height of the rail.
8. The support structure of claim 1, wherein the support rod protrudes a minimum of 5 inches.
9. 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.
10. 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.
11. 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.
12. 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.
13. 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 a lock element, through the tube and the existing handrail post; setting the existing handrail post; and bolting the flange to a surface.
14. The method for assembling a support structure of claim 13 wherein the handrail post is solid.
15. The method for assembling a support structure of claim 13 wherein the handrail post is hollow.
16. The method for assembling a support structure of claim 15 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 a pop rivet, through the existing handrail post and support rod.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Having thus described the disclosure in general terms, reference will now be made to the accompanying figures, wherein:
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[0039] 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
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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.
[0044] The support structure and the method for assembling thereof will now be described with reference to the accompanying drawings, particularly
[0045]
[0046] The support structure 100 may be provided with square or round metal tube. In some embodiments of the present disclosure, the support structure 100 may have a piece of solid square bar or tube that may be inserted into the center and welded in place from the bottom of the support structure 100. In some embodiments of the present disclosure, the support structure 100 may be adapted to rest as such in an upright position. In some embodiments of the present disclosure, the support structure 100 may be welded to a metal plate with holes in each corner. In some embodiments of support structure 100 as seen in
[0047] 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 4in 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. For solid square metal posts, the handrail can simply slip into the repair feet after adhesive application, such as the tube 204 in
[0048] The support structure 100 may include a support frame 102 and a support rod 104. To assemble, the support structure 100, the support frame 102 may be disposed beneath the support rod. The support frame 102 may be adapted to support the support rod 104. Specifically, the support rod 104 may be inserted in a hole of the support frame 102 such that the support frame 102 supports the support rod 104 by welding both together on one end, this same end is then welded to a metal flange 202 for added strength.
[0049] In some embodiments of the present disclosure, dimensions of the hole of the support frame 102 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 102. 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 102 and the dimensions of the cross-section of the support rod 104, without deviating from the scope of the present disclosure.
[0050] In some embodiments of the present disclosure, shape of the hole of the support frame 102 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 102.
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[0052] In some embodiments of the present disclosure, the flange 202 and ground end 306 may form an integral component of the support frame 102.
[0053] In some embodiments of the present disclosure, the flange 202 and the tube 204 may be separate components of the support frame 102. The 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.
[0054] The flange 202 may include a plurality of apertures 206a-206d (hereinafter collectively
[0055] referred to and designated as the apertures 206).
[0056] 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, there are 4 apertures 206, 1 aperture 206 on each corner of the flange having diameter. Apertures 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.
[0057] 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 100, without deviating from the scope of the present disclosure.
[0058] The apertures 206 may be disposed at corners of the flange 202. The apertures 206 may facilitate to couple the support frame 102 with the ground. To couple the support frame 102 to the ground, a fastener (not shown) may be inserted in a corresponding aperture of the apertures 206. In other words, the support frame 102 may be coupled to the ground upon insertion of the fastener in the corresponding aperture of the apertures 206. For example, to couple the support frame 102 to the ground, the first fastener may be inserted in the first aperture 206a, the second fastener may be inserted in the second aperture 206b, the third fastener may be inserted in the third aperture 206c, and the fourth fastener may be inserted in the fourth aperture 206d.
[0059] 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.
[0060] 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.
[0061] 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. The second end 208b at the top of the tube 204 may facilitate to slidingly receive the post 514, including either hollow handrail posts 600 or solid handrail posts 700, through hole 208c. The tube 204 may further include a hole 208c. The hole 208c may be disposed at the second 208b. The hole 208c may be adapted to receive inside the hole 208c any component such that the support frame 102 of
[0062] 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.
[0063] In some embodiments of the present disclosure, the flange 202 and the tube 204 may be separate components of the support structure 100 such as illustrated in
[0064] In some embodiments of the present disclosure, the support rod 104 may be coupled to support frame 102 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 support rod 104 to the ground end 302 of the support frame 102, without deviating from the scope of the present disclosure.
[0065] In some embodiments of the present disclosure, the support frame 102 may have a length that may be one of, 8 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 102, without deviating from the scope of the present disclosure.
[0066] Although,
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[0068] The lock element 210 may pass through a wall or a side of the tube 204. In other words, the lock element 210 may be partially inserted through the wall or the side of the tube 204. The lock element 210 may engage with the post 514 once adhesive is added into it. The lock element 210 when removed from the wall or the side of the tube 204, may disengage the post 514 inside it. The lock element 210, in the locked position, may engage with the post 514 such that the lock element 210 blocks or restrict sliding motion of the post 514 within the tube 204. The lock element 210, upon restricting the sliding motion of the post 514 to exhibit a stable position i.e., the at least one height from the range of heights.
[0069] The lock element 210 may be adapted to facilitate adjustment of the at least one height from the range of heights of the post 514 within the tube 204. Specifically, the lock element 210, in the unlocked position, may facilitate adjustment of the at least one height of the post 514 within the tube 204. The lock element 210, in the unlocked position, may disengage from the post 514 such that the lock element 210 permits or allows the sliding of post 514 within the tube 204.
[0070] In some embodiments of the present disclosure, the lock element 210 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 210, without deviating from the scope of the present disclosure.
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[0072] In some embodiments of the present disclosure, the lock element 210 may be rotated to facilitate insertion and ejection from the wall or the side of the tube 204. In one example of the present disclosure, the lock element 210 may be rotated in a clockwise direction that may facilitate insertion of the lock element 210 in the side or the wall of the tube 204. In some other examples of the present disclosure, the lock element 210 may be rotated in a counterclockwise direction that may facilitate ejection of the lock element 210 from the side or the wall of the tube 204. In some embodiments of the present disclosure, the lock element 210 may include threaded region that may be disposed or formed at the tail portion 210b. The threaded region may facilitate rotation of the lock element 210 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 element 210 that may either facilitate (i) insertion of the lock element 210 in the wall or the side of the tube 204 or (ii) the ejection of the lock element 210 from the wall or the side of the tube 204, without deviating from the scope of the present disclosure.
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[0074] In some embodiments of the present disclosure, the cross-sectional shape of the first portion 302 may be same to the cross-sectional shape of post 514 as illustrated in
[0075] In some embodiments of the present disclosure, the cross-sectional shape of the first portion 302 may be different from the cross-sectional shape of the second portion 304. For example, the cross-sectional shape of the first portion 302 may be a square and the cross-sectional shape of the second portion 304 may be a circle.
[0076] In some embodiments of the present disclosure, the support rod 104 may have the length that may be in range of 4, 6, and 8. Preferably, the support rod 104 may have the length that may be 5 coming out of first portion 302. In some examples of the present disclosure, the first portion 302 may have the length of 4 inches and the second portion 304 may have a total length of 9 with the length of 5 coming out of first portion 302. Embodiments of the present disclosure are intended to include and/or otherwise cover any dimensional value for the length of the support rod 104, without deviating from the scope of the present disclosure.
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[0078] At step 402, the assembling of the support structure 100 may require cutting the support rod 104. Specifically, cutting the first portion 302 such that the first portion 302 exhibits a first predefined length.
[0079] At step 404, the assembling of the support structure 100 may require grinding edges. Specifically, grinding the edges of the ground end 306 and post end 308 of the first portion 302.
[0080] At step 406, the assembling of the support structure 100 may require cutting of a support rod 304 and cutting any existing rust from post 514.
[0081] At step 408, the assembling of the support structure 100 may require cutting of the second portion 304. Specifically, cutting the second portion 304 such that the second portion 304 exhibits a second predefined length and coupling second portion 304 with first portion 302.
[0082] At step 410, the assembling of the support structure 100 may require inserting the support rod 104. Specifically, inserting the second portion 304 into first portion 302 and welding together. Once welded, steps 402-410 result in the device illustrated in
[0083] At step 412, the assembling of the support structure 100 may require coupling the ground end 306 of the first portion 304 with a flange 202 via welding. The resulting device of steps 402-412 is illustrated in
[0084] At step 414, the assembling of the support structure 100 may require applying adhesive inside the post 514 and inserting support rod 104 into the post 514. A hole is then drilled through post 514 into the inserted support rod 104 and secured using a pop rivet. Flange 202 is then bolted into ground, securing support structure 100 to ground.
[0085] In some embodiments of the present disclosure, post 514 may be inserted directly into a support frame 102 without support rod 104 and a lock element 210 may exhibit the locked position such that the lock element 210 engages with a post 514, as illustrated in
[0086] In some embodiments of the present disclosure, the lock element 210 may exhibit an unlocked position such that the lock element 210 disengages with the post 514.
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[0092] Similarly,
[0093] 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.