A connector for a handrail

Abstract

A connector 10 for a handrail includes an angled joint 12 for engaging end portions of adjacent tubular handrails. The angled joint is formed from two halves divided substantially longitudinally. The

Description

23 04 25 The present invention relates to a connector for a handrail and relates particularly, but not exclusively, to a connector 5 for joining tubular lengths of handrail together to form part of ramped access for people with reduced mobility. A handrail is a rail designed to be grasped by the hand so as to provide safety or support. They are commonly used inside and outside to aid an elderly or disabled person when ascending 10 or descending a slope or staircase and help prevent injury caused by falls or slips. Handrails are typically supported by balusters or attached to walls. Installation of handrails usually requires a skilled person, along with a range of materials and tools. When the 15 handrail is to be installed in an area with multiple levels, such as at steps or a sloped path with many corners and angle changes the number of materials and components increases drastically. To maintain a continuous handrail around these corners and angles, a specific connector between two straight 0 bars of handrail is required. Existing connectors are generally only available at set angles, whether 90°, 180° or similar. This limits the ability to provide a seamless handrail not at these specific angles. These connectors can be expensive to manufacture and 25 challenging to assemble as they are designed using multiple materials, typically nylon ABS (acrylonitrile butadiene styrene), or stainless steel with a thermoplastic sleeve. Being manufactured from metal makes fitting the connectors to the handrails awkward. The ribs located in the inside of the 30 connectors do not deform significantly meaning tube tolerances are tight leading to either a very rigid or too loose a fit. In such instances additional penetrative fixings may be required, detracting from the modularity of the handrail system and providing a point for corrosion. Other issues that occur after the installation include deterioration of the thermoplastic outer sleeve and the 5 inability to retrofit the existing connectors without fully dismantling the equipment. Once installed these connectors cannot be reused again and are either destroyed or sent to landfill after the process of removal. Furthermore, the multiple materials make recycling of 10 a used product difficult and impractical. Preferred embodiments of the present invention seek to overcome or alleviate the above described disadvantages of the prior art. 23 04 25 According to an aspect of the present invention there is 15 provided a connector for a handrail, the connector comprising: an angled joint comprising a first and a second portion and, said joint used for engaging end portions of adjacent tubular handrails, the joint formed from two halves divided substantially longitudinally and wherein said first and second 20 portions comprise a ball and socket; and a first and a second tubular retainer extending over opposing ends of said angled joint thereby, maintaining said halves in engagement. Having the angled joint in two parts makes the 25 manufacturing a simpler process. An angled connector formed as a single part requires extrusion of the material to form a tube and then bent into the required shape. When the connector is in two halves a mould is designed and manufactured for each half that is reused to create multiple angled joints. 30 Having an angled joint formed from two halves further enables a much wider range of angles to be achieved as opposed to an angled joint formed from a single component. This increases the number of available solutions for any type of slope or handrail required, thereby reducing the number of different components which must be stocked, as one component can be used in many different situations. 5 Furthermore, by enabling a glue-less method of connection avoids damage during disassembly and allows for easier reassemble as a consequence. Each retainer works by connecting and holding the two halves of the angled joint together forming a strong seal between 10 the two. In a preferred embodiment the angled joint is moveable relative to said retainers. In another preferred embodiment the junction further comprises first and second shims, wherein one of each said shims 15 extend into opposing ends of said first and second tubular retainers . 23 04 25 In a further preferred embodiment, the first and second shims are formed from two halves divided substantially longitudinally. 20 In an additional preferred embodiment, the first and second shims comprises a ridged surface that engages said retainers. Having a ball and socket joint allows greater freedom of movement. It also enables the user to choose any angle within this range of movement and does not require a catalogue of 25 separate manufactured parts at different angles. In a further preferred embodiment, the socket comprises at least one protrusion and said ball comprises at least one aperture that said at least one protrusion extends into. In an additional preferred embodiment said retainers are 30 formed by injection moulding. 23 04 25 In a preferred embodiment the joint is formed by injection moulding. According to another aspect of the present invention there is provided a wall connector for a handrail, the connector 5 comprising: an angled joint for engaging an end portion of a tubular handrail, said joint formed from two halves divided substantially longitudinally; a tubular retainer extending over an end of said angled 10 joint thereby, maintaining said halves in engagement; and a wall attachment fixed to a wall, said wall attachment extending over another end of said angled joint maintaining said halves in engagement and thereby attaching said angled joint to the wall. 15 In a preferred embodiment the angled joint is moveable relative to said retainers. In another preferred embodiment one of each said shims extend into opposing ends of said first and second tubular retainers . 20 In a further preferred embodiment, the first and second shims are formed from two halves divided substantially longitudinally. In an additional preferred embodiment, the first and second shims comprises a ridged surface that engages said retainers. 25 In a preferred embodiment the angled joint further comprises a first and a second portion. In another preferred embodiment the first and second portions comprise a ball and socket. In a further preferred embodiment, the socket comprises at 30 least one protrusion and said ball comprises at least one aperture that said at least one protrusion extends into. 23 04 25 In an additional preferred embodiment said retainers are formed by extrusion or injection moulding. In a preferred embodiment the joint is formed by injection moulding. 5 Preferred embodiments of the present invention will now be described, by way of example only, and not in any limitative sense with reference to the accompanying drawings in which:- Figure 1 is a side view of a connector of the present invention; Figure 2 is an exploded view of the connector of figure 1; 10 Figures 3 and 4 are close up perspective views of components of the connector of figure 1; Figures 5 and 6 are close up side views of the components of figure 3 and 4; Figure 7 is a close up perspective view of other components of 15 the connector of figure 1; Figures 8 and 9 are close up perspective views of the component of figure 7; Figure 10 is a perspective view of the component of figure 9; Figure 11 is a close up perspective view of further components 20 of the connector of figure 1; Figures 12 and 13 are perspective views of yet further components of the connector of figure 1; Figure 14 is another exploded view of the connector of figure 1; 25 Figure 15 is an alternative connector of the present invention; Figure 16 is another alternative connector of the present invention; Figures 17 and 18 are perspective views of an installation tool of the present invention; and Figure 19 is a perspective view of a variant of the installation tool of figures 17 and 18. Referring initially to figures 1 and 2, a connector 10 includes an angled joint 12, first and a second tubular 5 retainer 14 and 16, and a first and a second shim 18 and 20. The angled joint 12 is moveable relative to the retainers and includes a first and a second portion respectively forming a ball 22 and a socket 24 joint. 23 04 25 Referring now to figures 3 to 6, the ball 22 consists of a 10 sphere portion 26, a neck 28 and a first end 30. The neck 28 extends from the sphere portion 26 which in turn extends into the ribbed first end 30. The ball 22 is formed from two halves divided longitudinally, including a first ball half 32 and a second ball half 34. The two halves are substantially 15 corresponding shapes and sizes but being approximately mirror images of each other. Both halves 32 and 34 include a first aperture 36, a first protrusion 40 and, a first recess 44. The first apertures 36 of the two ball halves 34 and 36 extend into the sphere portion 2 6 of the ball 22, such that when in 0 engagement the first apertures are located along an axis. The first protrusions 40 and the first recesses 44 are located along a first internal edge 46 of the sphere portion 26 and neck 28. When the two halves of the ball 22 are in engagement, the first protrusion 40 of the first ball half 32 extends into the first 25 recess 44 of the second ball half 34, and the first protrusion of the second ball half extends into the first recess of the first ball half. This combination of protrusions and recesses holds the two halves lightly together to form the ball 22. When the first and second ball halves 32 and 34 are engaged, a series 30 of first ribs 50 extend around an external surface 48 of the first end 30. Moving on to figures 7 to 10, the socket 24 includes a spherical recess 52, an axle (not shown) and a second rib portion 23 04 25 52. The spherical recess 52 includes a first portion 60 and second portion 62. The first portion 60 complements the spherical shape of the sphere portion 26 of the ball 22, such that the sphere portion can extend into the spherical recess to 5 form the moveable angled joint 12. The first portion 60 further includes a series of fins 54 formed from the injection moulding process. The second portion 62 is slightly flatter in shape, complementing the cylindrical shape of the neck 28 of the ball 22. The second portion 62 prevents the ball 22 from rotating 10 beyond 180° when in full engagement with the socket 24. Extending from the spherical recess 52 is the second end 56 including a second external surface 62 having a series of second ribs 64. The socket 24 is also formed from two halves divided longitudinally, including a first socket half 66 and a second 15 socket half 68. The two halves are substantially corresponding shapes and sizes, also being approximately mirror images of each other and, when in engagement, form the axle (not shown). The axle is further formed from two portions, a first axle portion and a second axle portion (not shown) The axle portions extend 0 from an internal surface 74 of the spherical recess 52. The two axle portions are small extrusions that provide an axis or rotation but do not meet in the middle. When the two socket halves 66 and 68 are in engagement, a second protrusion 74 of the first socket half 66 extends into 25 a second recess 76 of the second socket half 68, and the second protrusion of the second socket half extends into the second recess of the first socket half. This combination of protrusions and recesses holds the two halves lightly together (along a second internal edge 38) to form the socket 24. When the first 30 and second socket halves 66 and 68 are engaged, the series of second ribs 64 extend around the second external surface 62 of the second end 56. When the ball 22 and socket 24 are in engagement the sphere portion 26 extends into the first portion 58 of the spherical recess 52. Each of the two axle portions 70 and 72 also extend through the first apertures 36 of the ball 22. The axle portions 5 70 and 72 form the axle within the ball 22 enabling the ball 22 to rotate around only one axis. The second and first portions 58 and 60 of the socket 24 further limit the angular motion of the ball 22 between 90° and 180°. As the ball 22 rotates within the socket 24 the neck 28 buts up against either the edge of the 10 first portion 58 or the edge of the second portion 60. As a result, the axes of handrails inserted into the joint can be separated by any angle between 90° and 180° Referring again to figures 1 and 2, extending over both the first and second ends 30 and 56 of the ball 22 and socket 45 are 23 04 25 the first and second tubular retainers 14 and 16. These retainers 14 and 16 are cylindrical in shape and have a radius only marginally larger than the radii of the first and second ends 30 and 56 of the ball 22 and socket 24. An interference fit is established between the retainers 14 and 16 and the first 0 and second ends 30 and 56 which is enhanced by the interaction of the ribs 50 and 64. Standard lengths of retainers (or sleeves) used are 40 mm, 60 mm (depicted as the second and first retainers 16 and 14 respectively) and 140 mm. These retainers can be of any length required and can be used to form a part of 25 handrail 101, where the rail is just a bit short, its length can be extended by using a longer joint and this additional length is most easily achieved by extending the retainers 14 and / or 16. Additionally referring now to figures 11 to 14 located, at the adjacent ends of the first and second tubular retainers 14 30 and 16 are the first and second shims 18 and 20. These shims fill the gap between the tubular retainers and the handrail and smooth the transition from the handrail to the junction. The first and second shims 18 and 20 are formed from a first shim 23 04 25 half 82 and a second shim half 84 divided longitudinally creating a cylindrical shape when together. Both shim halves 82 and 84 include a first surface 88, forming the external surface of the shims (for engaging the tubular retainers) and a second surface 5 90 forming the internal surface of the shims (for engaging the handrail 101). Located on the external first surfaces 88 are a series of third ribs 92 providing a friction fit when inserted into the ends of the tubular retainers 14 and 16. Situated on the internal second surfaces 90 are a further series of fourth 10 ribs 94. As seen in figure 12, the fourth ribs 94 extend along the internal diameter, perpendicular to the circumference. Figure 13 highlights a variation in which the fourth ribs 94 extend around the internal circumference of the shims. Located around the edges of the shims 14 and 16 is a rim 96. When the 15 shims 14 and 16 are engaged with first and second retainers 14 and 16 the rims 96 abut against the edges of the retainers preventing them from further travel. Located at opposing ends along the junction between the rim 96 and the third ribs on each shim is a recess 98. The recess 98 is used in conjunction with 0 an assembler / disassembler connector tool described in figures 17, 18 and 19. Operation of the connector 10 will now be described. When a section of handrail is to be replaced or commissioned, and the angle between each of the stair way sections has been calculated 25 the connector 10 can begin assembly. The ball 22 and socket 24 are combined to form the angled joint 12. This is achieved by placing each socket half 66 and 68 around the ball 22 ensuring that both axle portions 70 and 72 have been inserted through the first apertures 36 forming the axle within the ball. The first 30 and second retainers 14 and 16 are slotted over the first and second ribs 50 and 64, located at the ends of the ball 22 and socket 24, ensuring that an interference fit has been established between them. The connector 10 has now been assembled and can be inserted in between the lengths of handrail 101 or attached to a wall connector. As the angled joint has free movement between 90° and 180°, the ball 22 and socket are moved relative to the retainers to create the angle required for the section of handrail to be replaced. The handrails 101 are 5 inserted into the retainers 14 and 16. Then the first and second halves 82 and 84 of the shims 18 and 20 are placed into engagement with the handrails 101 so that the internal surfaces 90 are in contact with the external surface of the handrail. The shims are then slid along the surface of the handrail and 10 inserted into the opposing ends of the first and second retainers 14 and 16. The third ribs 92 of the shim engage the internal surface of the retainers ensuring an interference fit is created. The ribs 94 on the internal or concave surface of the shims help to prevent movement of the shims on the handrails. 23 04 25 15 Referring now to figures 15, in which components equivalent to those in figures 1 to 8 have been identified with like reference numerals increased by 100, a connector 110 includes a first tubular retainer 116 and a pair of shims 118 and 120 for joining two sections of the handrail 201. The tubular retainer 0 114 is cylindrical in shape having an aperture therethrough. The internal diameter of the retainer 114 is slightly larger than the external diameter of the handrail 201. The length of tubular retainer 114 can be varied and is, for example, at least 40 mm and could be as much as 160 mm. These are standard lengths 25 found in the industry; however, any such length could be used. Inserted at each end of the tubular retainer 114 are the first and second shims 118 and 120. Formed from a first shim half 182 and a second shim half 184, the shims 118 and 120 are divided longitudinally creating a cylindrical shape when together. The 30 shims include a series of third and fourth ribs 192 and 194 located internally and externally around their circumference. The shims also include a rim 196 and a recess 198. 23 04 25 Referring now to figure 16 in which components equivalent to those in figures 1 to 8 have been identified with like reference numerals increased by 200, a connector 210 is provided to attach a handrail 301 to a wall (not shown). The connector 5 210 includes an angled joint 212, a first and second retainer 214 and 216, a first shim 218 and a wall connector 303. The angled joint 212 is in the form of a ball 222 and socket 224 joint, both of which are formed from two halves as described above. The two halves of the socket 224 are held in place by 10 the first retainer 214, whilst the ball halves are contained by the socket 224 and the second retainer 216. The first retainer 214 further includes a first shim 218 extending into the opposing end and enabling the handrail 301 to engage with the first retainer 214. Extending from the opposing end of the second 15 retainer 216 is the wall connector 303. The wall connector 303 is disk like in shape and has a diameter larger than that of the retainers and these parts are generally formed together as a single component. The large diameter wall connector 303 ensures a large surface area for engaging with a wall and creates a 0 strong anchor point for the connector 210. To allow engagement with the wall, the wall connector 303 includes a trio of third apertures 305 spaced equidistant around the disk. The third apertures 305 are used for the insertion of screws or bolts to suitably affix the wall connector 303 to the wall. It can be 25 seen that the connector 10 (described above) contains the same components as the connector 210 except that one of the retaining members 16 has been replaced with a wall bracket including the retainer 216 and wall connector 303. Referring now to figures 17, 18 and 19 in which components 30 equivalent to those in figures 1 to 8 have been identified with like reference numerals increased by 300, a connector 310 can be assembled or dissembled through the use of an installation tool 307. The installation tool 307 includes a handle 309 and a head 311 extending therefrom. The head 311 has a semi-circular 23 04 25 cross-section with an internal diameter that matches the external diameter of the handrail. The head 313 has an insertion end 319 and a removal end 315. The insertion end 319 is shaped to engage the rim 396 of the shim 318. That is, the insertion 5 end has a recess 317 running around the semi-circular end of the head 311, that recess having a quarter circular cross-section to engage the rim 396 and evenly apply a pushing force to it. As shown in figure 17, the insertion tool works by the operator placing the shim 318 onto the handrail 401 adjacent the tubular 10 retainer 314. The insertion tool 307 is then placed on the handrail 401 on the other side of the shim 318 with the insertion end 319 of the head 311 in engagement with the rim 396 of the shim. The shim is then slid along the handrail 401 into engagement with the retainer 314. A pushing force is applied 15 to the end of the handle 309 of the tool 307 to evenly push the shim into the space between the tubular retainer 314 and the handrail 401. If necessary, tools such as a hammer or rubber mallet can be used to gently tap the end of the handle 309 so as to push the shim firmly into position so that the rim 296 0 contacts the end of the tubular retainer 314. The removal end 315 of the tool 307 is similarly shape to the insertion end 319 except for the addition of a tooth 313. Under the unusual circumstances where a shim is to be removed, the tool is used in the opposite orientation to insertion so 25 that the removal end 315 engages the rim 396 and the internal surface of the head 311 engages the handrail 401. In addition, the tooth 313 is inserted into the recess 398 in the rim 396 of the shim 318. In this position, the tooth 313 can apply a pulling force on the shim 318 to extract it from the tubular 30 retainer 314. The pulling force is generated by pushing on the end of the handle 309 and if necessary, using a hammer or mallet to apply additional force. It will be appreciated by persons skilled in the art that the above embodiments have been described by way of example only and not in any limitative sense, and that various alterations and modifications are possible without departure from the scope 5 of the protection which is defined by the appended claims. For example, the ribs in the embodiments described above run parallel to the handrail's axis. However, as an alternative they could around the circumference of the surfaces. 23 04 25

Claims

23 04 251. A connector for a handrail, the connector comprising:an angled joint comprising a first and a second portion and, said joint used for engaging end portions of adjacent tubular 5 handrails, said joint formed from two halves divided substantially longitudinally and wherein said first and second portions comprise a ball and socket; anda first and a second tubular retainer extending over opposing ends of said angled joint thereby, maintaining said halves in 10 engagement.

2. A connector according to claim 1, wherein said angled joint is moveable relative to said retainers.

3. A connector according to any preceding claim further comprising first and second shims, wherein one of each said 15 shims extend into opposing ends of said first and second tubular retainers .

4. A connector according to claim 3, wherein said first and second shims are formed from two halves divided substantially longitudinally.20 5. A connector according to any of claims 3 or 4, whereinsaid first and second shims comprises a ridged surface that engages said retainers.

6. A connector according to any preceding claims, wherein said socket comprises at least one protrusion and said ball comprises 25 at least one aperture that said at least one protrusion extends into .

7. A connector according to any preceding claims, wherein said retainers are formed by extrusion or injection moulding.

8. A connector according to any preceding claims, wherein said 30 joint is formed extrusion or by injection moulding.

9. A wall connector for a handrail, said connector comprising:23 04 25an angled joint for engaging an end portion of a tubular handrail, said joint formed from two halves divided substantially longitudinally;a tubular retainer extending over an end of said angled joint 5 thereby, maintaining said halves in engagement; anda wall attachment fixed to a wall, said wall attachment extending over another end of said angled joint maintaining said halves in engagement and thereby attaching said angled joint to the wall.10 10. A connector according to claim 9, wherein said angled jointis moveable relative to said retainers.

11. A connector according to claims 9 to 10 further comprising first and second shims, wherein one of each said shims extend into opposing ends of said first and second tubular retainers.15 12. A connector according to claims 9 to 11, wherein said firstand second shims are formed from two halves divided substantially longitudinally.

13. A connector according to claims 9 to 12, wherein said first and second shims comprises a ridged surface that engages said 20 retainers.

14. A connector according to claims 9 to 13, wherein said angled joint further comprises a first and a second portion.

15. A connector according to claims 9 to 14, wherein said first and second portions comprise a ball and socket.25 16. A connector according to claims 9 to 15, wherein said socketcomprises at least one protrusion and said ball comprises at least one aperture that said at least one protrusion extends into .

17. A connector according to claims 9 to 16, wherein said 30 retainers are formed by extrusion or injection moulding.

18. A connector according to claims 9 to 17, wherein said joint is formed by extrusion or injection moulding.23 04 25

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