Support Structure and Method for Manufacturing Thereof

The present disclosure generally relates to handrail support structures. More particularly, the present disclosure relates to a handrail support structure and method for manufacturing thereof. The support structure disclosed aids in preventing metal handrail posts from rotting below the surface when imbedded in concrete. Posts can be repaired by using the support structure to slip inside an existing hollow handrail post or sliding over an existing handrail post, hereinafter referred to as a “post,” that is either a solid handrail post or a hollow handrail post. Disclosed support structure acts as a casing for metal posts to anchor on top of cement thus eliminating contact with concrete and avoiding further decay and rot. The disclosed support structure increases the lifespan of not only the post but the longevity of the entire handrail as well.

Replacing a handrail can be a costly endeavor, often requiring significant investment due to the specialized nature of the work and the dwindling number of craftsmen skilled in this area. Metal handrail posts imbedded in concrete have been rotting out for decades. Although handrails imbedded into concrete may vary in their size or design, their bases eventually succumb to the corrosive nature of the concrete. This leads to rusted out, crumbling handrail posts that are not only off-putting but pose a safety hazard to users of the handrail. In some jurisdictions and homeowner insurance policies, safe and structurally sound handrails are required and repairs necessary within a short deadline. As such, finding affordable, easy, and quick solutions for necessary repairs is increasingly important. Handrail posts have a repeating pattern of rotting from the decay the cement causes while the remainder of the rail is structurally safe. When a handrail is initially installed, a hole is drilled to support the handrail posts. Concrete is poured into this hole and levels itself in the hole once the handrail post is put into this hole. The concrete then settles down inside the hole, leaving a pocket, and allows rain to puddle, further decaying the posts as concrete eats metal. It is very common to see handrails rusted at the bottom. The introduction of repair feet offers a cost-effective alternative, allowing for the maintenance and repair of handrails without the need for complete replacements. This eliminates the need to core drill a railing back into the concrete avoiding any further damage caused by concrete-induced corrosion. There is also no need for welding to repair the handrails once the adhesive is added into the feet of the support structures as they become waterproof as well.

These repair feet are designed to address specific issues associated with metal handrail posts, particularly those embedded in concrete, and they prevent further damage caused by concrete-induced corrosion. There are no other alternatives for these repair feet to have them match up correctly to an existing handrail post.

Existing prior art, such as US20090266026A1, presents a two-piece sleeve for repairing wood rotting in utility poles. These poles, typically a minimum of seven inches in diameter, are concreted into the ground, making this method unsuitable for smaller handrail posts. Similarly, patents like U.S. Pat. No. 1,189,182A, which pertains to voltage regulators, and U.S. Pat. No. 1,155,325B1, an anchoring device for wooden posts, do not provide solutions applicable to the unique requirements of metal handrails. The former has no relevance, while the latter's design is too large and complex for use on a one-inch square handrail post.

Other patents, such as U.S. Pat. Nos. 10,081,963B2 and 10,253,519B2, also focus on utility pole repairs, featuring designs with open tops and bottoms, and multiple interconnecting plates. This is also a sleeve piece that will cap over the existing base plate and existing threaded bolt pattern already in the concrete. This allows the pole to not be removed. Existing base plates on utility poles are minimum 7″ square by ¾ to 1″ thickness. This is a load bearing plate for utility poles set at no less than 35′ in height. Handrail requires a height between 36-38″. These methods are tailored for larger poles and lack the solid base required to support metal handrail posts. In contrast, the repair feet discussed here are designed with a solid base plate, hereinafter referred to as “flange” or “flange base,” open only at the top, which allows for filling with strong adhesives such as epoxy JB weld, 3M Epoxy adhesive, Loctite, E6000, Heavy Duty Gorilla glue, weld bond polyvinyl all of which are designed for metal-on-metal bonding so there is no need for welding. This also makes the repair feet waterproof. This design not only secures the handrail post but also eliminates the need to re-embed it in concrete, thus preventing and eliminating further decay.

Furthermore, patents like JP2003213635A, US20120255259A1, and U.S. Pat. No. 5,636,482 address various forms of wood post repairs or utility pole reinforcement but fail to offer viable solutions for metal handrails. They are either too large, involve unnecessary complexity, or require additional holes that could further damage the handrail. The repair feet, however, are tailored specifically for the dimensions and needs of metal handrails, ensuring a robust and durable fix without exacerbating existing issues. This focused approach makes them a superior option for maintaining the integrity and safety of metal handrail installations.

Previous repair methods for metal handrail posts have relied on flimsy 16-gauge tin strut channels, typically used for wood beam mounting, or on brittle cast iron feet that often cracked during installation. Recognizing over the past 20 years the persistent issue of concrete rotting metal handrail posts, I developed these repair feet. About 89% of homes have metal handrails and existing repair options are inadequate.

The above-mentioned limitations of the conventional handrails and supporting elements and techniques of repairing thereof would restrict the commercial/industrial deployment of the handrails. In an attempt to scale up the use of handrails, there remains a need for an efficient support structure and repairing and assembling method thereof that is capable of solving the aforementioned problems of the conventional handrails and supporting elements. Being specially designed to prevent rot in these upwardly extending repair supports.

In view of the foregoing, several support structures are disclosed. The support structure, as viewed in, includes a support frame and a support rod. The support frame includes a flange, a tube, and a support rod. The tube includes a first end such that the support rod is welded to the first end. The flange is welded to the same end to the tube and support rod. The support rod is all the way through the tube, protruding 5 inches. The support rod is configured to accept a pop rivet through the existing handrail post to secure the repair foot once adhesive is added into the existing handrail post.

In some embodiments of the present disclosure such as, support structure has a lock element. In the unlocked position, the lock element facilitates to adjust the at least one height of the existing handrail post within the tube.

In some embodiments of the present disclosure, the flange includes a plurality of apertures. The plurality of apertures facilitates to couple the support frame with a ground. The support frame is coupled to the ground upon insertion of a fastener in a corresponding aperture of the plurality of apertures. Preventing further contacts of post into concrete.

In some embodiments of the present disclosure, the lock element, in the locked position, engages with the existing handrail post to facilitate the need for one height.

In some embodiments of the present disclosure such as, the lock element, in the unlocked position, disengages from the existing handrail post to facilitate adjustment of the at least one height from the range of heights.

In some embodiments of the present disclosure, the first end is coupled with a flange. The hole is disposed at the second end. The hole facilitates to slidingly receive the existing handrail post.

In some embodiments of the present disclosure, the tube has a length of 8 inches.

In some embodiments of the present disclosure, the tube has a length of 6 inches.

In some embodiments of the present disclosure, the tube has a length of 4 inches.

In some embodiments of the present disclosure, the tube has a length of 3.75 inches.

In some embodiments of the present disclosure, the support rod has a length of 5 inches past any of the tubes.

In some aspects of the present disclosure, a method for assembling a support structure is disclosed. The method includes a step of cutting a tube such that the tube exhibits a first predefined length. The method further includes a step of grinding edges of first and second ends of the tube. The method further includes coupling a support rod to the first end of the tube. The method further includes welding tube and support rod to the flange on the same end makingsupport rod exhibits a second predefined length of 5″ sticking out of any tube. The method further includes a step of inserting the support rod within the existing handrail post such that the support rod is secured by a pop rivet through existing post into support rod inside post.

In some embodiments of the present disclosure, the method as seen infurther includes a step of locking, by way of a lock element, the existing post that facilitates to exhibit at least one height for the existing handrail post. This application of the support structure is viable on either on a solid handrail post or hollow handrail post, hereinafter referred to as a “hollow tube handrail post” or “hollow handrail post.”

In some embodiments of the present disclosure, the methodfurther includes a step of unlocking the lock element that facilitates to adjust the at least one height of the existing post within the tube.

In some embodiments of the present disclosure, the lock element exhibits a locked position such that the lock element engages with the handrail post that facilitates the handrail post to exhibit the at least one height from a range of heights to level handrail parallel to ground.

In some embodiments of the present disclosure, a tube is welded with a flange and matched up to existing handrail leg. This will be welded on for the more experienced professionals when preferred. This application of the support structure is viable on either on a hollow handrail post or solid handrail post.

Various objects, features, aspects and advantages of the present disclosure will become more apparent from the following detailed description of the embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.

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.

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.

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.

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.

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.

The support structure and the method for assembling thereof will now be described with reference to the accompanying drawings, particularly. The present disclosure further 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.

illustrates a perspective view of a support structure, in accordance with an embodiment of the present disclosure. The support structuremay be adapted to support handrail. Specifically, the support structuremay be coupled to a ground and may facilitate to support the handrail. The support structuremay be easily replaceable and repairable in the events of corrosion of the support structure. The support structuremay therefore save a lot of time and labor in repairing and replacing in the events of corrosion. The support structuremay facilitate easy repair for the handrail.

The support structuremay be provided with square or round metal tube. In some embodiments of the present disclosure, the support structuremay 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. In some embodiments of the present disclosure, the support structuremay be adapted to rest as such in an upright position. In some embodiments of the present disclosure, the support structuremay be welded to a metal plate with holes in each corner. In some embodiments of support structureas seen in, the metal square tube may be welded to a plate with a hole drilled into it for a set screw. 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.

The support structuremay 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 structuremay 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. For solid square metal posts, the handrail can simply slip into the repair feet after adhesive application, such as the tubein. This tubeis applicable for use on a hollow handrail postor solid handrail post. A user will just need to set the lock elementand bolt down the flange. Additionally, the bottom flangeserves as a cosmetic cover for the existing hole in the cement, reinforcing the handrail's functionality and safety for many years without re-cementing postback into the concrete.

The support structuremay include a support frameand a support rod. To assemble, the support structure, the support framemay be disposed beneath the support rod. The support framemay be adapted to support the support rod. Specifically, the support rodmay be inserted in a hole of the support framesuch that the support framesupports the support rodby welding both together on one end, this same end is then welded to a metal flangefor added strength.

In some embodiments of the present disclosure, dimensions of the hole of the support framemay correspond to dimensions of the cross-section of the support rodsuch that the support rodis inserted into the support frame. Embodiments of the present disclosure are intended to include and/or otherwise cover any value for the dimensions of the hole of the support frameand the dimensions of the cross-section of the support rod, without deviating from the scope of the present disclosure.

In some embodiments of the present disclosure, shape of the hole of the support framemay be same to as of shape of the cross-section of the support rodsuch that the support rodis inserted into the support frame.

illustrates a perspective view of the support frameof the support structureof the, in accordance with an embodiment of the present disclosure. The support framemay include a flangeand a tube. The flangemay be coupled to first portionof, more specifically the ground endof the first portion.

In some embodiments of the present disclosure, the flangeand ground endmay form an integral component of the support frame.

In some embodiments of the present disclosure, the flangeand the tubemay be separate components of the support frame. The flangemay be coupled to the tubeby 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 flangeto the tube, without deviating from the scope of the present disclosure.

The flangemay include a plurality of apertures-(hereinafter collectively

referred to and designated as “the apertures”).

In some embodiments of the present disclosure, the flangemay have a dimension that may be 3×3×⅛″. In a preferred embodiment of the present disclosure, there are 4 apertures, 1 apertureon each corner of the flange having ⅜″ diameter. Aperturesmay 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, without deviating from the scope of the present disclosure.

In some embodiments of the present disclosure, the flangemay 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 flangethat may provide adequate stability to the support structure, without deviating from the scope of the present disclosure.

The aperturesmay be disposed at corners of the flange. The aperturesmay facilitate to couple the support framewith the ground. To couple the support frameto the ground, a fastener (not shown) may be inserted in a corresponding aperture of the apertures. In other words, the support framemay be coupled to the ground upon insertion of the fastener in the corresponding aperture of the apertures. For example, to couple the support frameto the ground, the first fastener may be inserted in the first aperturethe second fastener may be inserted in the second aperturethe third fastener may be inserted in the third apertureand the fourth fastener may be inserted in the fourth aperture

In some embodiments of the present disclosure, the fastener may have a dimension of one of, ¼″, 5/16′ and ⅜″. 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, without deviating from the scope of the present disclosure.

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.

The tubemay include a first endand a second endThe first endand the second endmay be disposed opposite to each other. In other words, the tubemay have a length that may span between the first endand the second endThe flangemay be coupled to the first endThe second endat the top of the tubemay facilitate to slidingly receive the post, including either hollow handrail postsor solid handrail posts, through holeThe tubemay further include a holeThe holemay be disposed at the secondThe holemay be adapted to receive inside the holeany component such that the support frameofaccepts the post. For example, the holemay be adapted to receive the post, hollow handrail postsor solid handrail posts. Specifically, the holemay be adapted to slidingly receive the support rodsuch that the support framesupports the support rodby means of coupling together then coupling same end together with a flange, as illustrated in. Specifically, the support rodmay be slidingly received into the hollow handrail post.

In some embodiments of the present disclosure, the tubemay have a cross-sectional shape of a square, a rectangle, and a circle. Accordingly, the shape of the holemay be one of, the square, the rectangle, and the circle. Preferably, the tubemay have the cross-sectional shape of the square. Accordingly, the preferred shape of the holemay 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, without deviating from the scope of the present disclosure.

In some embodiments of the present disclosure, the flangeand the tubemay be separate components of the support structuresuch as illustrated inor coupled together as illustrated in.